About Kolkata Port TrustGeographical Location: - Kolkata Port trust is situated at 8824 E and 22.34 N at the bank of Hooghly River near Bay of Bengal which is in the deltaic plane of the Ganges.History; - Kolkata Port was set up by the British East India Company after the company received trading rights from the Mughal emperor Aurangzeb. Following the shift of power from the company to the British crown, a port commission was set up in 1870. Though the port was conceived to be a commercial port and gateway of eastern India, the port played a very important role in the Second World War. It was bombed twice by the Japanese forces. After the independence, the Commissioner for the Port of Kolkata was in View of the Calcutta Port in 1852 responsibility of the port till January 1975 when Major Port Trusts Act, 1963, came into force.In the 19th century Kolkata Port was the premier port in British India. After independence its importance decreased because of factors including the Partition of Bengal (1947), reduction in size of the port hinterland and economic stagnation in eastern India. In the 21st century due to the East Indian economic recovery and infrastructure improvements, the port grew swiftly to become the nation's second largest container port. It was one of India's fastest growing ports in 2004-05. Dock System: - Kolkata Dock System (KDS)It is situated on the left bank of the Hooghly River at 22 32' 53" N, 88 18' 5" E about 203km (126 miles) upstream from the sea. The pilotage station is at Gasper/ Saugor roads, 145 Kilometers to the south of the KDS (around 58km from the sea). The system consists of: Kidderpore Docks (K.P. Docks): 18 Berths, 6 Buoys / Moorings and 3 Dry Docks Netaji Subhas Docks (N.S. Docks): 10 Berths, 2 Buoys / Moorings and 2 Dry Docks Budge Budge River Moorings: 6 Petroleum Wharves Anchorages: Diamond Harbour 1. Saugor Road 2. Sand headsApart from this, there are around 80 major riverine jetties, and many minor jetties, and a large number of ship breaking berths.

Reasons Behind Growth:- KoPT have got a very large hinterland including to metropolitans of India named Kolkata and Delhi. It includes all the major deltaic cultivation land of northern India, the mines of ores in Chhotanagpur Plato and the Dears and Himalayan Hills.Besides it the historical background of Kolkata also provides it a readymade infrastructure for its both economical and technical growth.Difficulties of Port:- Since it is deltaic planes of Ganges continuous drazzing of the river is required which costs a lot.Since its docks are man made frequent maintenance is required.The swallow depth of Bay of Bengal does not allow the large vessel to enter.The downfall of heavy industries of north India is weakening its economic back bone.Solutions:-Due to the constraints of the river (like silting, sandbars etc) no sea-going vessel above 200 GRT is allowed to navigate without a qualified pilot of the Kolkata Port Trust. The total pilotage distance to KDS is 221km (comprising 148km in river and 75km in sea).Another sister dock complex is established nearer to sea named HDC (Haldia Dock Complex).i.

Section - ISection: -MarineDuration: - 21st June 2010 3rd July 2010

Introduction:-The section contains the findings during Summer Training at the Marine section of Kolkata Port Trust. This section basically contains The Following Contents. Deck Layout Of A Ship Kanho Deck Layout Of A Ship Lava Engine Room Layout Of Ship Lava Introduction to the design and functions of major structures of an ideal ship

Main parts of ship. 1:Smokestack or Funnel; 2:Stern; 3:Propeller and Rudder; 4:Portside (the right side is known as starboard); 5:Anchor; 6:Bulbous bow; 7:Bow; 8:Deck; 9:Superstructure

Deck Layout ofKanho

30

1. Forward side.2. Drivers Desk3. Port side4. Star board Side5. Cabin6. Engine Room.7. Chimney8. Engine Rooms Rear Part9. Exhaust Fan for Cooling Engines10. Bathroom11. Bathroom12. After side

