A Report On

Industrial Summer Training

At

OIL AND NATURAL GAS CORPORATION LTD.

MEHSANA ASSET,KDM BHAVAN,PALAVASANA,MEHSANA-384002,

GUJARAT

SUBMITTED TO SUBMITTED BY
RAJIV SRIVASTAV KISHAN PRAJAPATI
EX Engr. (MECH) 6th semester
MEHSANA (GPERI,MEHSANA)

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 Oil And Natural Gas Coporation
Mehsana Asset

CERTIFICATE
This is to certify by the SUMMER TRAINING PROGRAM ONGC, MEHSANA has been
attend by MR KISHANKUMAR DASHRATHBHAI PRAJAPATI, A Bachelor of Engineering
( Mechanical Engineering 6th Sem ) Student from GUJARAT POWER ENGINEERING AND
RESEARCH INSTITUTE , MEHSANA has successfully completed the summer training in
WORKSHOP, ONGC, Mehsana asset. The training was carried out from 24th May to 14th Jun
2018.

INDUSTRIAL GUIDE

MR. RAJIV SRIVASTAV

EX. Engr MECH.

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 ACKNOWLEDGEMENT

It is my pleasure to be indebted to various people, who directly or indirectly contributed in the

development of this work and who influenced my thinking, behaviour and acts during the course of
study.

I express my sincere attitude to our HOD, worthy Principal for providing me an opportunity to under go
summer training at ONGC, MEHSANA. I am Thankful to Mr. Rajiv Srivastav for his support,
cooperation and motivation provided to me during the training for constant inspiration, presence and
blessings.

Last, I would like to thank the almighty and my parents for their moral support and my friends with
whom I shared my day to day experience and received lots of suggestion that improved my quality of
work.

KISHAN PRAJAPATI

6TH semester, Mechanical

(GPERI,MEHSANA.)

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 TABLE OF CONTENTS
Sr.No. CONTENT PAGE.NO.
1 ACKNOLEDGEMENT 3
2 TABLE OF CONTENT 4
3 CHAPTER 1: INTRODUCTION 5
1.1 ABOUT ONGC 5
1.2 OBJECTIVE OF COMPANY 7
1.3 MISSION OF ONGC 7
4 CHAPTER 2: MACHINE SHOP 8
2.1 LATHE MACHINE 9
2.2 RADIAL DRILLING MACHINE 11
2.3 RUSSIAN SHAPER MACHINE 12
5 CHAPTER 3: DIESEL SHOP 14
3.1 DIESEL GENERATOR 14
6 CHAPTER 4: ASSEMBLY SHOP 16
4.1 HYDRAULIC PRESS 16
4.2 MAGNATIC BEARING HEATER 17
4.3 CENTRIFUGAL PUMP 18
4.4 DRILLING SWIVEL 19
4.5 HYDRAULIC JAW PULLER 21
4.6 CRANE 22
7 CHAPTER 5: FABRICATION SHOP 24
5.1 ARC WELDING 25
5.2 MIG WELDING 26
5.3 TIG WELDING 27
5.4 OXY ACETYLENE WELDING 29

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 CHAPTER 1: INTRODUCTION
1.1 About ONGC :-

 Oil and natural gas corporation limited is an Indian multinational oil and gas company
headquartered in Dehradun, uttarakhand, India.
 It is a public sector undertaking (PSU) of the government of India ,under the administrative
control of ministry of petroleum and natural gas.
 It is India’s largest oil and natural gas exploration and production company. It provide
around 69% of India’s crude oil and around 62% of its natural gas.
 On 31st march 2013 , its market capitalization was INR 2.6 trillion ,making of India’s
second largest publicly trated company. In a government survey for FY 2011-12,it was
ranked 357th in the fortune global 500 list of the world’s biggest corporation for the year
2012 it is ranked 17th among the top 250 global energy companies by plats.

 ONGC was founded on 14 August 1956 by Government of India, which currently holds a
68.94% equity stake.

