INSIGHTS INTO POWER AND INDUSTRY SOLUTIONS

SUMMER INTERNSHIP REPORT

Submitted by

PANKU ISAAC DANIEL

22341A0396

In partial fulfillment for the award of the degree

of

BACHELOROFTECHNOLOGY

in

MECHANICAL ENGINEERING

GMR Institute of Technology, Rajam

Andhra Pradesh, India

JULY 2024
 BONAFIDE CERTIFICATE

Certified that this summer internship report on “Insights into Power and Industry Solutions” is
the bonafide work of “PANKU ISAAC DANIEL” who carried out summer internship under our
supervision at BHARAT HEAVY ELECTRICALS LIMITED, VISAKHAPATNAM.

Signature of the Faculty supervisor Signature of the Industry Supervisor

Dr.Ch. VINODH BABU Mr. DURGA CHARAN BASKEY
Assistant Professor Addl. Engineer
MECHANICAL ENGINEERING CSP-II, BHEL

Signature of the Head of the Department

DR. G. SASI KUMAR
Professor & Head
Department of Mechanical Engineering
 ACKNOWLEDGEMENT
Every task, big or small, is successful largely due to the effort of several wonderful people who
have always given their valuable advice or lent a helping hand. I sincerely appreciate the inspiration,
support, and guidance of those who have been instrumental in making this Summer Internship a success .
I express my gratitude to the College principal Dr. C. L. V. R. S. V. Prasad for arranging the
summer internship as part of the academic schedule.
I also extend my gratitude to the Head of the Department, Dr. G. Sasi Kumar who supported us
in successfully completing the summer internship.
I am deeply in debt to our central internship coordinator Dr. M. Krishna Prasad, Professor for
his moral support in successfully completing the summer internship.
I am extremely thankful to our faculty supervisor Dr.Ch.Vinodh Babu, Assistant Professor of
Mechanical Engineering for his valuable suggestions and guidance during our internship period.
I am extremely grateful to the management of “BHARAT HEAVY ELECTRICALS
LIMITED” for giving me an opportunity to undergo a summer internship. I express my deepest thanks
to “Mr.K.Varaprasad Rao ”, Addl. Engineer who showed excellence in supervision and devotion to be
inspired during my internship.

Yours’ sincerely,
M.K.Varma
22341A0381

I
 ABSTRACT

This industrial training report provides a comprehensive overview of the operations and processes
at Bharat Heavy Electricals Limited (BHEL), specifically focusing on the Heavy Plates & Vessels Plant
(HPVP) located in Visakhapatnam. BHEL, a premier engineering and manufacturing enterprise in India,
is renowned for its contribution to the power, industrial, and infrastructure sectors. The Heavy Plates &
Vessels Plant is a pivotal unit within BHEL, specializing in the fabrication of heavy plates and vessels
critical for various industrial applications. The report encapsulates the training experience, covering the
plant's production methodologies, quality control measures, and the integration of advanced technologies.
It delves into the various stages of manufacturing, from raw material procurement and processing to the
final assembly and inspection of heavy-duty equipment. Emphasis is placed on the plant's adherence to
safety standards, environmental regulations, and the implementation of best practices to ensure operational
excellence. Additionally, the report highlights the plant's organizational structure, workflow processes,
and the role of skilled personnel in maintaining the efficiency and reliability of production. Through
hands-on training and interaction with industry professionals, valuable insights into the practical aspects
of heavy engineering and manufacturing are gained. This training at BHEL's HPVP not only enhances
technical knowledge but also provides a real-world understanding of industrial challenges and solutions.

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 TABLE OF CONTENTS
S.I. TITLE Page
No. No.
ACKNOWLEDGEMENT I
ABSTRACT II
TABLE OF CONTENTS IV
LIST OF FIGURES VI
1 INTRODUCTION TO INTERNSHIP 1-2
1.1 What do you mean by internship? 1
1.2 What is a Summer Internship? 1
1.3 The need of Summer Internships 1
1.3.1 Practical Experience 1
1.3.2 Career Exploration 1
1.3.3 Skill Development 1
1.3.4 Networking 2
1.3.5 Employability 2
1.3.6 Employer Benefits 2
1.4 How it is useful to Undergraduate Students 2-3
1.4.1 Application of Knowledge 2
1.4.2 Professional Exposure 2
1.4.3 Resume Building 2
1.4.4 Career Clarification 2
1.4.5 Skill Enhancement 2
1.4.6 Networking opportunities 3
1.4.7 Confidence Building 3
2 PROFILE OF THE COMPANY 4-7
2.1 About the Company 4
2.1.1 Services 4
2.1.2 Mission and Vision 4
2.1.3 Future plans 4
2.1.4 Official address 4
2.2 Quality 4
2.2.1 Quality Assurance 4

III
 2.2.2 Quality control 5
2.2.3 Quality Testing laboratory 5
2.2.4 Quality Control Stores 6
2.2.5 Non-Destructive test 6
3 TASKS TAKEN UP & PROBLEM DEFINITION 8-16
3.1 Job entrusted 8
3.1.1 Automation of production process 8
3.1.2 Quality control inspections 8
3.1.3 Documentation and Analysis 9
3.2 Problem Definition 9
3.2.1 Identifying in efficiencies in Manual Processes 9
3.2.2 Quality Control Challenges 10
3.2.3 Integration of new technologies 10
3.2.4 Resource Management 11
3.2.5 Environmental and Safety Concerns 11
3.3 Research & Development 12
3.4 Shops 13
3.4.1 Work Shops 14
3.4.2 Fedder Shops 14
3.4.3 Production Shops 14
4 METHODOLOGY & LEARNING 17-24
4.1 Definitions and Techniques 17
4.1.1 Process Analysis 17
4.1.2 Root Cause Analysis 17
4.1.3 Lean Manufacturing Techniques 18
4.1.4 Automation and Digitalisation 18
4.2 Practical Applications 18
4.2.1 Implementation process 19
4.2.2 Outcomes 19
4.2.3 Collaboration and Teamwork 19
4.2.4 Personal Growth and Development 20
4.3 Physical Learnings on Welding 20
4.3.1 Advantages of welding joints 20
4.3.2 Disadvantages on welding joints 20

