ACKNOWLEDGEMENT

All praise is to Almighty Allah, the Beneficent, and the Merciful. He showered

His great blessings upon us in the form of Holy Prophet, Hazrat Muhammad (P.B.U.H).

With much effort and time spent, we thank God for being able to complete the internship in HMC.

We wish to take this space and opportunity to express our thanks to all workers for providing us with helpful information and exchanging thoughts, family members for their financial support and HMC for supporting us in doing our project.

Thank you.

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Table of ContentsSr. no Workshops & Labs Page no.

1. Introduction to HMC ………… 3

2. Organization and Function of PPC ……….. 5

3. Basic Machine Shop ………… 8

4. TTC & Heat Treatment ………… 24

5. Fabrication Shop ………… 27

6. NDT Lab ………… 33

7. Material Testing Lab ………… 34

8. Pattern Shop ………… 36

9. Forge shop-I&II ………… 38

10. Inspection ………… 39

11. Recommendations ………… 40

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INTRODUCTION TO HMCHeavy Mechanical Complex (Pvt) Limited is a leading engineering goods manufacturing enterprise in Pakistan located at Taxila about 32 Kilometers north of capital Islamabad. It is a professionally managed progressive organization with over 160,000 sq. meters covered facilities and 1,100 employees.

Heavy Mechanical Complex Ltd. (HMC), Taxila is a major heavy engineering subsidiary of the State Engineering Corporation (SEC) under the Ministry of Industries & Production, Government of Pakistan.

In 1969, General YAHYA KHAN laid the basis of HMC. Then in 1971, HMC started its production. In 1975, Prime minister of Pakistan ZULFIQAR ALI BHUTTO inaugurated the HFF. For some years, these two industries worked separately. But after some years, both were combined because for many works they had need of one another

HMC defines itself as “A technical institute in which all types of machines including Sugar plants, Cement Plants, Road rollers, Over Head Cranes ranging from 0.5 to 50 tons Heat Exchanger boilers, Special Defense parts (i.e., NDC works), Special Vibratory Rollers (which can bear statistically 10 to 12 tons vibratory load) and Pakistan steel works. Some other processes that are also done by HMC are Designing and manufacturing and assembling and installation with the certification of ISO – 9001 and ASME Standards.

The Heavy Mechanical Complex (HMC), the biggest undertaking of its type in Pakistan, was established in 1976 with Chinese assistance. The Heavy Forge Factory (HFF) at this complex has proved crucial for Pakistan's defense production needs. HMC has the capability for designing, engineering and manufacturing of industrial plants and machinery. HMC has the largest fabrication and machining facilities in the country equipped with Computer Aided Designing (CAD) and can undertake a variety of fabrication / machining jobs on sub-contracting basis.

HMC manufactures equipment for hydro-electric power plants, thermal power plants, Sulphuric acid plants, industrial alcohol plants, oil & gas processing plants, and chemical & petro-chemical plants, etc. Boilers, cranes, construction machinery, material handling equipment, steel structure, railway equipment, etc. are some of the other products which are produced on regular basis. The company's capabilities include engineering and manufacturing of Sugar Mills ranging between 1,500 - 12,000 TCD (tons of cane crushing capacity per day), Portland Cement Plants of 700- 5,500 TPD (tons per day) module and White Cement Plant of 50 - 1,000 TPD.

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HMC have the resources to handle large projects with demanding delivery schedules. Being the largest and most extensive fabrication and machining facility equipped with state of the art technology. HMC provide manufacturing services both on our own or customers design. .

PRODUCTS

HMC is one of the leading industries of Pakistan especially in the field of Steel.

Heavy machineries are being produced here like:

Road rollers

Overhead cranes

Mobile crane

Sugar plants

Cement plants

Oil refineries

Power plants

Pressure vessels

Boilers 40 to 80 Ton

Heavy duty machinery

Hydral power plants

Turbines

Rod construction machinery

Asphalt mixing plant etc.

First Boiler With Capacity of 140 Tons

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Organization and Function of PPC (Production, Planning and Control)

Objective of PPC: - PPC is organized for improving the performance of company. PPC department is headed by Dy. General Manager. It has following sections.

A. Sales order numbering system :-

The sales order numbering system allocates a unique identification system to each order

acquired by the sales and marketing department. This sales order consists of six digits. The

first two of these numbers designate the product group number of the products to be

manufactured or services to be provided by the organization. The next two digits specify the

fiscal year in which the order is received and the last two digits give the number of similar

orders already received in the same fiscal year.

For example, a job order given as11-11-04 is read as follows

11_______ product group no for sugar spares

13_______represents 2013 as the fiscal year

04_______specifies the fourth order for the current yearThat is fourth order of sugar spares in 2013.

B. Core Planning:-

Core planning section has following works.