 It is involved in exploring for and exploiting hydrocarbons in 26 sedimentary basins of

India, and owns and operates over 11,000 kilometres of pipelines in the country.

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  Its international subsidiary ONGC Videsh currently has projects in 17 countries. ONGC has
discovered 6 of the 7 commercially producing Indian Basins, in the last 50 years, adding
over 7.1 billion tonnes of In-place Oil & Gas volume of hydrocarbons in Indian basins.

 Against a global decline of production from matured fields, ONGC has maintained
production from its brownfields like Mumbai High, with the help of aggressive investments
in various IOR (Improved Oil Recovery) and EOR (Enhanced Oil Recovery) schemes.

 ONGC has many matured fields with a current recovery factor of 25–33%.Its Reserve
Replacement Ratio for between 2005 and 2013, has been more than one.During FY 2012–
13, ONGC had to share the highest ever under-recovery of INR 8993.78 billion (an increase
of INR 567.89 million over the previous financial year) towards the under-recoveries of Oil
Marketing Companies (IOC, BPCL and HPCL).On 1 November 2017, the Union Cabinet
approved ONGC for acquiring majority 51.11 % stake in HPCL (Hindustan Petroleum
Corporation Limited). On Jan 30th 2018, Oil & Natural Gas Corporation acquired the entire
51.11% stake of GOI.

History

Before the independence of India in 1947, the Assam Oil Company in the north-eastern and Attock Oil company
in north-western part of the undivided India were the only oil producing companies, with minimal exploration
input. The major part of Indian sedimentary basins was deemed to be unfit for development of oil and gas
resources.
After independence, the Central Government of India realized the importance of oil and gas for rapid industrial
development and its strategic role in defense. Consequently, while framing the Industrial Policy Statement of
1948, the development of petroleum industry in the country was considered to be of utmost necessity.
Until 1955, private oil companies mainly carried out exploration of hydrocarbon resources of India. In Assam,
the Assam Oil Company was producing oil at Digboi (discovered in 1889) and Oil India Ltd. (a 50% joint
venture between Government of India and Burmah Oil Company) was engaged in developing two newly
discovered large fields Naharkatiya and Moraan in Assam. In West Bengal, the Indo-Stanvac Petroleum project
(a joint venture between Government of India and Standard Vacuum Oil Company of USA) was engaged in
exploration work. The vast sedimentary tract in other parts of India and adjoining offshore remained largely
unexplored.
In 1955, Government of India decided to develop the oil and natural gas resources in the various regions of the
country as part of the Public Sector development. With this objective, an Oil and Natural Gas Directorate was
set up towards the end of 1955, as a subordinate office under the then Ministry of Natural Resources and
Scientific Research. The department was constituted with a nucleus of geoscientists from the Geological Survey
of India.
A delegation under the leadership of the Minister of Natural Resources visited several European countries to
study the status of oil industry in those countries and to facilitate the training of Indian professionals for
exploring potential oil and gas reserves. Experts from Romania, the Soviet Union, the United States and West
Germany subsequently visited India and helped the government with their expertise. Soviet experts later drew
up a detailed plan for geological and geophysical surveys and drilling operations to be carried out in the
2nd Five Year Plan (1956–61).

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In April 1956, the Government of India adopted the Industrial Policy Resolution, which placed Mineral Oil
Industry among the schedule 'A' industries, the future development of which was to be the sole and exclusive
responsibility of the state.

1.2 OBJECTIVES OF COMPANY

 To maximize production of hydrocarbons, self reliance in technology, promoting
indiginuos efforts to achieve in all related equipments, material and servives.
 Environmental protection.
 Obtain 100% safety in work.

1.3 MISSION OF ONGC

 Dedicated to excellence by leveraging competitive advantages in R&D and technology
with involved people.
 Imbibe high standards of business ethics and organizational values.
 Abiding commitment to health, safety, and environment to enrich quality of emmunity life.

CHAPTER 2 : MACHINE SHOP


 There are number of parts can be manufacture and repair in this shop using manual
operated machines used for this.
 The layout of machine shop is shown in figure as below.

