PREFACE Training in an industry is a dynamic tool to get feeling of practical aspect of whatever has been learnt by us in the books.

It greatly enhances knowledge with the practical experience. Training in such great and well-managed company is a great opportunity for the trainer as apart from the basic training. Also we get a change to be familiar with certain other aspects of industry relations etc. Our main objective of undergoing industrial training is to acquire practical knowledge. Training enables us to get a clear-cut view of the subject that we have read. Both theory and practical are essential. Hence we can say, The theory is blind without practical and practical without theory. In fact, both are complementary to each other. As a part of three years of Degree with Industrial Engineering, I have undergone for two month Industrial Training after the sixth Semester. I am proud of receiving my Industrial Training in Tool Room at INDIAN SUGAR & GENERAL ENGINEERING CORPORATION (ISGEC) Yamunanagar, Haryana that is one of the top heaviest engineering industries of the country.

ACKNOWLEDGEMENT

During my training of two months as ISGEC ,whatever I learnt is going to be of great practical importance in my future. For this I would like to express my gratitude to Mr.Shiv Charan Sharma(Assistant Superivisor) so that under his guidance I successfully completed my training.

I would also like to thanks the whole staff of Tool Room whos friendly and cooperative behaviour help me lot in learning various techniques and gave me a never before experience in such reputed firm. I would like to thanks to Mr. Mohinder Saini who gave me a chance to do my training at ISGEC and to Mr.Shiv Charan Sharma for guiding me about my training. I convey my heartiest thanks to all those officers and employees of ISGEC who have given me their full co-operation and devoted their valuable time for rendering me their needy services, guidelines during the course of imparting me practical training and with whose sincere and precious helps, I have been able to complete my practical training successfully.

ISGEC PROFILE

THE COMPANY

1.

ISGEC the heavy engineering unit of Saraswati industrial ltd. was established in 1946 and is located at yamunangar, Haryana about 200kms from New Delhi. The annual turnover of ISGEC is US $ 50 million and group turnover of the Saraswati Industial Syndicate ltd.

2.

APPROVALS

ISGEC has been approved by Lloyds Register Asia (LRA) of quality assurance as an ISO-9001: 2000 company. The American Society of Mechanical Engineers (ASME) approves ISGEC for the use of ASME U, U2, R & S code stamps.

Lloyds Register Asia as class-I Manufacturing of Fusion welded pressure vessels approves ISGEC up to 200 mm thickness.

Engineers India Ltd. (EIL) approves ISGEC for Manufacture of vessels and columns in carbon and alloy steels up to 155mm thickness and in clad steel up to 130mm thickness.

Engineers India Ltd. approves ISGEC for Manufacture of Heat Exchangers up to maximum tube sheet thickness of 300mm.

China Safety Quality License

INFRASTUCTURE

1.

ISGEC has a sprawling works covering an area of about 25 hectares including covered production area of around 35,000 square meters.

2.

It has the capacity to handle jobs weighing upto 100 tonnes (single piece).

3.

Extensive facilities for hot & cold rolling, machining, welding, heat treatment and stringent quality controls to ensure strict compliance to international standards.

4.

More than 125 sophisticated machines and machine tools are installed in various production bays. Apart from these, more than 100 welding machines ( for various processes including SMAW, SAW, MIG, TIG and flash butt welding and under operation). ISGEC has own captive power generation of 3650 Kv through DG sets.

5.

CORPORATE PROFILE The Saraswati Industrial Syndicate Limited grew from the sugar mill and the general Engineering group. The engineering group was launched in 1946 with the establishment of the Indian Sugar And General Engineering Corporation now it is famous as ISGEC. Today, ISGEC is ISO 9001:2000. Company concentrates its production activities at Yamunanagar, Haryana about 200 km. North of Delhi, manufactures a variety of heavy Engineering equipments such as Chlorine Containers, Boilers, Sugar Machineries, Cement Machinery, Pressure Vessels, Mechanical and Hydraulic Presses, Plate Bending Rolls and Iron Castings.