Kanho on the dry deck of KoPT

General View of Kanho

Deck Layout Of M.Lava

1. Anchoring Mechanism2. Steering Desk3. Port Side4. Star Board Side5. Forward Side6. Cabin7. Mustool8. Chimney9. Engine room10. Air Exhaust of Engine Room11. Bathroom12. After Side13. Kitchen

General View of M.Lava

Layout Of Engine Room of M.Lava

1. 2. Fuel Tank3. Lubricant Tank4. Cooling Unit5. Main Engine6. Gear Box7. Propeller Shaft8. Cooling Water Pump9. Diesel Engine to drive Generator10. Generator for Domestic Supply11. Electric Mains12. Electric Wiring Board13. Electric Switch board

We could not had an opportunity to draw the Layout Of Engine Room of Kanho, as during our training period in Marine Section, Kanho was on dry deck for repairing purposes and its Engine Room was in a condition of total chaos with each and every part wide open. But from an over view of the room it was obvious that it was equipped with two six cylindered engines, each having their own gear boxes, power transferring and heat exchanging arrangements. It has also got cooling fans over each engine which draws in the cool air from the opening on the roof of engine room. Shown as exhaust fan in deck layout of Kanho.

the design and functions of major structures of an ideal ship Forward Side: - It is the front most part of a ship which is made V-shaped to minimize the retarding hydraulic factors of the ship during its motion. It basically consists the following structures-

I.Starboard Side: - Starboard is the nautical term that refers to the right side of a vessel as perceived by a person on board facing the front. The equivalent for the left-hand side is port. The starboard side of a vessel is indicated with a green navigation light at night.The origin of the term comes from early boating practices. Before ships had rudders on their centrelines, they were steered by use of a specialized steering oar. This oar was held by an oarsman located in the stern (back) of the ship.

Front view of Kanho However, like most of the rest of society, there were many more right-handed sailors than left-handed sailors. hence men sailing with the steering oar (which had been broadened to provide better control) used to be affixed to the right side of the ship. The word starboard comes from Old English steorbord, literally meaning the side on which the ship is steered, descendant from the Old Norse words stri meaning rudder (from the verb stra, literally being at the helm, having a hand in) and bor meaning etymologically board, then the side of a ship.It is indicated by green light in night which is an indication for an incoming ship intersecting the way of the first ship, to move ahead according to the traffic rules of sailing. II.Port Side: - Similarly, the term for the left side of the vessel, port or larboard, is derived from the practice of sailors mooring on the left side (i.e., the larboard or loading side) as to prevent the steering boards from being crushed. Because the words larboard and starboard sounded too similar to be easily distinguished, larboard was changed to port.During night sailors used to illuminate this part with red light which means a ship coming from the left side of first one and intersecting its path will have to stand and wait until it crosses away according to rules of sailing for avoiding collision between two vessels intersecting their paths.Steering: - It is part of a ship which uses to decide the direction of motion of ship. In old days it was done with a number of oars operated manually by a number of sailors costing very large expanse of money and labour. But now a days nothing but a circular wheel handle is used for the purpose which can be rotated right or left to turn the ship right or left accordingly which is a very much similar method as we have in cars.

An ideal steering wheel of a shipThe power given to the rotating steering wheel is supplied to the rudder of the ship fitted at the back of the ship just behind the propellers by ropes or by hydraulic mechanisms depending on the size of the ship which forces the rudder to rotate right or left and thus due to the hydraulic forces applied by the propelled fluid on bent rudder it causes the head of the ship to turn in an reverse order due to the lever action of the rigid body structure of the ship itself.

