A REPORT ON IN-PLANT TRAINING AT

THE FERTILIZERS AND CHEMICALS TRAVANCORE

LIMITED
(FACT)UDYOGAMANDAL

SUBMITTED BY
AKSHAY VENUGOPAL
B.Tech MECHANICAL ENGINEERING
AT
SNM INSTITUTE OF MANAGEMENT AND TECHNOLOGY,
MOOTHAKUNNAM

TRAINING PERIOD

ABSTRACT
I underwent in-plant training to acquaint myself for a period
of 10-days from to get an industrial exposure in a practical
aspect of technical implementation. During the course of
study I was able to interact freely with the officials and other
employees in the plant and fetch maximum relevant
information from them. I also got an opportunity to visit the
work area and get a hands on experience on various
industrial devices. The training helped me to get an idea about
the various manufacturing processes and the technical
instruments which are used in the plant. I also got familiarized
with the various equipments used in an industry for a
Mechanical Engineer

ACKNOWLEDGEMENT
I would like to take this opportunity to express my sincere
gratitude to all those who have helped me throughout this inplant training. It gives me immense pleasure to acknowledge
all those who have rendered encouragement and the support
for the successful completion of work
First of all I would like to thank my institution SNM
INSTITUTE OF MANAGEMENT AND TECHNOLOGY, for
allowing me to proceed with the in-plant training.
I place my sincere thanks to Mr. Velumani, Dy Manager (Trg)
of FACT Training department, for permitting me to do the
training at FACT.
I would also like to thank Mr. George Varghese and Mr. A.S.
Antony of UD Mechanical Workshop, Mr. R. Dileep AGM
Sulphuric Acid plant and Mr. Mohanachandran AGM
Ammonia Complex.
I express my hearty thanks to all the Employees of The
FERTILIZERS AND
CHEMICALS TRAVANCORE
LIMITED for their entire constant support during the training

FACT-AN INTRODUCTION
FACT, India's first large scale fertilizer unit was set up in
1943. In 1947, FACT Udyogamandal started production of
Ammonium Sulphate with an installed capacity of 10,000 MT
Nitrogen. FACT became a Kerala State Public Sector
Enterprise on 15th August 1960 and 21st November 1962, the
Government of India became the major shareholder.
The 2nd stage of expansion of FACT was completed in 1962.
The 3rd stage of expansion of FACT was completed in 1965
with setting up of a new Ammonium Sulphate Plant.
FACT Engineering and Design Organization was set up on
24th July 1965 to meet the emerging need for indigenous
capabilities in vital areas of Engineering, Design and
Consultancy for establishing large and modern fertilizer
plants. FEDO has since then diversified into Chemicals,
Petrochemicals, Hydrometallurgy, Pharmaceutical and other
areas. FEDO offers services from project identification and
evaluation stage to plant design, procurement, project
management, site supervision and commissioning of new
plants as well as revamping and modernization of old plants.
FACT Engineering Works was established on 13 th April 1966
as a unit to fabricate and install equipments for fertilizer
4

plants. Over the years FEW developed capabilities in the

fabrication of pressure vessels and heat exchangers. FEW
have also undertaken lying of cross country piping and
fabrication and installation of large penstocks of
hydelprojects.
The Cochin Division of FACT, the 2nd production Unit was
set up at Ambalamedu and the 1st phase was commissioned in
1973. The 2nd phase of FACT Cochin Division was
commissioned
in
1976.
As a diversification plans from the traditional field of
Fertilizers and Chemicals, 50000 TPA Caprolactam Plant at
Udyogamandal
was
commissioned
in
1990.
FACT set up 900 TPD Ammonia Plant at Udyogamandal at a
cost of 638 Crores following an order of the High Court of
Kerala in February 1994 on a Public Interest Litigation, to
decommission the existing imported Ammonia storage and
handling facility at Willington Island (Cochin Port). The
Ammonia
plant
was
commissioned
in
1998.
The company's main business is manufacture and marketing
of (a) Fertilizers (b) Caprolactam and Engineering
Consultancy and Fabrication of Equipment.