This flagship unit of group also maintains the process division at New Delhi; responsible for the design, sales, contracting, and erection and commissioning of turn key plants besides equipment for sugar and cement industries. In 1960 ISGEC collaborated with John Thompson, UK (now known as NEI International Combustion Limited, UK). Located at New Delhi, ISGEC John Thompson (IJT) designs, sales, erect a range of boilers and associated equipments. UP Steels was acquired in 1981 and latter merged with the parent company. Established as a foundry in 1966 with the technical know how from Japans Kobe steels, UP Steels, an ISO 9002 company at Muzaffar Nagar, UP about 100 km. North of Delhi, manufactures sophisticated alloy steels and steel casting, both hand and machine molded as well as alloy iron castings steel ingots. Saraswati Sugar Mill (SSM) located at Yamuna Nagar, Haryana is having crushing capacity of 9600 tones per day and has recorded best overall recovering in India.

ISGEC COLLABORATIONS

Working continuously towards further excellence in technology, ISGEC entered into technical collaborations with international well known companies.

To mention a few:-

1955 1960 1963 1964 1966 1968

A.F. Cariag & Co. U.K. John Thompson, U.K. Kawasaki, Japan Farrels, U.S.A. John Shaw & Sons Bronx, U.K.

Sugar Machinery Industrial Boilers Cement Machinery Sugar Mills Hydraulic Presses Plate Bending & Leveling machine.

1979

NEI International Combustion, U.K.

Pulverized Fuel Boilers. Mechanical Press.

1980

Rovetta, Italy

PRODUCT RANGE

Diversity of ISGEC products range enables us to serve industry from Automobile and ship building to oil & natural gas, defense, aeronautics and nuclear power. The groups product range includes for:-

1.

Hydraulic Presses, Mechanical Presses & Press brake. ISGEC has successfully commissioned around 100 presses built include a 3700 tonnes hydraulic presses for defense and a 2500 tonnes mechanical press. Process plant equipments (pressure vessels, heat exchangers, columns, storage and transport vessels, reactors etc.) from fertilizer refinery, petrochemical and other industries.

2.

3.

Industrial & power boilers (including pulverized fuel boilers upto 60 MW size bubbling as well as circulating fluidized bed boilers up 200 TPH size). Custom made equipments for Indias nuclear establishments. ISGEC has supplied equipment during last 15 years to Bhabha Atomic Research Center, Nuclear power corporation, center of advanced technology. Chlorine, Ammonia and other gases containers. ISGEC are the largest manufactures of chlorine in the world.

4.

5.

DIVISION OF ISGEC

ISGEC has been divided into three divisions as follows:-

1.

PRESSURE VESSEL DIVISION (PVD)

Pressure vessel division is the oldest of ISGEC and it manufactures pressure vessels such as boilers, heat exchangers etc. It is sub-divided into following shops:a) PVD-I b) PVD-II

c) PVD-III d) PVD-IV

2. MACHINE BUILDING DIVISION (MBD) Machine building division is very important division of ISGEC and it manufactures sugar mill machinery. Press components and other Steel plant machinery. It is sub-divided into following shops:-

a) FABRICATION SHOP-I,II b) MACHINE SHOP-I,II c) ASSEMBLY SHOP d) QUALITY SHOP

3. FOUNDRY GROUP (FG) Foundry group is the third important group of ISGEC and it is responsible for casting of large castings for the big industries.

4.TUBE SHOP Tube shop deals with tube manipulation and fabrication of tubing system used in economizers and super-heaters.

5.CONTAINER SHOP Container shop manufactures chlorine, ammonia and other gases containers.

FABRICATION SHOP

Fabrication shop is one of the constituents of the machine-building department. Almost all sort of fabrication work are done here. In this shop thick sheets of mild steel are cut, welded and bent according to the required design. For the cutting of plates and sheets CNC gas cutting techniques are made use of. Then different cut parts are joined together with the help of welding.