IV
 4.3.3 Electrodes 21
4.3.4 Types of Welding 21
4.3.5 Types of Weld joints 22
4.3.6 Heat Treatment process 23
4.3.7 Post Weld Heat Treatment 24
4.3.8 Sand Blasting 24
4.3.9 Supply of air to shops 24
5 CONCLUSIONS 25
REFERENCES 26

LIST OF FIGURES

Page
Figure No. Title of the Figure
No.

Figure 1 Quality Testing Laboratory Equipment 6

Figure 2 Types of Welding Joints 22

Figure 3 Heat Treatment Process Diagram 23

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 1. INTRODUCTION TO INTERNSHIP

1.1 What Do You Mean by Internship?

An internship is a period of work experience offered by an organization to give students and recent
graduates a taste of the professional world. Internships can be paid or unpaid and can vary in duration
from a few weeks to several months. The primary goal of an internship is to bridge the gap between
academic education and real-world professional experience, allowing individuals to apply their theoretical
knowledge in practical settings. Internships are often a crucial component of career development,
providing hands-on experience, industry exposure, and the opportunity to develop professional networks.
1.2 What Is a Summer Internship?
A summer internship specifically refers to an internship program that takes place during the
summer months, typically lasting anywhere from eight to twelve weeks. Summer internships are
particularly popular among undergraduate students because they coincide with the summer break from
academic studies. This period allows students to engage in full-time work without the conflict of academic
commitments. Summer internships are offered across various industries and disciplines, providing
students with a broad range of opportunities to gain practical experience and explore potential career paths.
1.3 The Need for Summer Internships
Summer internships serve multiple essential functions for students, educational institutions, and
employers alike:
1.3.1 Practical Experience
They provide students with hands-on experience in their field of study, enabling them to apply
theoretical concepts learned in the classroom to real-world situations.
1.3.2 Career Exploration
Internships allow students to explore different career paths and industries, helping them make
informed decisions about their future careers.
1.3.3 Skill Development
Interns develop both technical and soft skills, including communication, teamwork, problem-
solving, and time management.

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1.3.4 Networking
Internships offer opportunities to build professional networks, which can be invaluable for future
job searches and career growth.
1.3.5 Employability
Completing an internship can enhance a student’s resume, making them more competitive in the
job market upon graduation.
1.3.6 Employer Benefits
For employers, internships provide a way to identify and recruit talent early, test potential employees'
fit for the company, and gain fresh perspectives and innovative ideas from young minds.
1.4 How It Is Useful to Undergraduate Students
For undergraduate students, summer internships offer numerous benefits that significantly
contribute to their academic and professional development:
1.4.1 Application of Knowledge
Internships allow students to apply the knowledge and skills they have acquired in their
coursework to practical, real-world challenges. This application reinforces learning and enhances
understanding.
1.4.2 Professional Exposure
Students gain exposure to professional environments, understanding workplace dynamics,
industry standards, and professional expectations. This experience helps them transition more smoothly
from academia to the workforce.
1.4.3 Resume Building
An internship experience adds value to a student’s resume, demonstrating to potential employers
that the student has practical experience and is capable of applying academic knowledge in a professional
setting.
1.4.4 Career Clarification
By working in a specific industry or role, students can clarify their career interests and mak e more
informed decisions about their future career paths. They can determine if a particular field or role aligns
with their strengths and interests.
1.4.5 Skill Enhancement
Internships help students develop and refine both hard and soft skills. Hard skills may include
technical abilities specific to their field, such as programming, data analysis, or engineering design. Soft

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skills such as communication, teamwork, problem-solving, and adaptability are equally important and are
honed through daily interactions and responsibilities.
1.4.6 Networking Opportunities
Internships provide students with opportunities to meet and build relationships with professionals
in their chosen field. These connections can lead to mentorship, references, and even job opportunities
after graduation.
1.4.7 Confidence Building
Working in a professional setting helps students build confidence in their abilities and prepares
them for future job interviews and career challenges. Successfully completing tasks and projects during
an internship boosts self-esteem and professional self-assurance.