MILESTONES OF FACT
22-09-1943 - Incorporation
26-06-1947 - Production started
15-08-1960 - FACT came under Public Sector
21-11-1962 - Govt. of India major share holder
1959-1960
1962

- UD 1st stage expansion completed

- UD 2nd stage expansion completed

16-03-1964 - ICMA Award for utilizing byproduct

gypsum
15-10-1966 - UD 3rd stage expansion completed

1971

- ICMA Award for technology transfer

01-10-1971 - UD 4th stage Ammonia Plant

01-10-1973 - UD 4th stage 150TPD Ammonium

Phosphate
24-07-1965 - FACT Engineering and Design

Organization
13-04-1966 - FACT Engineering Works
07-06-1966 - CD Phase-I License issued
27-04-1973 - CD I Urea Plant commissioned
10-11-1976 - CD II Sulphuric Acid Plant

commissioned
6

 10-12-1976 - CD II Phosphoric Acid Plant

commissioned
10-01-1977 - CD II NPK trial run started

01-04-1976 - CD II NPK commercial production

started
18-05-1984 - PD Caprolactam technical collaboration

agreement
14-09-1984 - PD Zero date of ASCL Project
06-08-1985 - PD Caprolactam License issued
13-12-1989 - FEW shifted to Palluruthy
26-07-1989 - Award for excellence in performance

1986/7 from the Prime Minister of India

20-12-1990 - CD-12MW Captive Power Plant
01-03-1991 - PD Caprolactam commercial production

started
01-03-1991 - UD New Ammonium Sulphate

commercial production started

25-09-1993 - Foundation stone - 900 TPD Ammonia

Plant
23-03-1998 - 900 TPD Ammonia plant commercial

production started

FACT UDYOGAMANDEL
7

FACT Udyogamandal Plant, the oldest of FACT, which

started production of Ammonium Sulphate in 1947 using the
firewood gasification process, has during the last few decades
undergone several stages of expansion and diversification,
giving up old and obsolete technology and installing new and
sophisticated plants making use of naphtha as raw material.
Today, the Udyogamandal Plants has an installed capacity of
76,050 tonnes of N and 29700 tonnes of P2O5. Apart from
fertilizers like Ammonium Sulphate and Ammonium
Phosphate Sulphate (FACTAMFOS 20:20:0:13) FACT
Udyogamandal Plants also manufactures chemicals as
intermediate products like Sulphuric Acid, Anhydrous
Ammonia, Phosphoric Acid, Sulphur Dioxide, Oleum, etc.
Ammonium Sulphate liquor obtained as a byproduct from the
Caprolactam Plant is converted as a useful fertilizer product in
a New Ammonium Sulphate Plant, 2, 25,000 TPA capacity put
up in October 1990, at a cost of Rs.35 crore.
As a replacement to the existing high energy consuming old
Ammonia plants at Udyogamandal, a new 900 TPD capacity
Ammonia Plant at a cost of Rs.642 crore was put up in March
1998. FACT Udyogamandal plants received ISO 14001
certification in March 2000 for conforming to the
Environmental Management System standard
ENVIRONMENTAL POLICY
FACT-UD is committed to
1. Continual improvement in its environmental performance
and prevention of pollution
2. Compliance with environmental rules, regulations and
other requirements applicable
3. Conservation of resources and waste minimization
8

4. Improvement of communication with interested parties

5. Training for improved environmental management

FACT-PETROCHEMICAL PLANTS
FACT manufactures Caprolactam, the raw material for
Nylon-6 which is extensively used for the production of tyrecord, textile filament yarn and engineering plastics.
FACT, one of the only two manufactures of this product in
India, has the capacity to produce 50,000 tonnes of
Caprolactam in a year. FACT's Caprolactam exported to
various countries including in USA, not only earns precious
foreign exchange, but also appreciation on account of its
excellent quality.
The Caprolactam Plant also produces 2,25,000 tonnes of
Ammonium Sulphate per year as co-product and small
quantities of Soda Ash and Nitric Acid as by products.
The plant has been certified ISO 9001:2002 since April 1996
by RWTUV, Germany and ISO-14001 since December 1999
by DNV, Netherlands.