Some of the welding techniques adopted in ISGEC are:-

Gas Metal Arc Welding (GMAW)

 Submerged Arc Welding (SAW) Shielded Metal Arc Welding(SMAW) Semi Saw Plasma Arc Welding

Brief description of these welding techniques is given in the following pages. The bending of sheets is preferred in hydraulic presses. For bending, a specific type and size of the die is kept under the plate to be bent and then hydraulic pressure is applied above the plate. Extent of bending depends upon the radius of curvature of arc formed by bend plate. Gauging is used for cutting sheets.

WELDING TECHNIQUES
1. Shielding Metal Arc Welding (SMAW)

Principle:It is arc welding process in which coalescence if the metal is produced by heat from an electric arc. That is maintained between tip of a covered electrode and surface of base metal in joint being welded. The principal function of covering on electrode is to provide arc stability and to shield molten metal from oxidation with gases created as coating down from heat of the arc. For generating arc there should be some difference between electrode and workpiece. For better results length of the arc should be as small as possible.

Advantage:Auxiliary gas shielding or granular flux is not required any more.

Limitation:Due to high temperature are characteristics may change.

2.

Submerged Arc Welding(SAW) It produces the coalescence of metal by hating them with arc between

base metal electrode and work-piece. The arc and molten metal are submerged in a blanket of granular fusible flux. The main role of the flux is to control the chemical and mechanical properties of final weld. In the welding end of a continuous bare wire electrode is inserted into the mould of flux that covers area to be welded. An arc is initiated using one of the arc initiation methods. A wire feeding mechanism begins to feed electrode wire. Additional flux is fed along with electrode. Heat evolved by electric arc melts some of flux creating a pool of molten metal beneath layer of molten slag. The flux blanket on the top surface of weld pool prevents the atmospheric gases to mix.

Factors that usually effect SAW:-

Chemical composition and final deposits of weld. Type of metal to be welded. Position in which weld is to be made. Volume of welding to be performed.

3. Gas Tungsten Arc Welding (GTAW) It is technique that uses an arc between a tungsten electrode and weld pool. The process is adopted with/without shielding gas. Shielding gas is fed through torch to protect electrode, molten weld metal and shielding weld metal from oxidation. The arc is produced by the passage of current through conducting gas. The arc is established between the tip of electrode and work. Heat generated by arc melts the joining surfaces. Filler wire is added to leading edge to fill the joint.

4. Co2 Gas Welding/Metal Active Gas Welding (MGAW) MGAW is so called because Co2 is an active gas. MS wire electrode is fed automatically in the welding torch and Co2 gas is allowed to pass through the torch pipes. It acts as a shielding gas because it protects the weld pool from oxidation by atmospheric gases. If instead of Co2 we use helium/argon welding technique is called MIG.

5. Plasma Arc Welding (PAW) It is an arc welding process that produces coalescence of metals by heating with a constricted arc between electrodes and constricted nozzle. It uses a non consumable electrode. PAW torch has a nozzle that creates a gas in the chamber surrounding the electrode. The arc heats the gas fed into chamber to a particular temperature. It becomes ionized and conducts electricity. The ionized

gas is called plasma. It raises the gas temperature up to 30,000 degree F. It is very expensive technique. Principle:The gas is directed through the torch to surround the electrode. It bears ionized un arc to form plasma. For most operations auxiliary shielding gas is used. The arc construction nozzle is specified by nozzle diameter and throat length.

Disadvantage:Major disadvantage of PAW is the relatively high expenses of equipment. Also there are more control variables, more complex and expensive operator training.

ASSEMBLY SHOP

Study of liftable ladel turret assembly ; A ladle rotating turret arrangement to be used in a continuous casting plant. The central column can also be designed as a bushing and can serve for accommodating a liftable and lowerable ladle support. A ladle turret has two liftale forks, usually 180 apart. It has capacity of 300ton. It is used in steel plant industry where molten material at high temperature has to transfer from one place to other, where final shape has to be given to the molten material. Firstly, this molten material is collected in container and placed over the one end of the cradle for its movement. Main parts of this assembly ;

 Ladle turret rotation unit Portal Basement Central body Arms Lever Cradle

Hydrulaic cylinders

Bearings Manuplating isulators Manifold Motor

Construction
In this assembly the main part is the basement. In the basement so much type of piping is done. However, this piping is done to provide the required force at different positions in the assembly. As in central part hyduralic cylinders are provided, so for their movement required force comes from piping of basement.