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 Fig1; machine shop.

2.1 LATHE MACHINE:

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 Fig 2. Lathe Machine.

Working Principle: The lathe is a machine tool which holds the workpiece between two rigid
and strong supports called centers or in a chuck or face plate which revolves. The cutting tool is rigidly
held and supported in a tool post which is fed against the revolving work. The normal cutting
operations are performed with the cutting tool fed either parallel or at right angles to the axis of the
work.

Construction: The main parts of the lathe are the bed, headstock, quick changing gear box,
carriage and tailstock.

1. Bed: The bed is a heavy, rugged casting in which are mounted the working parts of the lathe.
It carries the headstock and tail stock for supporting the workpiece and provides a base for the
movement of carriage assembly which carries the tool.

2. Legs: The legs carry the entire load of machine and are firmly secured to floor by foundation
bolts.

3. Headstock: The headstock is clamped on the left hand side of the bed and it serves as
housing for the driving pulleys, back gears, headstock spindle, live centre and the feedreverse
gear. The headstock spindle is a hollow cylindrical shaft that provides a drive from the motor to
work holding devices.

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 Fig 3. Block Diagram Of Lathe Machine

4. Gear Box: The quick-change gear-box is placed below the headstock and contains a number
of different sized gears.

5. Carriage: The carriage is located between the headstock and tailstock and serves the purpose
of supporting, guiding and feeding the tool against the job during operation. The main parts of
carriage are:

a). The saddle is an H-shaped casting mounted on the top of lathe ways. It provides support to
cross-slide, compound rest and tool post.

b). The cross slide is mounted on the top of saddle, and it provides a mounted or automatic cross
movement for the cutting tool.

c). The compound rest is fitted on the top of cross slide and is used to support the tool post and the
cutting tool.

d). The tool post is mounted on the compound rest, and it rigidly clamps the cutting tool or tool
holder at the proper height relative to the work centre line.

e). The apron is fastened to the saddle and it houses the gears, clutches and levers required to
move the carriage or cross slide. The engagement of split nut lever and the automatic feed lever at
the same time is prevented she carriage along the lathe bed.

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6. Tailstock: The tailstock is a movable casting located opposite the headstock on the ways of
the bed. The tailstock can slide along the bed to accommodate different lengths of workpiece
between the centers. A tailstock clamp is provided to lock the tailstock at any desired position.
The tailstock spindle has an internal taper to hold the dead centre and the tapered shank tools such
as reamers and drills.

Working :
A lathe is a tool that rotates the workpiece about an axis of rotation to perform various operations
such as cutting, sanding, knurling, drilling, deformation, facing, and turning, with tools that are
applied to the workpiece to create an object with symmetry about that axis.
Lathes are used in woodturning, metalworking, metal spinning, thermal spraying, parts
reclamation, and glass-working. Lathes can be used to shape pottery, the best-known design being
the potter's wheel. Most suitably equipped metalworking lathes can also be used to produce
most solids of revolution, plane surfaces and screw threads or helices. Ornamental lathes can
produce three-dimensional solids of incredible complexity. The workpiece is usually held in place
by either one or two centers, at least one of which can typically be moved horizontally to
accommodate varying workpiece lengths. Other work-holding methods include clamping the work
about the axis of rotation using a chuck or collet, or to a faceplate, using clamps or dogs.
Examples of objects that can be produced on a lathe include screws, candlestick holders, gun
barrels, cue sticks, table legs, bowls, baseball bats, musical instruments (especially woodwind
instruments), crankshafts, and camshafts.

2.2 RADIAL DRILLING MACHINE:.

The radial drill is a large drill press designed to cut holes in large parts. It has a radial arm along
which the drilling head can be moved and clamped. The head therefore can be positioned along
the arm at locations that are a significant distance from the column to accommodate large work.
The radial arm can also be swiveled about the column to drill parts on either side of the worktable.

Salient Features :

• Massive and rigid construction.