PRODUCTS OF FACT
STAIGHT FERTILIZERS
AMMONIUM SULPHATE: Ammonium Sulphate is a
nitrogenous fertilizer containing 20.6% nitrogen, entirely in
ammonical form. It has excellent physical properties; nonhygroscopic, crystalline and free flowing. It is ideal as a
straight nitrogenous fertilizer and also as an ingredient in
fertilizer mixtures. It is the most widely preferred nitrogenous
fertilizer for top dressing on all crops. Another unique
9

advantage is that it contains 24% sulphur, an important

secondary nutrient.

COMPLEX FERTILIZERS
FACTAMFOS (AMMONIUM PHOSPHATE SULPHATE):
FACTAMFOS 20:20:0:13 is a chemical blend of 40 parts of
ammonium phosphate and 60 parts of ammonium sulphate. It
contains 20% N and 20% P2O5. The entire N is in ammonical
form and P is completely water soluble. In addition,
FACTAMFOS contains 13% sulphur, a secondary plant
nutrient which is now attaining great importance in the
agricultural scene. FACTAMFOS 20:20:0:13, with the
granular form and non-hydroscopic and free flowing nature,
have excellent physical properties. It is ideal for application
on all soils and all crops. FACTAMFOS 20:20:0:13 can also
be used for foliar application

FACTMIX
FACT prepares on a very large scale all the standard NPK
mixtures under the brand name 'FACTMIX' for different crops
for Kerala as stipulated by the Department of Agriculture. In
addition, FACT prepares special tailor made fertilizer
mixtures of any required grade for plantation crops like
coffee, tea, rubber, etc. FACT mixtures are superior in quality
with the presence of ammonical nitrogen, water soluble
phosphorus, and other major nutrients like sulphur, calcium,
etc.

GYPSUM
A byproduct of phosphoric acid, is a rich and cost effective
source of 16% sulphur and 22% calcium. FACT is marketing
10

bagged gypsum in brand name FACT Gypsum all 4 southern

states as a soil conditioner with fertilizing properties

IMPORTED FERTILIZERS
FACT markets imported Urea and Potash from Gulf Countries
and Russia for consumption in all 4 southern states as per
requirement. Urea with 46% Nitrogen in the granular/prilled
form and Potash with 60% K20 serves the nutritional
requirement in the 4 southern states.

ZINCATED FACTAMFOS
This special product containing 0.3% Zinc in FACTAMFOS
has been launched to address the widespread deficiency of
Zinc in most soils of South India

ZINCATED GYPSUM
This soil amendment and ameliorant contains 2% Zinc in
addition to 16% Sulphur and 22% Calcium for rectifying
alkaline soils and improving soil fertility and physical
properties

600 TPD DCDA SULPHURIC ACID

PLANT
Sulphuric acid is made in several stages from SO2, obtained
from the oxidation of sulphur or collection of SO2 from the
smelting of sulphide ores such as copper, zinc or lead. This
second collection of SO2 is very attractive as it is utilising the
by-products of other processes and reduces emissions and
waste.
SO2 (g) SO3 (g) H2SO4 (aq)
11

In the following slides we will break down this process into

three main steps.
Furnace or Burner (Only necessary if raw sulfur is used
Air is cleaned by electrostatic precipitation, dried then heated
to approx. 600oC.
Pure (liquid) sulphur is sprayed under pressure into the
furnace, reacting with the oxygen in the air. The product is
sulphur dioxide
S (l) + O2 (g) SO2 (g)
Alternative sources of sulphur dioxide are also used, either
extracted from natural gas (some deposits contain a lot of
hydrogen sulphide) or from the roasting of sulphide ores in
the extraction of metals like zinc or lead. If so this stage can
be skipped.

The converter
The converter contains trays or layers of porous pellets of a
catalyst, vanadium (V) oxide (V2O5). The sulphur dioxide
reacts with more air to form sulphur trioxide. This reaction is
reversible and reaches equilibrium. It is also an exothermic
reaction and the temperature will rise to over 600 oC. The
mixture is continuously cooled to 400oC between each tray.