On the basement ladle turret unit is placed. There are no of bearings system is also attached in between the central part and the basement. Motor is also provided to give the motion to rotary unit (pinon). Bearing gives the relative motion to central body. In central body there is attachement of hydrulaic cylinders,which gives the motion to cradle. There are two arms provided on the either side of portal. On these arms cradles are attached. The motion of cradle is controlled by the cylinders via levers. Portal is the vertical part, where all these parts are assembled. Surfaces of the cradles are tapered. It is because the containers which has molten material in it has to place on this tapered part. In the cradle pins and load cells are attached, which acts as shock absorber during the movement of cradle. Around the load cells manifold pipe is provided. It is because when there is dissipation of heat during movement of cradle, this pipe give cool air there.There are no. of holes on the manifold for removal of cool air. Isulating plate is attached on the outer part of cradle to maintain the temperature inside the assembly.

WORKING

As the simple working definition of this assembly is that the transfer of molten material from one place to other where final shape has to given to this molten material.

But each part in this assembly has its own and important role for carrying out this process and the important parts are basement, central body, arms and cradle;

BASEMENT It is the main part of the assembly. In this hydraulic and pneumatic piping is done as per the require force in different sections of the assembly. It is made up of such strong material so that it can bear the whole load of the upper part and can absorb the any type of shock observed during movement.

CENTRAL BODY

In this part hydraulic cylinders are attached. The main function of these cylinders is to control the motion of the cradles via levers. To move these cylinders, we also require some force which comes from the basement piping. The motion of the cylinders with respect to cradle is opposite or relative i.e. when cylinders move upward cradle moves downward and vice versa. This central body also rotates relative to the basement due to motion of rotary unit. Relative motion to the central body is

provided by bearing and motor attached in between the central body and basement.

ARMS

On the either side of portal arms are attached to give support to the cradles. Cradles are attached to the bushes of arms, which are self lubricating. It is because when cradle move up and down or rotates then friction and wear tear losses will be there. So to remove these effects lubrication is provided to bushes.

CRADLE

This part of assembly attached to the arms. It has tapered surface on which molten material carrier is placed. Its motion is controlled by hydraulic cylinders. Levers of this cradle give it require motion for movement. Pins are attached in this cradle which acts as shock absorber. Load cells are also attached in this cradle for the same function. However, these load cells have springs to resist. During the motion of cradle heat is generated, which is controlled by manifold piping. It has so many holes for the exit of cool air and is attached around the load cells in the cradle. This cool air balances the temperature inside the cradle assembly.

Xeramic fiber insulator plate is attached on the outer surface of the cradle. Once all the inner parts of cradle are well assembled, then this plate is attached. This is placed like plate/insulator/plate. As explained earlier function of inner plate to control the inner temprature and function of outer plate is to resist the outer temperature to come in contact with inside.

This process of transfer is so rapid. It is because when one part of cradle takes the molten material, it moves to other position and 2nd part of cradle comes nearer to the furnace of molten material to move it away. Now if this process of take and transfer is slow, then the molten material will cool down. Thats why this process is so rapid to keep the material hot. Because of this rapid process there is attachment of load cells to absorb the shocks. Because of this process every component plays an important role on their specified positions. For e.g.

Insulating plate Hydraulic cylinders Pins Bearings Motor Rotary unit

SOME OTHER COMPONENTS USED IN THIS ASSEBLY Washer

Hex bolt phosphatized L40

External serrated washer Pin Hex bolt L60 Hex bolt L20 Cover Plate SML pipe U bolt complete with nuts/washers Mounting Latch housing Cam Bed plate MF UNION taper seat ZIN COAT Chain Door

Weld on number MAT.PER RETI DI TERRA #.45MT HEX SOCKET HEADCAP SCREW Slotted counters

So, these are also some helpful components used in this assembly to support the large parts.