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 2. Profile of the Company
2.1 About the Company
Bharat Heavy Electricals Limited (BHEL) is an integrated power plant equipment manufacturer
and one of the largest engineering and manufacturing companies in India. It provides comprehensive
solutions for power generation, transmission, industry, transportation, renewable energy, and defence.
2.1.1 Services
BHEL offers a wide range of services, including design, engineering, manufacturing, construction,
testing, commissioning, and servicing of products and systems. The company's expertise spans various
sectors, making it a versatile and reliable partner for industrial projects.
2.1.2 Mission and Vision
BHEL's mission is to provide sustainable business solutions in the fields of energy, industry, and
infrastructure. Its vision is to be a global engineering enterprise that delivers quality products and services
in a manner that is safe, cost-effective, and environmentally responsible.
2.1.3 Future Plans
BHEL is focused on expanding its footprint in the global market, enhancing its technological
capabilities, and investing in renewable energy projects. The company aims to innovate continuously to
meet the changing needs of its customers and to contribute to the nation's energy security and economic
growth.
2.1.4 Official Address
Bharat Heavy Electricals Limited (BHEL) - Heavy Plates and Vessels Plant (HPVP)
Visakhapatnam, Andhra Pradesh, India
2.2 Quality
Quality at BHEL is ensured through stringent quality assurance (QA) and quality control (QC)
measures, maintaining high standards in manufacturing processes. Advanced quality testing laboratories
and non-destructive testing (NDT) techniques are employed to ensure the reliability and durability of
products. Continuous improvement and adherence to international quality standards are integral to
BHEL's commitment to excellence.
2.2.1 Quality Assurance
Quality assurance at BHEL involves systematic processes to ensure that products meet predefined
standards. This includes planning, control, and improvement activities aimed at providing confidence in

4
the quality of products. The quality assurance team is responsible for developing and implementing quality
management systems, conducting audits, and ensuring compliance with industry standards.
2.2.2 Quality Control
Quality control is a critical aspect of BHEL's operations. It involves rigorous testing and inspection
of products at various stages of production to ensure they meet the required specifications. Quality control
equipment are:
 Ultrasonic Testing
 Radiographic Testing
 Hardness Testing
 Dimensional Inspection
2.2.3 Quality Testing Laboratory
The quality testing laboratory at BHEL is equipped with advanced instruments and tools for
conducting various tests. These tests include mechanical, chemical, and non-destructive testing methods
to evaluate the properties and performance of materials and products. Quality testing laboratory equipment
is represented in Figure 1.

Figure 1: Quality Testing Laboratory Equipment

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2.2.4 Quality Control Stores
Quality control stores are dedicated areas where materials and components are stored and
inspected. These stores ensure that only materials meeting the required quality standards are used in
production. The quality control stores are managed systematically, with records maintained for traceability
and accountability.

2.2.5 Non-Destructive Test

Non-destructive testing (NDT) methods are used to evaluate the properties of materials and
components without causing damage.
The five most common testing methods used for weld examinations are:
 Visual Testing
 Dye Penetrant Test
 Magnetic Particle Test
 Ultrasonic Test
 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, fibre
scope, mirror, micro scope etc.
Dye penetrate 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 penetrates, 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 materials &coating to prevent corrosion is also
applied.
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.

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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 visualise a cross-section specimen shaving depth of futures that are recorded.
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
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.

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 3. Tasks Taken Up and Problem Definition

During my 28-day internship at BHEL, Visakhapatnam, I was assigned various tasks that spanned
different departments, providing a holistic understanding of the company's operations and challenges. This
section details the specific tasks I undertook, the problems I encountered, and the strategies developed to
address these issues.
3.1 Job Entrusted
During my internship at BHEL, I was entrusted with tasks related to the automation of industrial
processes, including the programming and maintenance of PLC systems. I worked on identifying and
resolving operational inefficiencies, contributing to the optimization of production workflows. This role
required a keen understanding of mechanical engineering principles and the ability to apply them in a
practical, high-stakes environment.
3.1.1 Automation of Production Processes
One of the primary tasks assigned to me was the automation of certain production processes.
BHEL, known for its heavy electrical equipment, requires highly efficient and precise manufacturing
techniques. Automation is essential for improving efficiency, reducing errors, and maintaining consistent
quality. My responsibilities included:
Assessing Current Processes: I began by observing and documenting the existing manual processes. This
involved detailed note-taking and discussions with operators to understand each step.
Identifying Automation Opportunities: Through my observations, I identified repetitive tasks and
processes that could benefit from automation. These included material handling, welding, and assembly
operations.
Proposing Automation Solutions: I researched and proposed various automation technologies, such as
programmable logic controllers (PLCs), robotic arms, and automated guided vehicles (AGVs). I presented
these solutions to my supervisor, highlighting their potential benefits and cost implications.
3.1.2 Quality Control Inspections
Quality control (QC) is critical in ensuring that BHEL's products meet industry standards and
customer expectations. My involvement in QC included:
Conducting Inspections: I assisted the QC team in performing inspections on finished products. This
included checking dimensions, surface finish, and material properties against predefined standards.

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Documenting Findings: I meticulously documented inspection results, noting any deviations from the
standards. This data was crucial for identifying trends and recurring issues.
Participating in Root Cause Analysis: When defects were found, I participated in root cause analysis
meetings to determine the underlying causes and develop corrective actions.
Assisting in Experimental Setups: I helped set up experiments for testing new materials and technologies.
This involved preparing samples, setting up testing equipment, and monitoring experiments.
Data Analysis: I analysed experimental data to evaluate the performance of new materials and
technologies. This included statistical analysis and graphical representation of results.
Reporting Findings: I compiled reports summarizing the experimental results and presented them to the
R&D team. My reports highlighted the potential applications and benefits of the new technologies.
3.1.3 Documentation and Analysis
Accurate documentation and analysis are essential for continuous improvement and knowledge
sharing. My documentation tasks included:
Creating Process Flowcharts: I created detailed flowcharts of various production processes, which helped
in identifying bottlenecks and inefficiencies.
Analysing Production Data: I analysed production data to identify trends, such as variation in output and
defect rates. This analysis helped in understanding the impact of different variables on production
efficiency and quality.
Developing Standard Operating Procedures (SOPs): Based on my observations and analysis, I developed
SOPs for various tasks. These SOPs aimed to standardize processes and ensure consistency in operations.
3.2 Problem Definition
Throughout my internship, I encountered several problems that needed to be addressed to improve
the efficiency and quality of operations at BHEL.
3.2.1 Identifying Inefficiencies in Manual Processes
One of the significant problems was the inefficiency in certain manual processes. These
inefficiencies were caused by:
Human Error: Manual tasks were prone to errors due to fatigue, lack of concentration, or insufficient
training.
Inconsistent Performance: Different operators performed tasks at varying speeds and quality levels,
leading to inconsistencies in the final product.