• Ergonomically grouped controls for operating convenience.
• Light centering of spindle.
• Precise depth release.
• Electrohydraulic clamping provided for drill head, arm & sleeve.
• Shock-free engagement of taps through clutch and spindle reverse for withdrawals.
• Machine with drilling capacity 80 mm / 100 mm also available

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 Fig 4. Radial Drilling Machine

2.3 SHAPER MACHINE:

Fig 5. Shaper Machine

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Working Principle: 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 motion mechanism. As the ram reciprocates, the tool
cuts the material during its forward stroke. During return, there is no cutting action and this
stroke is called the idle stroke. The forward and return strokes constitute one operating cycle of
the shaper.

Fig. Block Diagram Of Shaper Machine

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 CHAPTER 3: DIESEL SHOP

3.1 DIESEL GENERATOR:

A diesel generator is made up of a combination of a diesel engine and an alternator for converting the
mechanical energy into electrical energy. Diesel generator sets are widely used for places without
connection to the power grid and for emergency power supply.

 Diesel generator is the combination of a diesel engine with an electric generator (often an
alternator) to generate electrical energy. This is a specific case of engine-generator. A
diesel compression-ignition engine is usually designed to run on diesel fuel, but some
types are adapted for other liquid fuels or natural gas.
 Diesel generating sets are used in places without connection to a power grid, or as
emergency power-supply if the grid fails, as well as for more complex applications such
as peak-lopping, grid support and export to the power grid.
 proper sizing of diesel generators is critical to avoid low-load or a shortage of power.
Sizing is complicated by the characteristics of modern electronics, specifically non-linear
loads. In size ranges around 50 MW and above, an open cycle gas turbine is more
efficient at full load than an array of diesel engines, and far more compact, with
comparable capital costs; but for regular part-loading, even at these power levels, diesel
arrays are sometimes preferred to open cycle gas turbines, due to their superior
efficiencies.

Fig 6; Diesel Generator

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Major components of a diesel generator :

Fig 7. Major components of a diesel generator

The major components of a diesel generator can be classified as follows:

1. Diesel Engine: The source of the mechanical energy input for the generator. Its size and output
capacity are what determines how much power a unit can generate.
2. Alternator: Produces electrical energy from the mechanical input supplied by the diesel engine.
3. Radiator & cooling system: Continually using the generator heats up various components.
The cooling system helps withdraw heat produced when the generator is working.
4. Exhaust system: Exhaust fumes emitted by a diesel generator contain highly toxic chemicals
that need to be properly managed.
5. Air filter: The filter composed of fibrous materials, which removes solid particles such as dust,
pollen, mold and bacteria from the air.
6. Control panel: The user interface for controlling the generator, including start up, shut down
controls, fuel gauges, phase selector switches & etc.
7. Base frame & fuel tank: The base frame provide a tructural base support. The fuel tank
stores fuel to be used by the generator, it usually has adequate capacity to keep the generator to run for
6-8 hours on an average.
8. Circuit breaker: Ensures the proper output for use with a given electrical system and protect
the generator from damage from overload or shortcut.
CHAPTER 4: ASSEMBLY SHOP
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  A place where a machine or its components are assembled. In assembly shop parts are
assembled and repaired in this shop by qualified workers.
 The layout of assembly shop is shown in figure.

Fig 8; assembly shop layout.

4.1 HYDRAULIC PRESS :

Fig 9. Hydraulic Press

 The hydraulic press depends on Pascal's principle-the pressure throughout a closed system
is constant. One part of the system is a piston acting as a pump, with a modest mechanical
force acting on a small cross-sectional area; the other part is a piston with a larger area

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 which generates a correspondingly large mechanical force. Only small-diameter tubing
(which more easily resists pressure) is needed if the pump is separated from the press
cylinder.
 Pascal's law: Pressure on a confined fluid is transmitted undiminished and acts with equal
force on equal areas and at 90 degrees to the container wall.
 A small effort force acts on a small piston. This creates a pressure which is transferred
through the hydraulic fluid to a large piston