Steering mechanism of a shipIt is also equipped with a mariners compass to have the sense of direction of the motion of the ship

Speed Control: - The speed of a ship is controlled by varying the speed of propellers and like any other machine it is also done by a gear box. Generally there are two methods of speed control in the ships are seen-a)Bridge Control: - With this system driver alone can change the speed the ship with levers he have on the desk itself.b)Engine Room Control: - It is a very old system to change the speed. In this case driver sends his desired value of speed to another engine operator sitting in engine room by various indications of bells or with two dials provided on the deck and engine room. Now when driver sets a value of speed in the dial he have it is immediately transferred to the engine room dial by means of wires and springs or by telegraph and after receiving this speed signal engine room operator immediately changes the gears of engine and changes its speed Cabin: - It is the residential areas of a ship for crew members and the passengers. Equipped with all possible and adorable luxuries and comforts and if the ship is a cargo one it also includes its godown. But as both the ship we had seen (i.e. M. Lava and Kanho) were surveying ships there cabin contains only two small rooms for resting of crew members.

Mustool: - It is projected top most part of ship on the roof of the cabin. It very much looks like a pantograph of a tram. It carries multicoloured lights and sirens and very often the flag of the owner country or organisations.It is used to allocate the position and condition of the ship during nightand days having poor view. The colour of light on the mustool says that is it moving in a certain direction or is it anchored to the local traffic control room and other ships.

Engine Room: - It is the most important and indispensible part of a ship. It also may be called the master control room for all the mechanical processes on the ship. Although the design and quality of engine rooms varies widely with the function and sizes of the ships. So here Im going to describe the engine room of the surveying vessel. It contains the following parts.a) Oil Containers: - Generally two large containers are provided in the engine room one for carrying fuel during voyage and other for the lubricant for the engine.b) Generator: - It is a simple DC-generator unit coupled with a separate IC-engine which charges a number of Pb-acid accumulators which are used to supply the power on the deck of the ship for domestic usage even if when the ship is anchored and main engine is not running.

Image of generator of M LavaSpecifications of generator of M Lava

Speed Bhp: 1800 rpm : 60 kw

c) Electrical Components: - These are generally electrical switches and wirings necessary to run the ship properly along with the batteries for storing the power.d) Centrifugal Pumps: - Two centrifugal pumps are provided on the deck of the ship. One is to pump the water out of the deck if some secretes in from the gaps in ship body and the second one is to suck in the water in the engine room from sea to cool the engine.Like any other centrifugal pumps it also contains an impeller to rotate an convert mechanical energy into pressure head of fluid at outlet, volute casing to avoid Eddys formation and to diffuse the water stream so that KE of the fluid changes to pressure head, suction pipe with a foot valve to suck in the water and a delivery pipe for fluid output.A centrifugal pump works by converting kinetic energy into potential energy measurable as static fluid pressure at the outlet of the pump. This action is described by Bernoulli's principle.With the mechanical action of an electric motor or similar, the rotation of the pump impeller imparts kinetic energy to the fluid through centrifugal force. The fluid is drawn from the inlet piping into the impeller intake eye and is accelerated outwards through the impeller vanes to the volute and outlet piping.As the fluid exits the impeller, if the outlet piping is too high to allow flow, the fluid kinetic energy is converted into static pressure. If the outlet piping is open at a lower level, the fluid will be released at greater speed

Radial Flow Centrifugal Pump PrincipleSingle Stage Radial Flow Centrifugal Pump

Specification of Centrifugal Pumps of M Lava

Speed : 1500 rpmBhp : 50 kwShaft Material : SteelImpeller Material : Phosphor-Bronze, Mn, C.I.Body Material : C.I.Keys Material : Mild Steel e) Diesel Engine: - The giant diesel fed machines which converts the chemical energy of fuel into mechanical energy for propeller rotation and causes the ship to move. According to load and size of the ship the numbers and capacity of engines also varies widely.Layout of Engine of M. Lava

1. 2. Heat Exchanger3. Casing Enclosing Cylinders4. Air Filter 5. Air Injection Pipe to Cylinders6. Exhaust Pipe7. Fuel Filter8. Lubricant Filter9. Gear Box10. Propeller Shaft

The engine of a ship contains following major Parts-A. Filters: - An engine of a ship carries three filters to restrict the entry of dust and impurities to the cylinders and other critical parts of the engines.I. Air Filter: - It filters air entering in the engine first with the sieves in the base of the dome it has. There after the air is supplied to a cylinder below for electrolytic precipitation of the air and then with a delivery it is sent to cylinders when needed.II. Fuel and Lubricant Filters: - These are basically two cylindrical sieves used to filter the oils in midway of their path from containers to cylinders.