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Time-Consuming: Manual processes were often time-consuming, limiting the overall productivity of the
plant.
To address these issues, I proposed the automation of key processes, as detailed earlier. Automation would
not only reduce errors and inconsistencies but also significantly improve productivity.
3.2.2 Quality Control Challenges
Maintaining high-quality standards was another critical challenge. Specific issues included:
Defect Identification: Despite rigorous inspections, certain defects were not identified until later stages
of production, leading to rework and delays.
Root Cause Analysis: Identifying the root cause of defects was often challenging, especially when
multiple variables were involved.
Documentation: The manual documentation process was time-consuming and prone to errors, making it
difficult to track and analyse QC data effectively.
To mitigate these challenges, I suggested the implementation of automated inspection systems and
advanced data analysis tools. Automated systems would ensure more accurate and consistent inspections,
while data analysis tools would streamline the documentation process and facilitate root cause analysis.
3.2.3 Integration of New Technologies
Integrating new technologies into existing systems posed several challenges, including:
Compatibility Issues: New technologies often had compatibility issues with the existing equipment and
software, requiring significant modifications.
Training Requirements: Operators and technicians needed extensive training to effectively use new
technologies, which added to the implementation time and cost.
Resistance to Change: There was some resistance to adopting new technologies among the workforce,
primarily due to fear of job displacement and unfamiliarity with the new systems.
To address these issues, I recommended a phased implementation approach. This approach involved:
Pilot Testing: Conducting pilot tests of new technologies in specific areas before full-scale
implementation. This would help identify and resolve compatibility issues early on.
Comprehensive Training Programs: Developing training programs to equip the workforce with the
necessary skills to operate and maintain new technologies.
3.2.4 Resource Management
Effective resource management was crucial for maintaining productivity and minimizing costs.
However, several problems were identified, including:

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Resource Allocation: Inefficient allocation of resources, such as materials, manpower, and machinery,
led to bottlenecks and delays in production.
Inventory Management: Inaccurate inventory records resulted in material shortages and overstocking,
affecting production schedules and increasing costs.
Maintenance: Unscheduled maintenance and breakdowns of machinery disrupted production and
increased downtime.
To improve resource management, I proposed the following solutions:
Resource Planning Tools: Implementing advanced resource planning tools to optimize the allocation of
resources based on real-time data and production requirements.
Inventory Management Systems: Adopting automated inventory management systems to ensure accurate
tracking of materials and reduce instances of shortages and overstocking.
Predictive Maintenance: Utilizing predictive maintenance techniques to monitor the condition of
machinery and schedule maintenance proactively, minimizing unexpected breakdowns.
3.2.5 Environmental and Safety Concerns
Ensuring environmental sustainability and workplace safety were also significant challenges.
Specific issues included:
Waste Management: Inefficient waste management practices led to environmental concerns and potential
regulatory violations.
Safety Hazards: Certain processes posed safety hazards to workers, including exposure to hazardous
materials and the risk of accidents.
Energy Consumption: High energy consumption in production processes resulted in increased operational
costs and environmental impact.
To address these concerns, I recommended:
Sustainable Practices: Implementing sustainable manufacturing practices, such as recycling waste
materials and reducing emissions, to minimize environmental impact.
Safety Protocols: Enhancing safety protocols and providing regular training to workers to mitigate safety
hazards.

3.3 Research and Development

BHEL's Research and Development (R&D) department is dedicated to innovation and
technological advancements. The R&D team focuses on developing new products, improving existing

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technologies, and finding solutions to industry challenges. The R&D projects at BHEL include
advancements in power generation, renewable energy, and industrial automation.
BHEL places strong emphasis on innovation and creative advancement, which leads to the
development of technologically competitive products and services. The research and developmental
efforts of the company are not only aimed at improving the performance of the products of current
manufacture, but also developing new products and systems using state-of-the-art technologies, relevant
to the needs of the various business sectors. With a spending of nearly 2.5% of its annual turnover on
R&D projects, BHEL is the largest spender on R&D in the heavy industry segment, to which it belongs.
BHEL also generates nearly 20% of its annual turnover from in-house developed products and services
introduced in last five years.
To carry out research in identified specialized areas, BHEL has established 14 Centres of
Excellence. The Corporate R&D Division is currently equipped with ten Centres of Excellence (COE)
carrying out advanced R&D in engineering disciplines like, Simulators, Computational Fluid Dynamics
(CFD), Permanent Magnet Machines (PMM), Surface Engineering, Intelligent Machines and Robotics,
Machine Dynamics, Compressor and Pumps, Nano Technology, Ultra High Voltage (UHV) and
Advanced Transmission Systems. Two COEs, for Power Electronics, IGBT and Controller Technology,
and for Control and Instrumentation (C&I), are located at Electronics Division, Bengaluru. Two COEs,
for Advanced Fabrication Technology and Coal Research Centre, are established the Tiruchirappalli unit.
In addition, BHEL has also established five specialized institutes to pursue R&D in identified
areas. They are Welding Research Institute (WRI) at Tiruchirappalli, Ceramic Technological Institute
(CTI) at Bengaluru, Centre for Electric Traction (CET) at Bhopal, Pollution Control Research Institute
(PCRI) at Haridwar and Amorphous Silicon Solar Cell Plant at Gurugram.
BHEL has the distinction of filing more than one patent per calendar day if the record number of
508 filings done during 2016-17 is considered. Currently the company is the proud owner of more than
3900 IPR assets, which are in productive use in the company’s business. The company has won several
awards and recognitions for its outstanding work in this area, including the National IP Award, WIPO
International IP Award. Other laurels received by BHEL for R&D and related activities include Best
Maharatna PSU Award for Innovation and R&D from the India Today Group and CII-Thompson Reuters
Innovation Award. BHEL has been ranked the Ninth “Most Innovative Company in the World” by the
renowned US business magazine “FORBES”, based on a listing of “innovation premium” to rank the
world’s most innovative companies, developed by professors from Harvard Business School, Brigham