 Hydraulic presses are commonly used for forging, clinching, moulding, blanking,
punching, deep drawing, and metal forming operations.[3][4]With the growth and
importance of light-weighting in the aerospace and automotive industry, more applications
are present in Thermoplastics, Composites, SMC Sheet Molded Composites, RTM Resin
Transfer Molding, GMT Glass Mat Transfer and Carbon Fiber Molding

3.2 MAGNETIC BEARING HEATER :

Fig 10. Magnatic Bearing Heater

 An induction heater consists of an electromagnet, and an electronic oscillator that passes a
high-frequency alternating current (AC) through the electromagnet. The rapidly alternating
magnetic field penetrates the object, generating electric currents inside the conductor
called eddy currents.

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  Generally this machine is used to provide heat to the bearings so it can be expand and then
fit it on a proper place with best fitting.

 An induction heater consists of an electromagnet, and an electronic oscillator that passes a

high-frequency alternating current (AC) through the electromagnet. The rapidly
alternating magnetic field penetrates the object, generating electric currents inside the
conductor called eddy currents. The eddy currents flowing through the resistance of the
material heat it by Joule heating. In ferromagnetic (and ferrimagnetic) materials like iron,
heat may also be generated by magnetic hysteresis losses. The frequency of current used
depends on the object size, material type, coupling (between the work coil and the object to
be heated) and the penetration depth.

4.3 CENTRIFUGAL PUMP:

Fig 11. Centrifugal Pump

Centrifugal pumps are a sub-class of dynamic axisymmetric work-
absorbing turbomachinery. Centrifugal pumps are used to transport fluids by the conversion of
rotational kinetic energy to the hydrodynamic energy of the fluid flow. The rotational energy
typically comes from an engine or electric motor. The fluid enters the pump impeller along or near
to the rotating axis and is accelerated by the impeller, flowing radially outward into a diffuser
or volute chamber (casing), from where it exits.
Common uses include water, sewage, petroleum and petrochemical pumping; a centrifugal fan is
commonly used to implement a vacuum cleaner. The reverse function of the centrifugal pump is
a water turbine converting potential energy of water pressure into mechanical rotational energy.

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 Fig 12. Centrifugal Pump

Centrifugal pumps are a sub-class of dynamic axisymmetric work-absorbing

turbomachinery.Centrifugal pumps are used to transport fluids by the conversion of rotational
kinetic energy to the hydrodynamic energy of the fluid flow. The rotational energy typically
comes from an engine or electric motor. The fluid enters the pump impeller along or near to the
rotating axis and is accelerated by the impeller, flowing radially outward into a diffuser or volute
chamber (casing), from where it exits.

Common uses include water, sewage, petroleum and petrochemical pumping; a centrifugal fan is
commonly used to implement a vacuum cleaner. The reverse function of the centrifugal pump is a
water turbine converting potential energy of water pressure into mechanical rotational energy.
Like most pumps, a centrifugal pump converts rotational energy, often from a motor, to energy in
a moving fluid. A portion of the energy goes into kinetic energy of the fluid. Fluid enters axially
through eye of the casing, is caught up in the impeller blades, and is whirled tangentially and
radially outward until it leaves through all circumferential parts of the impeller into the diffuser
part of the casing. The fluid gains both velocity and pressure while passing through the impeller.
The doughnut-shaped diffuser, or scroll, section of the casing decelerates the flow and further
increases the pressure.

4.4 DRILLING SWIVEL :

 A Swivel is a mechanical device used on a drilling rig that hangs directly under
the traveling block and directly above the kelly drive, that provides the ability for the
kelly (and subsequently the drill string) to rotate while allowing the traveling block to
remain in a stationary rotational position (yet allow vertical movement up and down the
derrick) while simultaneously allowing the introduction of drilling fluid into the drill
string.

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  The swivel is a rotary tool that is hung from the hook and the travelling block to suspend
and permit free rotation of the drill stem. The swivel also provides a connection for the
rotary hose and a passage way for the flow of drilling fluid into the drill string (drill
stem).