2SO2 (g) + O2 (g) 2SO3 (g)

As the temperature rises the equilibrium shifts to the left (not
forming SO3). To counter this the gases are allowed to cool
slightly before they pass over the next layer of catalyst, by
carefully controlling the process almost all sulphur dioxide is
converted to sulphur trioxide
12

The absorption tower

Sulphur trioxide will dissolve in water to form our final goal
of sulphuric acid. However it is violently exothermic and
usually results in a mist of sulphuric acid droplets that are
very difficult to control.
In practice the sulphur trioxide dissolves almost completely
and is bubbled through concentrated sulphuric acid (that
contains relatively little water) to form 98% sulphuric acid,
known as Oleum (H2S2O7)

a)SO3(g) + H2SO4(l) H2S2O7(l)

b)H2S2O7(l) + H2O(l) H2SO4(l)

13

14

MECHANICAL WORKSHOP
FACT has a fully equipped mechanical workshop. The main objective
of the workshop is to provide various services to the other
departments such as repairing and designing of machinery parts. The
workshop with modern machines and dedicated operators is capable
of operating the requirements of all other departments. Workshop has
several machines namely Lathe machine, Shaping machine, Slotting
machine, Drilling machine, Boring machine, grinding machine etc. It
also has Welding and Cutting equipment. Moreover, the workshop
offer services to automobiles and locomotives through its garage.
The principal machines in the workshop are briefly
described in the following section:

LATHE MACHINE:
Lathe is the most commonly used machine of workshop. A lathe is a
machine tool which rotates the work piece on its axis to perform
various operations such as cutting, turning, threading, grooving, and
knurling, drilling, boring, chamfering, facing with tools that are
applied to the work piece to create an object which has symmetry
about an axis of rotation.
Lathes are used in woodcutting, metalworking, metal spinning, and
glass working. Most suitably equipped metalworking lathes can also
be used to produce most solids of revolution, plane surfaces and
screw threads or helices.
Moreover, eccentric jobs can be performed in this lathe machines.
Shafts of different sizes with varying cross section can be machined
with the help of a lathe machine.
15

For improving accuracy and ease of machining some accessories and

attachments are used -

SHAPER MACHINE
A Shaper is a type of machine tool that uses linear relative motion
between the work piece and a single-point cutting tool to machine a
linear tool path. It can cut curves, angles and many other shapes. It is
analogous to that of a lathe, except that is (archetypal) linear instead
of helical.
Shapers are mainly classified as standard, draw cut, and horizontal,
universal, vertical, geared, crank, hydraulic, contour and travelling
head. The horizontal arrangement is the most common. Vertical
shapers are generally fitted with a rotary table to enable curved
surfaces to be machined.
The main uses of a shaper machine are:
16

Key cutting
Keyways cutting
Surfacing
Splines cutting
Dovetail cutting
Contour surfaces

SLOTTING MACHINE:
Slotting machines are similar to those of Shaper machine with the
difference that the ram holding the toll in slotting machine
reciprocates in vertical direction. The cutting action of the tool is only
during the downward stroke.

17

The slotting machine can be considered as

a vertical shaper and its main parts are:

Base, column and table

Ram and tool head assembly
Saddle and cross slide
Ram drive mechanism and feed
mechanism

The slotting machine is used for cutting

grooves, keys and slots of various shapes
making regular and irregular surfaces both
internal and external cuttings, internal and
external gears and profiles. The slotter
machine can be used on any type of work
where vertical tool movement is considered
advantageous.

essential

and

WORKING MECHANISM OF SHAPER AND SLOTTING

MACHINE
The job is rigidly fixed on the machine table. The single point cutting
tool held properly in the tool post is mounted on a reciprocating ram.
The reciprocating motion of the ram is obtained by a quick return
mechanism. As the ram reciprocates, the tool cuts the materials during
its forward stoke. During return stoke there is no cutting action and
the stroke is called the idle stroke. The forward and return stroke
constitute one operating cycle of the shaper. The quick return
mechanism is understood with the help of the following diagram.