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Young University and INSEAD. There are three other condensers used in HVAC (Heating, Ventilation
and Air conditioning) systems.

 Water-cooled
 Air-cooled
 Evaporative
Water-cooled: Although a little pricier 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.

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 condenser’s 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. 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.
3.4. SHOPS
BHEL-HPVP features various specialized shops, including workshops, feeder shops, and
production shops, each dedicated to different stages of the manufacturing process. These shops are
equipped with advanced machinery and tools, ensuring precision and efficiency in production. The
collaborative efforts across these shops contribute to the seamless execution of complex projects and high-
quality output.
3.4.1 Work Shops
The workshops at BHEL are equipped with a variety of machinery and tools for manufacturing
components and assemblies. These workshops are divided into different sections, each specializing in
specific processes such as machining, welding, and assembly.

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3.4.2 Fedder Shops
Fedder shops are specialized sections within the production facility where specific components are
manufactured. These shops are equipped with dedicated machinery and tools for producing parts such as
feeders, nozzles, and other critical components.
3.4.3 Production Shops
Production shops are the primary areas where the main manufacturing processes take place. These
shops are organized to optimize workflow and ensure high productivity. The production shops include
sections for machining, assembly, welding, and finishing.
Material preparation (MP): In material preparation, as per the customer specification the design
department releases the drawing for the marking. Depending upon the drawing specifications materials
are brought from the stores. These materials are mostly the plates of required compositions that are
imported at the stage of receiving of project itself. Usually the designers will send the part drawings of a
unit to the material preparation shop where the technicians analyse these drawings and proceed for
marking in such a way that the maximum material is utilised reducing the wastage since optical utilisation
of the available sources is the ultimate aim. The plates are of 2 types:
• Trimmed plates.
• Untrimmed plate
Trimmed plates : The plates which are having soft edges are called Trimmed plates.
Untrimmed plates: The plates which are not having soft edges are called untrimmed plates.
Machines in material preparation shop: In material preparation, welding plays a vital role for cutting.
Once the markings are completed the sheets 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
 Flame Planning Machine.
 Gas Cutting Pug Machine.
 Edge Planning Machine.

Flame planning machine: Flame cutting is an important industrial production process suitable especially
for materials like carbon and low alloy steels. Using this cutting method, a carbon steel up-to 150 mm can
be cut with typical tolerances from+1.5mm. This is a semi-automatic machine consisting of three torches
(just like as in gas cutting) side by side. Generally, the centre torches used for direct vertical cutting depth
wise whereas remaining two torches were used for angular cutting i.e. Bevel edge preparation. On a

14
horizontal beam which moves to and fro, two gas cutting machines are mounted on either side so that
material can be removed on the either side of the plate. The machine was basically used for cutting of
lengthy plates of thickness ranging from 16mm to200mm. Flame cutting used to groove weld joint metal
designs and to prepare the edges of metal plates and also used to cutwork pieces of small sizes from large
metal plates for further usage in production.
Advantages Of Flame Cutting Method:
1.Equipment's used in flame cutting process are portable and can be used effectively for field work.
2.Flame cutting machines with multiple torches can cut number of steel profile pieces simultaneously.
3. Main advantage of this machine is that it is a semi-automatic and bevel Edges are prepared parallel
while cutting extra material
Disadvantages Of Flame Cutting Method:
1.This method is limited to the cutting of steel and cast-iron materials.
2.The heat and red hot slag expelled during this metal cutting method present fire and burn hazardous to
plant and workers.
3.Proper fume control and adequate ventilation is must for the place of cutting.
Gas Cutting Pug Machine: It is a general cutting machine which carries a torch and works just like a gas
Cutting equipment. But only difference is that it is a semi-automatic and is generally used for small lengths
of straight line cutting and contour cuttings.
Advantages of pug machine:
1.Easy to handle.
2.The body is made of pressed steel with asbestos heat deflector.
3.The cutter is a injected type, especially designed to prevent backfire.
Disadvantages of pug machine:
1.High capital cost.
2.Slow handling of machine to prevent hazardous.
3.Difficult to cut the metal.