Fig 13. Drilling Swivel

 The swivel uses seals called swivel packing, which are special rubberized compounds
placed in a swivel to prevent drilling fluid under high pressure from leaking out.
 The swivel stem is a length of pipe inside the swivel that is installed to the swivel's
washpipe and to which the kelly (or a kelly accessory, such as the upper kelly cock) is
attached. A swivel sub may also be present to protect the threads of the swivel from
excessive wear during make-up and breakout.
 The arrangement allows the drill stem to rotate the swivel's stem while the swivel itself is
moved vertically up and down without rotational movement. Regardless of whether a
kelly or top drive are used, a swivel will be present between the rotary hose carring fluid
from the mud pumps.
 The swivel is parrt of the circulating system which circulates drilling fluid, or mud, down
the rotated drill string, or drill stem, and pushes the mud with drill cuttings up the bore
hole until the shakers can remove the cutting and place the mud in the mud pits. Mud is
then pumped from the mud pits to the standpipe and rotary hose into the swivel an drill
string to complete the circulated flow of drilling mud.

4.5 HYDRAULIC JAW PULLER :

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 Fig 14; Hydraulic Jaw Puller
The SKF TMHP 10E jaw puller kit is equipped with a hydraulic spindle, which facilitates effortless
bearing dismounting up to 100 kN (11.2 ton US). The versatile puller kit includes three different
arm sizes and can be assembled as a two-arm puller or a three-arm puller depending on the space
and demand of the application.
• High load rating of 100 kN (11.2 ton US) makes the puller suitable for a variety of dismounting
jobs
• The 3 different arm sizes, with a maximum effective arm length of 200 mm (7.9 in), make the
TMHP 10E suitable for use in a wide range of applications

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• The self-locking arms minimise the risk of the puller slipping from the application when under
load
• Hydraulic spindle facilitates effortless dismounting
• The hydraulic spindle is equipped with a safety valve, which minimises the risk of puller overload
by limiting the applied force to 100 kN (11.2 ton US)
• Long stroke of hydraulic spindle, 80 mm (3.1 in), facilitates dismounting in one operation
• Extension pieces of the hydraulic spindle allow quick adaptation to pulling length
• The spring-loaded centre point of the hydraulic spindle allows easy centring of the puller on the
shaft without damaging it.

4.6 CRANE :

Fig 15; Crane

An overhead crane, commonly called a bridge crane, is a type of crane found in industrial
environments. An overhead crane consists of parallel runways with a traveling bridge spanning
the gap. A hoist, the lifting component of a crane, travels along the bridge. If the bridge is rigidly
supported on two or more legs running on a fixed rail at ground level, the crane is called a gantry
crane (USA, ASME B30 series) or a goliath crane (UK, BS 466).
Unlike mobile or construction cranes, overhead cranes are typically used for either manufacturing
or maintenance applications, where efficiency or downtime are critical factors.
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They are available in the range of 5 tons and 15 tons in the ONGC WORKSHOP.

Applications
Overhead cranes are commonly used in the refinement of steel and other metals such as copper
and aluminium. At every step of the manufacturing process, until it leaves a factory as a finished
product, metal is handled by an overhead crane. Raw materials are poured into a furnace by crane,
hot metal is then rolled to specific thickness and tempered or annealed, and then stored by an
overhead crane for cooling, the finished coils are lifted and loaded onto trucks and trains by
overhead crane, and the fabricator or stamper uses an overhead crane to handle the steel in his
factory. The automobile industry uses overhead cranes to handle raw materials. Smaller
workstation cranes, such as jib cranes or gantry cranes, handle lighter loads in a work area, such
as CNC mill or saw.
Almost all paper mills use bridge cranes for regular maintenance needing removal of heavy press
rolls and other equipment. The bridge cranes are used in the initial construction of paper machines
because they make it easier to install the heavy cast iron paper drying drums and other massive
equipment, some weighing as much as 70 tons.