18

This mechanism is made of a diving crank and of a driven slider

crank. In the considered configuration, the fixed pivot of the driven
crank is located on the outside of the circle on which the end of
driving crank moves. The leads to an alternated motion of the slider
crank.
The angular speed of the driven crank is variable. The duration of the
motion for its part corresponding to the blue arc (AB clockwise) is
shorter than the one related to the red arc (AB anticlockwise). This is
why this device is named as Quick Return Mechanism, which was
used in crank shapers, with the slow part or the stroke being used for
the working time of the tool and the quick part for the non-productive
time.
MILLING MACHINE

19

Milling is a machining operation in which a rotating cutter cuts the

job when the job is feeding in a direction at an angle with the axis of
the tool. With various attachments milling machine can be used for
boring, slotting, circular milling, dividing and drilling. This machine
can also be used for cutting keyways, racks and gears and for fluting
taps and reamers.
Milling operates on the principle of rotary motion. A milling cutter is
spun about an axis while a work piece is advanced through it in such a
way that the blades of the cutter are able to shave chips of material
with each pass. Milling processes are designed such that the cutter
makes many individual cuts on the material in a single run, this may
be accomplished by using a cutter with many teeth, spinning the
cutter at high speed, or advancing the material through the cutter
slowly. Most often it is some combination of the three. The speed at
which the piece advances through the cutter is called feed rate, or just
feed; it is most often measured in length of material per full
revolution of the cutter.

DRILLING MACHINE
20

Drilling is a operation of producing circular hole in the workpiece by

using a rotating cutter called drill. Holes of different diameters can be
produced using drills of different sizes. A drilling machine, called a
drill press, is used to cut holes into or through metal, wood, or other
materials. Drilling machines use a drilling tool that has cutting edges
at its point. This cutting tool is held in the drill press by a chuck or
Morse taper and is rotated and fed into the work at variable speeds.
Drilling machines may be used to perform other operations like
countersinking, boring, counter boring, spot facing, reaming and
tapping.
All drilling machines have following construction characteristicsPillar drilling machine at HNL
Workshop

Spindle,
Sleeve or quill,
Column, head,
Worktable and
Base.

Main types of Drilling Machines

are

Ra

Po

dial Drilling Machine

rtable Drilling Machine

Sensitive Drilling Machine
Upright Drilling Machine
Special Purpose Drilling Machine
Gang Drilling Machine
21

 Multi-spindle Drilling Machine

Special purpose drilling machine
BORING MACHINE
Boring is the process of enlarging a hole that has already been drilled,
by means of single point cutting tool. A horizontal boring machine is a
machine tool which bore holes in a horizontal direction. Horizontal
boring machines are often heavy-duty industrial machines used for
roughing out large components but there are high precision models
too.
Boring is used to achieve a greater accuracy of the diameter of a hole,
and can be used to cut a tapered hole. Boring can be viewed as an
internal diameter counterpart to turning, which cuts internal
diameters.
There are three types of horizontal boring machine:
Table type
Planer type
Floor type

The table type is the most common and most versatile. So it is known
as the universal type boring machine.
Some important point about boring machine is:

Vertical movement of the spindle head is possible.

The table can have rotary motion.
Both hand and power feed are available.
Robust jobs can be machined.
Main applications are- boring, drilling and facing
2 Horizontal and 1Vertical Boring Machine is there at FACT
Udyogamandal Workshop
22

SPECIFICATIONS:
FEATURES:
(2) Swiveling Rams:
CAPACITY:
Table Diameter: 72"
Maximum Swing: 82"
Maximum Height under Rail: 62"
Vertical Travel of Ram Heads: 53"
Maximum Height under Ram Head: 601/2"
Ram Head Swivel (Left or Right): 60 Degree
Minimum Center Distance between Heads. 205/8":
Table Speeds (16): 1.3 to 45 RPM
Feeds (24): .003 to .500 IPR
Rapid Traverse: 10 FPM
Main Motor Power: 30 HP
Approximate Weight: 55,000 Lbs
Dimensions (Width x Depth): 214" x 156"
Machine Height: 158"7/22/2016 72"
King Vertical Boring Mill #22878 (Inch Conversion) Prestige
Equipment