PLANNING AND SELECTION OF ASSEBLY

Now in any organisation basically there are three levels of management Top level Middle level Bottom level

So in the top level of management managers and higher authorities set up a project in an organisation. After discussion there is selection of best method for achievement of the goal. So it is set up for the next level of the organisation.

Now in the next level, executive engineers and other staff members read this method properly and after removing any difficulties, it is implemented.

So workers of organisation work as per scheduling and requirement of the project. For this so many supervisors are provided to workers to ask any difficult during working or carrying out the project.

Now selection of any assembly is done by BOM (bill of

material). In BOM specification of every part is given. With this diagram of each component is also sent by that industry which gives the order of assemblies to such companies.

By

the study of BOM, it become easy to make decisions that

which kind of assembly shop is available or kind of assembly can be done and what parts has to be purchased for the require product. After proper studying of BOM decisions are made for the required assembly.

A layout of assembly;

Fabrication Machining Assembly Quality Dispatch

Firstly some parts which required welding etc send to fabrication shop as per requirement. Then machining is done of some parts to remove the sharp edges. After that finally machined parts assembled to required positions. Quality is checked by the comparing the final product with standard and then dispatched to the industry.

During assembly of pins in the cradle, chemphering is done. It can be done by two ways by filler and grinder. By grinder it can be done faster than the filler. It is done to make the radius of pin equal to that part where it is going to attach. Because if there is any tolerance left, it may make the assembly loose. Thats why proper oiling is done of the pins and bolts are clamped tightly. It is done by so many workers so work rate of each worker is checked out. Incentives are given as per there working hours. By this time study we can also calculate the time taken by each assembly and no of workers also.

CONCLUSION

Hence it is a modern approach to carry out a process in short time to keeping the material nearly at the same temperature at which we are taking from the furnace. It is very rapid process by the help of which productivity can be increased and also the efficiency of product.

MACHINE SHOP

Machine shop is the main work station of the organization. Here various machining operations are carried out to produce different parts of hydraulic and mechanical presses. There are two division of machine shop a) Machine shop-I :- Heavy Work Division b) Machine shop-II:- Light Word Division

Various Machine Employed at Machine Shop-I

1. 2. 3. 4. 5.

SACEM CNC Horizontal Boring Machine. WELDRICH COBURG plano-miller SWIFT LATHE H.M.T Radial Drilling Machine SKODA Horizontal Boring Machine

HB-9 P-4 L-14 RD-4 HB-1

6. 7. 8.

HAURISTI Horizontal boring machine WMW UNION Horizontal boring machine SKODA Horizontal boring machine

HB-8 HB-5 HB-3

PROCEDURE OF WORK:Every department or every work station works under planning department of ISGEC. So the Machine-I planning Department prepare the design of the press and any other job, to be manufactured. It prepares the drawing and route card, which are directly obtained through the computers installed at shop floor directly linked with the planning department. Route card is document at which the whole process to be carried out and is printed in sequence i.e. operations to be performed on the machine tool and after completion of work on job on one machine then at which machine tool to be transferred and sequence of job on one machine to be performed on that machine tool and operation observed.

FOUNDRY SHOP

Foundry shop is the main work station of the organization. Here various types of difficult castings are to be cast, as required by the client. There is only one division of casting in the ISGEC, rest of the work of casting is done at the U.P. Steel plant of ISGEC group.

Pattern:- Pattern is the same or the original shape of the substance which we have to cast.

Mould:- Whereas mould is the replica of the pattern which is used for giving the proper shape to the casting as required and these moulds are made from the sand.

Types of Sand used:-

There are two types of sand used in ISGEC for casting. 1. 2. Cement Sand Phenolic Sand

1.