CHAPTER 5: FABRICATION SHOP

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  Metal fabrication is the building of metal structures by cutting, bending, and assembling
processes.
 It is a value added process that involves the creation of machines, parts, and structures from
various raw materials. A fabrication shop will bid on a job, usually based on the engineering
drawings, and if awarded the contract will build the product. Large fab shops employ a
multitude of value added processes in one plant or facility including welding, cutting, forming
and machining. These large fab shops offer additional value to their customers by limiting the
need for purchasing personnel to locate multiple vendors for different services. Metal
fabrication jobs usually start with shop drawings including precise measurements, then move
to the fabrication stage and finally to the installation of the final project. Fabrication shops are
employed by contractors, OEMs and VARs. Typical projects include loose parts, structural
frames for buildings and heavy equipment, and stairs and hand railings for buildings.
 The layout of fabrication shop is shown in figure.

Fig 16; The layout of fabrication shop

5.1 ARC WELDING :

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 Fig 17; Arc Welding Machine
Arc welding is a process that is used to join metal to metal by using electricity to create enough
heat to melt metal, and the melted metals when cool result in a binding of the metals. It is a type
of welding that uses a welding power supply to create an electric arc between an electrode and the
base material to melt the metals at the welding point. They can use either direct (DC)
or alternating (AC) current, and consumable or non-consumable electrodes. The welding region is
usually protected by some type of shielding gas, vapor, or slag. Arc welding processes may be
manual, semi-automatic, or fully automated. First developed in the late part of the 19th century,
arc welding became commercially important in shipbuilding during the Second World War. Today
it remains an important process for the fabrication of steel structures and vehicles.

WORKING PRINCIPLE OF ARC WELDING:

Arc welding is a process that is used to join metal to metal by using electricity to create enough
heat to melt metal, and the melted metals when cool result in a binding of the metals. It is a type of
welding that uses a welding power supply to create an electric arc between an electrode and the
base material to melt the metals at the welding point. They can use either direct (DC) or

25
alternating (AC) current, and consumable or non-consumable electrodes. The welding region is
usually protected by some type of shielding gas, vapor, or slag. Arc welding processes may be
manual, semi-automatic, or fully automated. First developed in the late part of the 19th century,
arc welding became commercially important in shipbuilding during the Second World War. Today
it remains an important process for the fabrication of steel structures and vehicles.

5.2 MIG WELDING :

Fig 18 ; MIG Welding Machine

Gas metal arc welding (GMAW), sometimes referred to by its subtypes metal inert
gas (MIG) welding or metal active gas (MAG) welding, is a welding process in which an electric
arc forms between a consumable wire electrode and the workpiece metal(s), which heats the
workpiece metal(s), causing them to melt and join.
Along with the wire electrode, a shielding gas feeds through the welding gun, which shields the
process from contaminants in the air. The process can be semi-automatic or automatic. A
constant voltage, direct current power source is most commonly used with GMAW, but
constant current systems, as well as alternating current, can be used. There are four primary
methods of metal transfer in GMAW, called globular, short-circuiting, spray, and pulsed-spray,
each of which has distinct properties and corresponding advantages and limitations.

WORKING OF MIG WELDING :

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5.3 TIG WELDING:

Fig 19;TIG Welding

Gas tungsten arc welding (GTAW), also known as tungsten inert gas (TIG) welding, is an arc
welding process that uses a non-consumable tungsten electrode to produce the weld. The weld
area and electrode is protected from oxidation or other atmospheric contamination by
an inert shielding gas (argon or helium), and a filler metal is normally used, though some welds,
known as autogenous welds, do not require it. A constant-current welding power supply produces
electrical energy, which is conducted across the arc through a column of highly ionized gas and
metal vapors known as a plasma.
GTAW is most commonly used to weld thin sections of stainless steel and non-ferrous metals
such as aluminum, magnesium, and copper alloys. The process grants the operator greater control
over the weld than competing processes such as shielded metal arc welding and gas metal arc

27
welding, allowing for stronger, higher quality welds. However, GTAW is comparatively more
complex and difficult to master, and furthermore, it is significantly slower than most other
welding techniques. A related process, plasma arc welding, uses a slightly different welding torch
to create a more focused welding arc and as a result is often automated.