Oil Filters

Air FilterB. C. Piston & Cylinders: - Cylinders are the parts of an engine in which combustion of fuel occurs and temperature of the gas in it excessively increased to have an very large amount expanding forces all at a sudden and thus the chemical energy of the fuel is transferred to mechanical energy following diesel cycle which further forces the movable Piston outward and transfers power to crank causing it to rotate with the help of Slider Crank Mechanisms.

Six Pistons of Kanho

The entry and ejection of air and fuel to the cylinders is automatically controlled by the valves fitted with it which gets the signals from the cams rollers fitted with the rotating crank at a certain angle of rotation. Here the crank itself acts as the disk of the cam with sophisticatedly designed profile.Piston and Cylinders of Kanho

D. Exhaust Pipe: - These are the pipes in which exhaust valves of a cylinder do open. Later on these pipes unite to form a wider pipe which leads the smoke and burnt hot air to the chimney. Besides expelling the hot air out from the cylinder it also plays a role in heat rejection by expelling the heat out of the cylinder with the thrown out smoke of burnt fuel and air.E. Crank:- It is rotating part of an engine connected with the shaft of the sliding piston with a revolute joint. It is generally shaped like a profile of a cam disk having rollers fitted at a fixed angle of rotation which governs the opening and closing of the valves of the cylinder.

Now for a multicylindered engine the cranks of each cylinders are sophisticatedly attached to each other in a series with a constant angular offset of their profile in such way that the always adds each other multiplying the net power output of the engine as a unit.Now interestingly the cranks are not connected to each other with a single shaft have constant axis of rotation but two adjacent disks are individually connected with a separate shaft so the piston shaft should have no hindrance during its path.

Crank of KanhoF. Heat Rejection: - There are generally two methods of heat rejection are adapted in ships.I. Radiators: - These are used to transfer thermal energy from one medium to another for cooling and heating. It always heats the environment. Hence either it may act as a heater to environment or cooler to the fluid supplied to it. It is made up of materials having good corrosion resistance and thermal conductivity.II. Cooler Or Heat Exchanger: - Here lubricant supplied to the engine loses its heat coming in contact of a stream of cool sea water sucked into the engine room by the pump.

Specification of Engine of M. Lava

Type : Diesel EngineSpeed : 900 rpmBhp : 190 kwTemperature : 318 KPressure : 760 mm of Hgf) Gear Box: - It is the mechanism in the engine room used to control the speed of the rotating propeller with the help of a complex train. Here power input is from the rotating crank from engine while output is fed to propeller shaft.g) Propeller Shaft: - It is the shaft coming out of the gear box and running up to the rear part of the ship and attached with the propeller at its terminal. It is the mean to transfer the power from gear box to propellers.It is well machined in the Lathe m/c prior to being attached to ship and then fitted at its exact position with help of sufficient number of bearings. Generally universal joints are used to couple the main shaft with propellers and shaft out of gear box.

Propeller shaft is generally made with Steel so that it can have required degree of strength and smooth surface finish to minimize friction during rotation

Specification of Propeller shaft of Kanho Length : 4.22 ft Dia. : 8.25 cm Materials :Steel with a gun metal covering Rotation : 300-1200 rpm Direction of rotation :Both clockwise and anticlockwise

.Engine of Kanho

Chimney :- It is the square or cylindrical pipe on the top most roof of the ship just beside the mustool which used to expel out all the smoke formed in the engine and generator with the help of the exhaust pipes from each individual mechanical prime movers in the engine room.