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Edge Planning Machine: In high thick carbon steel plates and stainless-steel plates edge preparation is
not possible by ordinary gas cutting machine. In those cases, we go for machining of the plate by edge
planning machine. Basically, for holding the plates firmly during machining, hydraulic jacks and
mechanical jacks were used which are arranged alternatively above the bed. Main advantage of these
machining is that it can even be used for less steels. A planer is a type of metal working machine tool that
uses linear relative motion between the work pieces. A planner is similar to a shaper, but larger, and with
work piece moving, where as in a shaper the cutting tool move.
Advantages Of Edge Planning Machine:
1.Main advantage of these machining is that it can even be used for less steels.
2.It can cut the metal into small strips.
3.Low power cost.
Disadvantages Of Edge Planning Machine:
1.High expensive.
2.The machine occupies a large space which cuts the material in different thickness.

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 4. Methodology & Learning

The methodology adopted during my internship at BHEL, Visakhapatnam, was crucial in

addressing the tasks and challenges I encountered. This section elaborates on the specific methods and
techniques used, as well as the key learnings derived from these experiences.
4.1 Definitions and Techniques
The methodologies employed during the internship at BHEL included process analysis, root cause
analysis, and lean manufacturing techniques to identify and address inefficiencies in production.
Automation and digitalization were integral, involving the use of PLC programming and advanced data
analytics to enhance process efficiency. These techniques facilitated a systematic approach to problem-
solving and continuous improvement in manufacturing operations.
4.1.1 Process Analysis
Process analysis involved a detailed examination of existing workflows to identify inefficiencies
and areas for improvement. The steps included:
Observation: I observed various production processes to understand the current state of operations. This
involved spending time on the shop floor, talking to operators, and noting down each step in the workflow.
Data Collection: I collected quantitative data on process times, defect rates, and resource utilization. This
data was essential for identifying bottlenecks and measuring process efficiency.
Mapping: I created detailed process flowcharts to visualize the workflows and identify areas where
improvements could be made. These flowcharts helped in understanding the sequence of operations and
pinpointing stages that caused delays or errors.
4.1.2 Root Cause Analysis
Root cause analysis (RCA) was employed to identify the underlying causes of problems,
particularly in quality control. The techniques used included:
5 Whys Analysis: This technique involved asking "Why?" multiple times to drill down to the root cause
of a problem. For example, if a defect was found in a product, I would ask why it occurred, then why that
reason happened, and so on until the fundamental cause was identified.
Fishbone Diagrams: Also known as Ishikawa diagrams, these were used to categorize potential causes
of problems into major categories such as equipment, methods, materials, and manpower. This visual tool
helped in systematically exploring all possible causes.

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Pareto Analysis: By applying the Pareto principle, I focused on identifying the few critical factors that
caused the majority of problems. This involved analysing defect data to prioritize issues that had the most
significant impact on quality.
4.1.3 Lean Manufacturing Techniques
Lean manufacturing techniques aimed at minimizing waste and maximizing efficiency were
pivotal in improving production processes. The methods included:
Value Stream Mapping: This technique involved mapping out all the steps in a process to identify and
eliminate non-value-added activities. By focusing on value-added steps, I helped streamline workflows
and reduce waste.
Kaizen: Kaizen, or continuous improvement, was a philosophy I adopted to make incremental
improvements in processes. This involved regularly reviewing and refining workflows based on feedback
and performance data.
5S Methodology: The 5S methodology (Sort, set in order, Shine, Standardize, Sustain) was implemented
to organize the workplace, reduce waste, and improve efficiency. This approach ensured a clean, orderly,
and standardized work environment.
4.1.4 Automation and Digitalization
Automation and digitalization played a significant role in enhancing process efficiency and
accuracy. The steps included:
PLC Programming: I utilized programmable logic controllers (PLCs) to automate repetitive tasks and
improve process consistency. This involved writing and testing PLC programs to control machinery and
processes.
Data Analytics: Advanced data analytics tools were used to analyse production data and identify trends.
By leveraging data analytics, I was able to make data-driven decisions and propose evidence-based
solutions.
Simulation Software: Simulation software, such as TIA Portal, was used to model and test automation
solutions before implementation. This helped in identifying potential issues and optimizing solutions.
4.2 Practical Applications
The practical applications of these methodologies at BHEL included pilot testing and feedback
collection to refine solutions before full-scale implementation. These efforts resulted in enhanced process
efficiency, improved quality control, and innovative approaches to manufacturing. The experience

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fostered collaboration and teamwork, underscoring the importance of cross-departmental communication
and collective problem-solving.
4.2.1 Implementation Process
The implementation process involved several key steps to ensure that proposed solutions were
effective and feasible:
Pilot Testing: Before full-scale implementation, I conducted pilot tests of proposed solutions in a
controlled environment. This involved setting up test scenarios, monitoring results, and making necessary
adjustments.
Feedback Collection: Feedback from operators and supervisors was crucial in refining solutions. I
regularly communicated with team members to gather their insights and incorporate their suggestions into
the implementation process.
Documentation: Detailed documentation of the implementation process was maintained to ensure
transparency and facilitate knowledge sharing. This included creating standard operating procedures
(SOPs) and maintaining records of test results and adjustments.
4.2.2 Outcomes
The outcomes of the methodologies and techniques applied during my internship included:
Enhanced Efficiency: The implementation of lean manufacturing techniques and automation solutions
led to significant improvements in process efficiency. This was evident from reduced process times, lower
defect rates, and increased productivity.
Improved Quality Control: Advanced quality control measures, such as automated inspection systems
and root cause analysis, helped in maintaining high standards of quality. This resulted in fewer defects
and higher customer satisfaction.
Innovation and Learning: The hands-on experience with advanced technologies and methodologies
contributed to my professional development. I gained a deeper understanding of industrial processes and
the importance of continuous improvement and innovation.
4.2.3 Collaboration and Teamwork
Working at BHEL provided valuable insights into the importance of collaboration and teamwork.
Key aspects included:
Interdepartmental Collaboration: Effective communication and collaboration across departments were
essential in identifying and solving problems. I regularly interacted with colleagues from production,
quality control, R&D, and maintenance departments to gather insights and feedback.