VERTICAL BORING MACHINE AT FACT

23

HORIZONTAL BORING MACHINE AT FACT

WORKSHOP ASSETS
24

SL.
No

Name/Description

UNIT

SIZE

SUPPLIERS

Geared Head
Lathe
Geared Head
HMT Lathe LB 17
Geared Head
HMT Lathe LB 20

16x144

610x1.5M

Sebastian
USA
HMT

18x72

HMT

Geared Head
HMT Lathe NH
26/2000
Geared Head
HMT Lathe NH
26/3000
Geared Head NH
32/3000

HMT

Geared Head
Bombay Lathe
Kirloskar
Geared Head
Kirloskar GD2
Lathe
Geared Head
Centre Kirloskar
Lathe 1330
Geared Head
Bombay Lathe
Kirloskar
Geared Head
HMT lathe NH
26/3000
Vertical double
Column Boring
Machine(vertical
turret)

2000mm
Bed
Length
3000mm
Bed
Length
3000mm
Bed
Length
26x84

2
3
4
5
6
7
8
9
10
11
12

1
1

HMT

HMT

Kirloskar

Kirloskar

10000mm
between
centers
36x84

Kirloskar

3000mm
Bed
Length
Table dia
62

HMT

25

Kirloskar

KING,USA

WO/PO
No
&DATE
WAR
Model
1962

COST

31691
05-071968
4363 2103-1978

Rs. 24,175/-

NA
NA

Rs.1,54,205/-

50945
30-091976
CP/1677
10-061991
1965

Rs.1,67,500/-

31692
02-071968
CP/926
07-041987
35639/
11-081969
4504 3103-1978

Rs.10,712/-

WAR
Model

Rs.5,28,500/-

NA

NA

Rs.59,633/-

Rs.1,69,255/-

NA

Horizontal Boring
Machine
Horizontal Boring
Machine

Standard
Mechanical
Shaping Machine
Standard
Mechanical
Slotting Machine
Standard
Mechanical
Slotting Machine
Milling Machine
knee type
Horizontal plane
Milling Machine
knee type
Horizontal
Universal
Radial Planes
(Elevating arm
drilling )
Die type screw
cutting machine
Band Saw Metal
Cutting Machine

Throat
24

23

Vertical straight
crank press 20T

20 Tonne

24

Dynamic
Balancing m/c
HD-1000
Power Hack Saw

1000Kgs

NA

13
14
15
16
17
18
19
20
21
22

25

1
1
1

Spindle
MWMGDR
NA
dia 80mm
Spindle Heavy Engg. CP/473/C
dia
Co
a 06-05100mm
1985
Stroke
GEM Co
WAR
Length
USA
Model
24
Stroke
NA
39498
Length 7
30-041971
Stroke
NA
CP/383/C
Length 7
KN 0301-1985
Long
NA
WAR
Trouvers
Model

NA
NA

NA

Rs.18,720/-

NA

NA

Long
Trouvers
11swing

Perfect M/c
Tools

29895/
11-121967

Rs./-

2 and
half Drill
capacity
4 dia rod

Hole Wizard
USA

WAR
Model

NA

Land IS M/c
Co USA
Brown and
Surface
sharp USA
Grinder
Federal
Press Co
USA
FIE
Kolhapur

WAR
Model
WAR
Model

NA

WAR
Model

NA

1347 3003-1977

Rs.1,35,420/-

38714
05-011971

Rs.3,350/-

26

Maneklal
and Sons

NA

26

Hand Press

27

Air Compressor
Model CP
Over Head Crane
(EOT)
Over Head Crane
Manually operated
LG Pressure
Washing Pump

31
32

Water Cooler

1
3

33
34

Pedestal Grinder

28
29
30

35
36
37
38
39
40
41
42
43

Floor Crane

Tool Post grinder

Jib Crane (Inner

Trolling Bracket)
Hydraulic Jack
EOT Over Head
Crane FEW
Jib Crane
Electric Furnace

Electric Furnace
Tilting type
Melting Furnace
Tilting type
Melting Furnace
Air Blower for
Furnace