Cooling Fans :- These are the fans provided in cylindrical pipes situated beside the chimney and draws cool air from the atmosphere to the engine room above the engines to cool it down. Propeller : - A propeller is a type of fan which transmits power by converting rotational motion into thrust. A pressure difference is produced between the forward and rear surfaces of the airfoil-shaped blade, and water is accelerated behind the blade. Propeller dynamics can be modelled by both Bernoulli's principle and Newton's third law.

Different types of propellers

A propeller is the most common propulsor on ships, imparting momentum to a fluid which causes a force to act on the ship.The ideal efficiency of any size propeller (free-tip) is that of an actuator disc in an ideal fluid. An actual marine propeller is made up of sections of helicoidal surfaces which act together 'screwing' through the water (hence the common reference to marine propellers as "screws"). Three, four, or five blades are most common in marine propellers, although designs which are intended to operate at reduced noise will have more blades. The blades are attached to a boss (hub), which should be as small as the needs of strength allow - with fixed pitch propellers the blades and boss are usually a single casting.

Marine propeller nomenclature

1) Trailing edge2) Face3) Fillet area4) Hub or Boss5) Hub or Boss Cap

6) Leading edge7) Back8) Propeller shaft9) Stern tube bearing10) Stern Tube

Materials Used in Propeller Design For Propellers Body :Phospho-Bronze For Shaft : Steel For different Bushes : Gun metalCardan Shafts are also used in marine applications for the transmission of power between gear box and propeller

Rudder :- A square sheet of metal attached to the rear most part of ship just behind the Propellers by means of a vertical shaft attached to its one end. It is made able to rotate right or left around the shaft as axis of rotation. It is used to turn the ship. It receives power from the steering on deck by hydraulic means which is converted into the rotation of its axis by means of gears and wires.Now if rudder is rotated towards right the outward flow of water from right side of propeller is resisted which causes a force on the sheet of rudder and in reaction sheet also applies an equal opposite force on right hand side of the rear part of the ship which acts as a torque to rotate the front part of ship towards left.

Turning of a Ship Towards Right

After Side :- The Rear part of the deck of a ship is called after side. It is generally the part of a ship which is equipped with all the gear and wire mechanisms to steer the rudder of the ship

Section - IISection : - New Machining and Fitting ShopDuration: - 5th July 2010 13th July 2010

Materials generally Used: Gun Metal Monal Metal Mild Steel Phospho-Bronze Copper Platinum( in gasket sheets for leak proof)

Job Seen At Machine Shop: Lathe Operationsi. Machining of Propeller Shaftsii. Making a part of square bar cylindrical by turningiii. Thread Cutting on a part of studsiv. Making Nuts with a hexagonal parallelepiped

Fitting Shopi. Vice Operationii. Study of Main Parts of a Centrifugal Pump

Layout Of New machining & Fitting Shop

1. Marine Workshop & Planning Office2. Area Of Keeping Spare Parts3. Staff Table4. Vice Table5. Wooden Block6. Wooden Block7. Wooden Block8. Vice Table9. Lathe M/C10. Lathe M/C11. Lathe M/C12. Vice Table13. Vice Table14. Vice Table15. Vice Table16. Marking Table17. Pipe Thread Cutting Table18. Shaping M/C19. Drilling M/C20. Drilling M/C21. Vertical Boring M/C22. Milling M/C23. Lathe M/C24. Lathe M/C25. Lathe M/C26. Lathe M/C27. Lathe M/C28. Lathe M/C29. Lathe M/C30. Lathe M/C31. Slotting M/C32. Shaping M/C33. Horizontal Boring M/C34. Grinding M/C35. Grinding M/C36. Staff Room37. Lathe M/C38. Lathe M/C39. 40. Lathe M/C41. Lathe M/C42. Lathe M/C43. Lathe M/C44. Lathe M/C45. Lathe M/C