WORKING OF TIG WELDING :

Manual gas tungsten arc welding is a relatively difficult welding method, due to the coordination
required by the welder. Similar to torch welding, GTAW normally requires two hands, since most
applications require that the welder manually feed a filler metal into the weld area with one hand
while manipulating the welding torch in the other. Maintaining a short arc length, while
preventing contact between the electrode and the workpiece, is also important.
To strike the welding arc, a high frequency generator (similar to a Tesla coil) provides an electric
spark. This spark is a conductive path for the welding current through the shielding gas and allows
the arc to be initiated while the electrode and the workpiece are separated, typically about 1.5–
3 mm (0.06–0.12 in) apart.
Once the arc is struck, the welder moves the torch in a small circle to create a welding pool, the
size of which depends on the size of the electrode and the amount of current. While maintaining a
constant separation between the electrode and the workpiece, the operator then moves the torch
back slightly and tilts it backward about 10–15 degrees from vertical. Filler metal is added
manually to the front end of the weld pool as it is needed.
Welders often develop a technique of rapidly alternating between moving the torch forward (to
advance the weld pool) and adding filler metal. The filler rod is withdrawn from the weld pool
each time the electrode advances, but it is always kept inside the gas shield to prevent oxidation of
its surface and contamination of the weld. Filler rods composed of metals with a low melting
temperature, such as aluminum, require that the operator maintain some distance from the arc
while staying inside the gas shield. If held too close to the arc, the filler rod can melt before it
makes contact with the weld puddle. As the weld nears completion, the arc current is often
gradually reduced to allow the weld crater to solidify and prevent the formation of crater cracks at
the end of the weld.[15][16]

5.4 OXY ACETYLENE WELDING & CUTTING :

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 Fig 20; Oxy Acetylene Welding
Oxy-fuel welding (commonly called oxyacetylene welding, oxy welding, or gas welding in the
U.S.) and oxy-fuel cutting are processes that use fuel gases and oxygen to weld and cut metals,
respectively. French engineers Edmond Fouché and Charles Picard became the first to develop
oxygen-acetylene welding in 1903. Pure oxygen, instead of air, is used to increase the flame
temperature to allow localized melting of the workpiece material (e.g. steel) in a room
environment. A common propane/air flame burns at about 2,250 K (1,980 °C; 3,590 °F), a
propane/oxygen flame burns at about 2,526 K (2,253 °C; 4,087 °F), an oxyhydrogen flame burns
at 3,073 K (2,800 °C; 5,072 °F), and an acetylene/oxygen flame burns at about 3,773 K (3,500 °C;
6,332 °F).
Oxy-fuel is one of the oldest welding processes, besides forge welding. In recent decades it has
been obsolesced in almost all industrial uses due to various arc welding methods offering more
consistent mechanical weld properties and faster application. Gas welding is still used for metal-
based artwork and in smaller home based shops, as well as situations where accessing electricity
(e.g., via an extension cord or portable generator) would present difficulties.
In oxy-fuel welding, a welding torch is used to weld metals. Welding metal results when two
pieces are heated to a temperature that produces a shared pool of molten metal. The molten pool is
generally supplied with additional metal called filler. Filler material depends upon the metals to be
welded.
In oxy-fuel cutting, a torch is used to heat metal to its kindling temperature. A stream of oxygen is
then trained on the metal, burning it into a metal oxide that flows out of the kerf as slag.
Torches that do not mix fuel with oxygen (combining, instead, atmospheric air) are not considered
oxy-fuel torches and can typically be identified by a single tank (oxy-fuel cutting requires two
isolated supplies, fuel and oxygen). Most metals cannot be melted with a single-tank torch.
Consequently, single-tank torches are typically suitable for soldering and brazing but not for
welding.

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