Cement Sand:- Cement sand contains two or three things i.e river Sand, cement and molasses. These three things are mixed in fixed proportion so that sand does not loose its adhesive nature. In Cement Sand there is 85% to 90% is river sand, 8% molasses and 4% cement. In this mixture molasses act as binder, which binds the sand properly and its adhesive nature. Cement sand is used only for filling the vacant area around the mould. After the proper ramming of the cement, sand baked so that it does not fatal by gaining moisture. Phenolic Sand:- Phenolic sand is also the mixture of three things i.e silica sand, resin and catalyst. The composition of Phenolic Sand is 90% to 93% Silica Sand and 2% to 3% Catalyst. Here resin acts as chemical which increases the properties of the sand and catalyst is used as binder or hardener which helps in setting the sand. Silica sand is coarse sand, so there is no need of baking it. After mixing all the things for making the mixture of Phenolic sand, it is taken to the patterns where it is properly rammed. After that it would be left for some time so that it becomes as hard as stone.

2.

Types of Materials Used for Making Patterns

1.

Mostly the patterns used in ISGEC are made from thermocol sheets. These thermocol sheets are cut in the shapes as per drawing given to pattern making man. Pattern making man cut the big blocks of thermocol in the pieces as per dimensions given in the drawing with the help of cutters and element wire ( Element wire is that wire which is used in heaters. This wire becomes hot and cuts the thermocol sheets very smoothly without damaging the material). Wooden patterns are also used for making the moulds .Wooden patterns are used when more finishing is required. Metal patterns are also used in castings. These patterns are used only for taking the prints on the mould.

2.

3.

Direction for Moulding Work

On getting the patterns and moulding, understand the shape of casting clearly.

Discuss the position of risers and setting clearly with the supervisor. Check the mixture poured from the mill. Never use the set moulding and coarse sand. Ram the sand in the moulds very well. Always repair the moulds with the same sand, fix the repairing portion with nails. It is necessary to paint mould. Never use thinner for oily sand and never use water paint for silicate sand.

 Dry the core or mould of oil paint in the core oven or with the help of burner. Decide the thickness of mould and core assembly according to the drawing. Before closing the moulds provide passage for the release of the gases. Release the gases of core and moulds separately. Clean the mould with air and brush before closing it. Use thin sealing between mould boxes or between the cores before closing it. Place weight on the moulding boxes or tight them with the help of bolts.

Procedure for Making a Mould

Check clearly that the pattern is not wet from anywhere and it is not damaged from anywhere.

Always place the pattern on the plain surface.

The handles used on the patterns should not be loose and always be straight.

Ramming in the pockets and contours should be properly done. After facing sand provide proper vents in the cement sand. Always check there is no alignment in the mould and the ramming of upper box should be properly done. The height of the upper box should not less than 10 or it should be according to pouring basin.

STUDY OF TIME CONSUMPTION

Types of time consumption:1. 2. Manual Time Machining Time

1.

Manual Time:- Manual time is the time which is consumed during the manual activity. Manual time is classified as: Loading and Unloading Preparation Time study Setting Time Study

a.

Loading and Unloading This is the time which gets consumed during the loading and unloading

of the job from the machine. This involves operator involvement but it is beyond limits to get it under control unless and until whose system is computerized.

b. Preparation Time Study Preparation time study is the study of all activities, which starts just after unloading the finished job and halts before setting of the job in parallel and perpendicular with the machine. Activities include in PTS are:-

1. 2.

Loading of the job Clamping of the job

3. 4. 5. 6. 7.

Search for the clamps Instructions from supervisor Getting route card Setting tool on machine Getting tool from tool room

c.

Setting Time Study

Setting time study is carried out to record the time consumed during setting of the job in parallel and perpendicular with bed and tool of the machine, concentric with the chuck of the lathe and checking for circular run out on lathe. As the machining operation involve lease operator interventions and it has to work with the pace fed/set by the operator so to snatch time from this part is difficult rather impossible. Now we are left only manual activities.