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Team Meetings and Discussions: Participating in team meetings and discussions helped in understanding
different perspectives and developing well-rounded solutions. These interactions also fostered a
collaborative environment where ideas and knowledge were freely exchanged.
4.2.4 Personal Growth and Development
The internship experience at BHEL contributed significantly to my personal growth and
development. Key learnings included:
Technical Skills: I gained hands-on experience with advanced manufacturing technologies, automation
tools, and quality control techniques. This practical knowledge will be invaluable in my future career.
Problem-Solving Skills: The methodologies and techniques applied during the internship enhanced my
problem-solving skills. I learned to approach problems systematically, analyse data, and develop
evidence-based solutions.
Professionalism: Working in a professional environment taught me the importance of punctuality,
discipline, and effective communication. These skills will be crucial in my future professional endeavours.
4.3 Physical Learnings on Welding
Welding is a fabrication or sculptural process that joins materials, usually metals or
thermoplastics, by causing fusion, which is distinct from lower temperature metal-joining techniques
such as brazing and soldering, which do not melt the base metal. In addition to melting the base
metal, a filler material is typically added to the joint to form a pool of molten material (the weld pool)
that cools to form a joint that, based on weld configuration (butt, full penetration, fillet, etc.), can be
stronger than the base material (parent metal). Welding also requires a form of shield to protect the
filler metals or melted metals from being contaminated or oxidized.
4.3.1 Advantages of Welding Joints
Welding joints offer several advantages, including:
Strength: Welded joints are typically stronger than the base materials.
Permanence: Welding provides a permanent joint that does not loosen over time.
Versatility: Suitable for various metals and thicknesses.
Efficiency: Welding processes can be automated for high productivity.
4.3.2 Disadvantages of Welding Joints
While welding joints have many advantages, there are also some disadvantages to consider:
Distortion: Welding can cause distortion in the materials being joined.
Residual Stresses: Welding may introduce residual stresses that can affect the performance of the joint.

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Inspection Challenges: Non-destructive testing is required to ensure weld quality.
Health Hazards: Welding processes can pose health risks to workers if proper safety measures are not
followed.
4.3.3 Electrode
An electrode is an electrical conductor used to make contact with a non-metallic part of a circuit
(e.g. a semiconductor, an electrolyte, a vacuum or air). In are welding, an electrode is used to conduct
current through a workpiece to fuse two pieces together. Depending upon the process, the electrode is
either consumable, in the case of gas metal arc welding or shielded metal are welding, or non-consumable,
such as in gas tungsten are welding. For a direct current system, the weld rod or stick may be a cathode
for a filling type weld or an anode for other welding processes. For an alternating current are welder, the
welding electrode would not be considered an anode or cathode.
4.3.4 Types of Welding
Oxy-fuel welding: Oxy-fuel welding also known as oxyacetylene welding or oxy welding, uses fuel gases
and oxygen to weld and cut metals.
Shielded metal arc welding (SMAW) - also known as "stick welding" or "electric welding", uses an
electrode that is coated in flux to protect the weld puddle. The electrode holder holds the electrode as it
slowly melts away. Slag protects the weld puddle from atmospheric contamination.
Gas tungsten arc welding (GTAW)- also known as TIG (tungsten, inert gas), uses a non- consumable
tungsten electrode to produce the weld. The weld area is protected from atmospheric contamination by an
inert shielding gas such as argon or helium.
Gas metal arc welding (GMAW) - commonly termed MIG (metal, inert gas), uses a wire feeding gun that
feeds wire at an adjustable speed and flows an argon-based shielding gas or a mix of argon and carbon
dioxide (CO2) over the weld puddle to protect it from atmospheric contamination.
Flux-cored arc welding (FCAW) - almost identical to MIG welding except it uses a special tubular wire
filled with flux; it can be used with or without shielding gas, depending on the filer. • Submerged are
welding (SAW) - uses an automatically fed consumable electrode and a blanket of granular fusible flux.
The molten weld and the arc zone are protected from atmospheric contamination by being "submerged"
under the flux blanket.
Electro slag welding (ESW) - a highly productive, single pass welding process for thicker materials
between 1 inch (25 mm) and 12 inches (300m m) in a vertical or close to vertical position.

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Electric resistance welding (ERW) - a welding process that produces coalescence of laying surfaces
where heat to form the weld is generated by the electrical resistance of the material. In general, an efficient
method, but limited to relatively thin material. Many different energy sources can be used for welding,
including a gas flame, an electric arc, a laser, an electron beam, friction, and ultrasound. While often an
industrial process, welding may be performed in many different environments, including in open air, under
water, and in outer space. Welding is a hazardous undertaking and precautions are required to avoid burns,
electric shock, vision damage, inhalation of poisonous gases and fumes, and exposure to intense ultraviolet
radiation.
4.3.5 Types of Weld Joints
Various types of weld joints are used in welding, including butt joints, lap joints, corner joints,
edge joints, and T-joints. Each type has specific applications and characteristics. The following figure 2
shows us the types of welding

Figure 2: Types of Welding Joints

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4.3.6 Heat Treatment Process
The heat treatment process involves heating and cooling metals to alter their physical and
mechanical properties. It is used to improve hardness, strength, and ductility. The below Figure 3
represents the Heat Treatment Process Diagram.