Job Seen At Machine Shopi. Machining of Propeller Shafts

Name Of M/C : Lathe M/CSpecifications : 6 Jaws Manually Centred Chuck 22 ft Bed LengthPosition : 30th M/C of New Machining & Fitting ShopProcedure : Machining of propeller shaft consists following steps I. The propeller shaft is cantered in between the Head stock and Tailstock of the lathe m/c with help of the chuck and live centre fitted with the tail stock with the sufficient numbers of well centred support in between.II. An appropriate machining tool is fitted at the tool post with a very small cutting depth.III. Auto feed is engaged in the m/c with the appropriate gear settings with the help of the gear setting manual printed at the body of head stock.IV. Now when one complete horizontal displacement of the tool is complete the direction of feed is immediately reversed with the help of a lever provided below the tool post.V. Now the desired level of surface finish is obtained by changing the width of tool tip, feed speed and cutting speed. Lesser will be the feed rate higher will be the degree of the smoothness

ii. Making a part of square bar cylindrical by turning

Name Of M/C : Lathe M/CSpecifications : 4 Jaws Manually Cantering Chuck 12 ft Bed LengthPosition : 27th M/C of New Machining & Fitting ShopProcedure : Process includes the following steps I. The job is carefully cantered in between the chucks jaws so that the centre of the biggest in circle of the square base remains aligned with the tip of the live centre attached with the tail stock.II. Now the job is rotated freely to mark that centre.III. The turning length on the job is measured using a steel rule and marked with a file.IV. There after a cutting tool is fitted at the tool post with a depth slightly less than the farthest distance between the centre of live centre and perimeter of the job and m/c is started after engaging the appropriate feed rate and cutting speed.V. The direction of feed is immediately reversed when the cutting edge of the tool reaches the file mark.VI. The process is repeated with increasing depth of cut until it reaches the point of contact of the biggest in circle at base and perimeter of the job or until the value of the radius of desired dimensions of the base is achieved.

iii. Thread Cutting on a part of studs

Name Of M/C : Lathe M/CSpecifications : 4 Jaws Manually cantering Chuck 12 ft Bed LengthPosition : 27th M/C of New Machining & Fitting ShopBasic Principle : If the feed rate of a m/c per unit rotation is greater than the width of the cutting edge of the tool then it starts to scratch the marks of cut on the rotating job. This property is used for making external threads on the cylindrical surfaces. Procedure : Process includes the following steps I. The job is properly cantered in between the lathe m/c.II. Now a tool with the depth of cut a little bellow the job perimeter is fixed.III. The gears and levers are engaged to give the speed of cut and feed rate so that a thread of desired pitch is obtained by using the thread cutting manual on the headstock.IV. The direction of feed is immediately reversed as soon as the tool reaches the mark from which the thread has to be initiated.V. The process is repeated with increasing depth of cut until it reaches up to desired value.

iv. Making Nuts with a hexagonal parallelepiped

Name Of M/C : Lathe M/CSpecifications : 6 Jaws Self Cantering Chuck 6 ft Bed LengthPosition : 28th M/C of New Machining & Fitting ShopProcedure : Process includes the following steps I. The job piece is marked with a file at an interval equal to the height of the nut.II. Now the marked job piece is inserted in the self cantering chuck and fixed tightly.III. The live centre in the tail stock is replaced with a drill bit of tap drill radius equal to the inner radius of the nut threads.IV. Now the feed is given to the tail stock until it approximately drills up to the depth slightly greater than the height of the nut to be made.V. After that the drill bit is replaced with an internal thread cutting tool of L-shape and tightened in tail stock with the nuts provided below so that the depth of cut equals the depth of thread in nut.VI. Now the gear settings are changed to give auto feed to tailstock and cutting speed for internal thread cutting of desired depth.VII. Now again the thread reaches the depth little deeper than the height of the nut the direction of feed is reversed.VIII. After completion of thread cutting in the groove a single point cutting tool is fitted at tool post and placed at the mark of nut height. Depth of cut is engaged to auto feed without giving any feed to the horizontal motion of the tool post.IX. The m/c is allowed to run until the tool cuts off the nut.