NA

NA

60 Ps1

Atlas
Compound
Compound

NA

NA

5T

Cranex Ltd

NA

NA

5T

NA

NA

NA

Working
pressure
14Gg/CM
2
NA

NA

34082
20-051991

NA

Voltas

NA

NA

4000Lbs

MCKR

NA

3
2

NA

NA

38318
13-111970
NA

250mm

2000Kg

51216
30-101976
NA

NA

Tool Post
Elec Co
Bombay
NA

1
1

2000T

NA

NA

NA

15T

NA

NA

NA

1
1

40000Kgs

NA

NA

NA
Rs.1,14,500/-

1
1

6Kgs

46489
03-101974
NA

NA

NA

NA

NA

250Kgs

Skelnar PVC
Ltd India

NA

NA

NA

39865
05-071971
NA

25KW

27

Therloc
Furnace
Private Ltd
NA

NA

NA

NA

NA

44

Power Hammer

20T

45
46
47
48
49
50
51
52

Hydraulic Pin

1
1
2
1
2
2
1
2
1
1

53
54
55

Bench Drill
Bench Grinder
Polishing Grinder
Anvil
Swage Block
Platform Balance
Air Blower for
Smith Furnace
Sand Mixer
Sand Sewing
Machine
Pillow Drilling
Machine

NA

NA

drill

Blacker Co
UK
NA

NA

NA

NA

NA

NA

NA

NA

NA

NA

NA

NA

NA

NA

NA

NA

NA

NA

NA

300Kgs

NA

NA

NA

300Kgs

NA

NA

NA

60Kgs

NA

NA

NA

60Kgs

NA

NA

NA

20mm
Drill
NA

NA

NA

NA

NA

NA

NA

WELDING SECTION
Welding is a fabrication or sculptural process that joins materials,
usually metals or thermoplastics, by causing coalescence. This is
often done by melting the work pieces and adding a filler material to
form a pool of molten material (the weld pool) that cools to become a
strong joint, with pressure sometimes used in conjunction with heat,
or by itself, to produce the weld. This is in contrast with soldering and
brazing, which involve melting a lower melting point material
between the work pieces to form a bond between them, without
melting the work pieces.
There are mainly two processes of welding- Arc Welding and Gas
Welding
ARC WELDING
28

NAME

AWS

Characteristics

Applications

Atomic
hydrogen
Welding

149

AHW

Two metal electrodes in

Hydrogen atmosphere

Historical

Bare metal arc

Welding

113

BMAW Consumable electrode, no

Flux or shielding gas

Historical

Carbon arc
Welding

181

CAW

Carbon electrode

Historical,
repair

Flux cored arc

welding

136- FCAW
137

Continuous consumable
Electrode filled with flux

Industry,
Construction

Gas metal arc

welding

131- GMAW Continuous consumable

135
electrode & shielding gas

Gas
tungsten 141
arc
Welding

GTAW

Plasma arc
Welding

115

PAW

Shielded metal
Arc welding

111

Submerged arc
welding

121

Industry

Non
consumable Aerospace, tool &
electrode,
slow,
high die,
quality welds
Construction(piping)

Non
consumable
electrode,
Constricted arc
Consumable
electrode
SMAW covered in flux , can weld
any metal

SAW

copper

Automatic, arc submerged

in granular flux

29

Tubing,
instrumentation

Construction,
outdoors,
Maintenance

Magnetically
185
impelled
arc
butt

MIAB

Both tube ends are Pipelines and Tubes

electrodes, no protection
gas, arc rotates fast along
edge by applied magnetic
field

OXY FUEL GAS WELDING

NAME
Air acetylene
Welding

321

AAW

Oxyacetylene
Welding

311

OAW

Oxygen/
Propane
Welding

312

Oxy hydrogen
welding

313

Pressure gas
welding

Characteristics

AWS

Applications

Chemical welding process, not Limited

popular
Combustion of acetylene with Maintenance,
oxygen
produces
high Repair
temperature flame, inexpensive
equipment
Gas welding with Oxygen or
Propane flame

OHW

Combustion of hydrogen with Limited

oxygen produces flame

PGW

Gas flames heat surfaces and Pipe, railway

pressure produces the weld
Tracks(limited
)

30

CONCLUSION
The training I got in FACT was of immense help for me
and I was fortunate to be guided by experienced
operators and engineers.
All in all the training at FACT was a lifetime experience
which lends me the opportunity to get an on hand
experience of how this govt. of KERALA enterprise
works for producing best quality of FERTILIZERS

31