Figure 3: Heat Treatment Process Diagram

Heat treatment of steel involves a combination of heating, holding and cooling at controlled rates
to produce the desired conditions.

•Annealing.
•Normalising.
•Hardening.
•Tempering.
Annealing: The term annealing refers to any heating and cooling operation that is usually applied to
induce softening. It is commonly employed for castings and forgings to reduce the coarse grain structure
prior to machining.

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Normalising: It is the process of heating the steel ot above the upper critical temperature (810-930°C)
followed by cooling in still air. Normalising is widely used in industry because it's more economical than
annealing. This process is usually performed after cooling, forging or casting for grain refinement and to
put steel in the best condition for machining or hardening.
Hardening: It is defined as the process of heating steel to austenite phase followed by rapid cooling in a
liquid bath such as water or oil. The hardening process consists of heating the steel to a temperature of 30
to 50°C above A1 hypereutectoid steel and 30 to 50°C above A13 for hypereutectoid steel.
Tempering: It is a process of heating hardened steel to a temperature below lower critical temperature,
followed by slow cooling. Tempering renders the steel tough hand ductile. The process involves heating
the hardened steel below lower critical temperature, holding at this temperature for sufficient time and
slow cooling in air. Cutting tools are tempered between 230°- 300°C. Tempering causes transformation
of marten site into troostite or sorbate.
4.3.7 Post Weld Heat Treatment
Post Weld Heat Treatment (PWHT) is applied to welded components to relieve residual stresses
and improve their mechanical properties. It involves controlled heating and cooling of the welded area.
4.3.8 Sand Blasting
Sand blasting is a process used to clean or prepare surfaces by propelling abrasive particles at high
velocity. It is commonly used for removing rust, paint, and other contaminants from metal surfaces. The
following Figure 8 shows the sand blasting.
4.3.9 Supply of Air to Shops
Air is sucked from the suction filter and then in the blown cylinder. When the piston moves
back the air enters into the cylinder and develops up-to a pressure of3kg/cm at 80°c and when piston
moves front, the air from suction valve enter to the heat excha nger where air passes from shell side
and enters into a high-pressure cylinder with a pressure of 7kg/cm and exists through the delivery
valves. Air is cooled and collected in air collecting tank. And water in tube side gets heated and goes
to the outside chamber of the water collection tank.

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 5.CONCLUSION
My internship at Bharat Heavy Electricals Limited (BHEL), Visakhapatnam, has been an
invaluable learning experience. Over the course of 28 days, I had the opportunity to immerse myself
in the company's diverse operations, from production and quality control to research and
development and welding techniques. Each department provided a unique insight into the
complexities and challenges of the heavy electrical industry.
Following are the Key learnings from the Summer Internship in BHEL, Visakhapatnam;
Production and Manufacturing: Gained hands-on experience with state-of-the-art machinery and
learned about the production processes for various industrial components.
Quality Assurance and Control: Understood the importance of maintaining high-quality standards
through rigorous testing and inspection.
Research and Development: Explored the role of innovation in developing new technologies and
improving existing products.
Welding Techniques: Learned about various welding methods, their applications, and the advantages
and disadvantages of each technique.
Project Management: Observed the systematic approach to managing large-scale projects, including
planning, execution, and quality control.
Team Collaboration: Experienced working in a collaborative environment, interacting with
professionals across different departments.
Problem-Solving: Developed problem-solving skills by tackling real-world challenges and finding
practical solutions.
The internship at BHEL, Visakhapatnam, has provided me with a comprehensive
understanding of the heavy electrical industry. The exposure to various departments and processes
has enhanced my technical skills and professional development. This experience has not only
deepened my knowledge in mechanical engineering but also prepared me for future challenges in my
career. I am grateful to BHEL and GMR Institute of Technology for this opportunity, and I look
forward to applying these learnings in my future endeavors.
This concludes my detailed report on the internship experience at Bharat Heavy Electricals
Limited, Visakhapatnam. The insights gained and the knowledge acquired during this period will
significantly contribute to my academic and professional growth.

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 References

1. BHEL Official Website: www.bhel.com

2. International Organization for Standardization (ISO): www.iso.org
3. American Welding Society (AWS): www.aws.org
4. National Institute of standards and Technology: www.nist.gov
5. MIT Open Courseware: ocw.mit.edu
6. Womack, J. P., Jones, D. T., & Roos, D. (2007). The machine that changed the world: The story
of lean production--Toyota's secret weapon in the global car wars that is now revolutionizing
world industry. Simon and Schuster.
7. Hughes, T. G. (2020). Multiproduct Facility Design: An Integrated Approach. In Biotechnology
and Biopharmaceutical Manufacturing, Processing, and Preservation (pp. 293-332). CRC Press.
8. Klesta, E. J., & Bartz, J. K. (1996). Quality assurance and quality control. Methods of Soil
Analysis: Part 3 Chemical Methods, 5, 19-48.
9. Yew, J. M. (2016). Exploration of IEC 1131-3’s LAD and SFC Languages in PLC Programming.
IRC.
10. "The Role of Internships in EngineeringCoker, D. (2005). The effects of participation in the
Louisiana Principal Internship/Induction program on school performance scores and on teacher
and principal perceptions of principals' knowledge, skills, and dispositions.

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