Live centre (top) Dead centre (bottom)

Main Parts of a Lathe M/C

Main Parts of a Centrifugal Pump: -a) Impellerb) Casingc) Suction Pipe with Foot valve and Strainer.d) Delivery Pipe

The description and working principle of these parts are already stated in the marine section (pg: 12 & 13). Under the heading Centrifugal Pump.

Section - IIISection : - Boiler & Fabrication ShopDuration: - 14th July 2010 20th July 2010

Contents: - The section Contains-

Layout Of Boiler and Fabrication Shop.

Description of Machines Seen. Bending M/C Rolling M/C

Power Transfer by Shafts.

Making of Buoys Used for Traffic Control.

Various Welding Techniques and Parameters.

Layout Of Boiler & Fabrication Shop

1. Fabrication & Welding Zone2. Bending M/C3. Rolling M/C4. Electric Motor5. Staff Table & Planning Room.

Description of Machines Seen.

Name of the machine : Bending M/C

Functions : i. Straightening of bent rods or sheets. ii. Bending the rods or the sheets as per need.

Mechanism : The machine is made to run on simple slider crank mechanism. First the input pulleys of m/c are rotated by a belt which is coupled with a overhead rotating shaft.Now this power is fed to a big fly wheel which further transfers the power to the crank gear with the help of a complex gear train. Now a slider is connected with the crank at a very small offset of axis of rotation causing the slider to reciprocate with immense amount of power.

Top view of Bending M/C

Operations : For straighteninga) With the help of engaging lever the belt is force to slide from free rotating pulley to the pulley engaged with gears.b) There after an I-bar is placed between the hand wheel operated supporting bars and bending slider.c) Now the bent job is placed in between the I-bar and the slider show that the point of bent or dent faces the slider.d) The hand wheels are rotated to forward the I-bar placed ahead of the supporting bars until the desired alignment is achieved.For bendinga) After engaging the pulley the job is placed in such a way that the point of bent faces the siding jaw.b) Then the both the hand wheels are separately rotated to achieve the desired degree of bent.

Name of the machine : Rolling M/C

Functions : i. Rolling flat sheets to make an arc shape.

Mechanism : i. Here there are two input pulleys which rotates lower rolls with the help of suitable gear train. ii. The upper roll is used to maintain the required pressure by means of hand wheel and screw gear mechanism depending upon the the thickness of sheets and demand of the work.

iii. The bar provided before the rolls is used to support the sheets while inserting them into the rolls.

Power Transfer by ShaftsIn the shop the power to the each and every machine is transferred with the help of a long motor driven rotating shaft fitted overhead with the roof of the shop. For the reason a sufficiently large motor efficient enough to drive the all the machine in the shop simultaneously is established at one end of the workshop. Now the output pulley of the motor is connected to the shaft by means of a belt. Now this rotating shaft acts as the prime source of power in the shop. The power from this shaft can be extracted by means of pulley and belt whenever and whenever required.It is very often not possible to have a shaft of a length of the shop. Because according to BIS standards the maximum length of a shaft is 13m for convenience in its transportation. Hence the shafts are coupled in series to achieve the desired length.The sufficient no of bearings and supports are provided with the shaft.

Power Transfer by Shaft Making of Buoys Used for Traffic Control

Buoys are hollow more or less cylindrical barrels made up of mild steel sheets and able to float in the water which is used to locate the path and signals in seas or water ways. This is the only medium in the water ways to warn the incoming stranger ships in a water zone about the swallow water and other dangers.

1) First the 8mm thick ms sheets are rolled in rolling m/c and then cut into a piece having a length equal to the perimeter of the barrel and width equal to the height of the barrel.2) There after the sheet is rolled to make a cylinder and welded at the joint.3) Now a sheet of 10mm thickness is cut into a shape of circle and joined at both the open faces of cylinder.

4) Now sufficient numbers of holding arrangement made up of 25mm thick m.s. sheets and iron bars are welded at its top. These holding arrangements are used to hold the buoy amidst of waves of seas.

Various Welding Techniques and Parameters

1. Metallic arc welding using A.C. transformer :- Used only for ferrous metal.

2. Metallic arc welding using D.C. rectifier motor generator :- Used for both ferrous and nonferrous materials like Brass, Copper etc.

Types of Welded Joints

Positions of Weld

(1) Flat (2) Vertical (3) Horizontal (4) Overhead

Melting point of alloysAlloysM.P.

M.S.1370C

W.I1535C

C.I.1250C

C.S.1500C

Cu1083C

Ni1445C

Al630C

Brass930C

Bronze900C

N.B.While welding nonferrous alloys D.C. is compulsory. Its +ve pole terminal is connected with the job and ve with the holder. Low hydrogen evolving electrode (not above 2%). Open ckt. voltage 80V to 100V & close circuit voltage in a almost zero Where as close ckt. voltage 15V to 25V with usually bare or lightly coated electrode and up to 45V with some special electrode..

Size of ElectrodeDia of ElectrodeCurrent Read

16 S.W.G.1.5 M.M.25-45 amp

14 S.W.G.2 M.M.50-70 amp

12 S.W.G.2.5 M.M.65-75 amp

10 S.W.G.3.2 M.M.90-130 amp

8 S.W.G.4.0 M.M.120-135 amp

6 S.W.G.5 M.M.150-250 amp

4 S.W.G.6 M.M.180-300 amp

Oxy Acetylene Gas Welding

Gas used :- Oxygen & Acetylene

Uses :- a. Cutting b. Welding c. Brazing

Flames:- 1. Oxidising 2. Neutral 3. Carburising

Cutting Neutral Flame is used for cutting mild steel and Carburising Flame for cutting cast iron.Equipments : i. By cutting torch ii. By profile cutting m/c

Regulators :i. Single Stageii. Double Stagei. Single Stage : 1/9 th of original pressure Oxygen pressure = 1800 lbs Single stage pressure = 1/9 x 1800 = 200lbsii. Double Stage : Single stage is fixed while double stage is adjustable with the adjustable screw. Pressure of Oxygen cylinder = 1900lbs/sq inch Volume of Oxygen Cylinder = 6.5 cubic meter Dissolve Acetylene Pressure = 250 lbs/sq inch Volume of each cylinder = 6cubic meter

Selection of Cutting NozzlePlate Thickness124681012

Nozzle Size1/323/641/161/161/645/643/647/641/8

Welding

FlameMax. Temp.Uses for Welding

Oxidising3480CBrass (Cu 75% + Zn 25%) at 700CBronze (Cu 80% + Sn 20%) at 910CCast Iron at 1147C

Neutral3230CCopper at 1050CStainless Steel at 1450CMild Steel at 1490CAluminium At 650C

Carburising3125CShear Blades , Shackles and Valve Seats etc.

Flames

BrazingA method of joining dissimilar metals by means of an alloy (Cu & Zn)where parent metals will not be melting.

Function of a Pressure Regulator

1. To reduce the cylinder pressure to a workable pressure.2. To maintain delivery pressure &gas volume with the pressure variation at the source.

Range of Pressure Gauge:

Name of The GasWelding Pressure GaugeCylinder Pressure Gauge

Acetylene0 2 Kg/Sq Cm0 40Kg/Sq Cm

Oxygen0 14 Kg/Sq Cm0 200 Kg/Sq Cm

BibliographyDuring the making of the report I had to refer the following destination

http://www.kolkataporttrust.gov.in http://www.inthewoodshop.org/methods/trlathe.shtml http://www.Wikimedia Foundation. Inc http://www.uknationalmarinemuseum.org/methods/trlathe.shtml http://www. treatiseonengineering.com