Master schedule planning. Order Activity plans. Monitoring of all the schedules. Preparation of various periodic reports for MIS. Maintaining of balance order position. Maintaining sale and production report. Sale/production budget. Project review meeting and follow up. Data entry for DP list and updating of all files. Processing of all data and generation of reports.

C. Project planning:- To ensure receipt of all drawings and documentation from design. To issue the material purchase requirement.

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To prepare the requirements of materials to be issued. To coordinate the production technology for preparation of necessary production

documents for manufacture. To prepare and issue job orders and prepare the follow up. To suggest the alternate materials for use from available stock to design. To compile standard material requirements for all products and projects. To draw the standard items /equipments from stores for dispatch to costumer sites. To prepare data for ICR (Income tax Cost and Revenue) for the survey by CBR

(Central Board of Revenue).

D. Material Management (MMG):- C-1:- MMG Section:-

Material requirement planning. Intending and follow up of indent. To keep updated purchase status of all project documents. Establish stock levels for general consumable items and raw materials. Coding of store items. Insurance of material to appropriate job. To keep and maintain updated stock status of all store items. To look after stores and related functions.

C-2:- General Stores:- To receive and issue all the materials and equipments in stores as per laid down

procedure. Maintain detailed record of stock movement. Maintain stock location system. Ensure daily submission of issue and receipt statement to concerned department. Ensure that all the storage areas (open/covered) are kept properly secured and organized.

E. Production Technology:- D-1:- Feasibility/Quantitative Detail:-

Feasibility study and quantitative details of client´s enquiries for cost estimates.

D-2:-Process Planning:-Preparation of following documents.

Detail parts list. Route card (machining and fabrication) if required. Cutting plans. Time sheets.

D-3:- Tool designing:-

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Designing of all types of press tools, dies, templates, jigs and fixtures. To produce drawings for machinery components for maintenance. Cutting plans, cutting/marketing templates for shop.

F. Dispatch Cell/Material Handling:- E-1:- Material handling:-

To keep all the material handling equipment operation worthy. Provide material handling services to stores and dispatch cells and shops as and when

required. Keep the open yard tidy and organized. Receive materials from shops for surface preparation. Arrange sand blasting/paint as per contractual requirement. Receive raw materials from general stores for onward issuance to shops against job

orders.

E-2:- Dispatch Cell:- To receive finish goods from shops/material handling sections. To draw the standard items/equipments from stores for dispatch to costumer/sites. To organize preservation/packing. Maintain detailed dispatch records of finished goods, equipments, standard items against

each contract. Organize transportation. Ensure complete and accurate documentation along with each dispatch. To prepare the dispatch plans and ensure compliance.

G.I.C.R (Income tax Cost and Revenue):- To defend in litigation/adjudication and contravention. To organize industrial survey. To obtain the consumption certificates and release of guarantee. To obtain extension/coordination from CBR (Central Board of Revenue) and custom

collectrate. To deal with matter pertaining to custom duty and sale tax. To clear consignments for dry port and Islamabad airport. To keep close contact with collectorates of custom, sales tax, Central Excise

Islamabad/Rawalpindi and Central Board of Revenue (CBR) for all matters to HMC´s imports.

To follow up for the settlement of all customs and sales tax matters with concerned agencies

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Basic Machine Shop

In the development of every nation industries are very important and for industries machinery is key factor. To check the development of any industry check it’s machinery.

In the machine shop of Heavy mechanical Complex there are nearly 500 machines of different sizes and capacities. The machine shop of HMC contains various types of machines.

Available machines:

Lathe machine (three jaws and four jaws chucks, turret). Planer. Milling machine. Drilling machine. HDL (heavy duty lathe). BVT (boring vertical turret lathe machine). Gear hobbing machine. Gear shaper machine. Straight bevel machine. Horizontal lathe machine. Radial drilling machine. Slotting machine. Double housing planner. Face plate machine. Column drilling machine.

MACHINING OPERATIONS AND MACHINE TOOLS:-

• Turning and Related Operations

• Drilling and Related Operations

• Milling

• Machining Centers and Turning Centers

• Other Machining Operations

• High Speed Machining

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Machining

• A material removal process in which a sharp cutting tool is used to mechanically cut away material so that the desired part geometry remains

• Most common application: to shape metal parts

• Machining is the most versatile and accurate of all manufacturing processes in its capability to produce a diversity of part geometries and geometric features (e.g. screw threads, gear teeth, flat surfaces)

Classification of Machined Parts

1. Rotational - cylindrical or disk-like shape. Achieved by rotation motion of the workpart. Ex. turning and boring

2. Nonrotational (also called prismatic) - block-like or plate-like. Achieved by linear motion of the workpart. Ex. Milling, shaping, planing and sawing

Turning

• A single point cutting tool removes material from a rotating workpiece to generate a cylindrical shape

• The tool is fed linearly in a direction parallel to the axis of rotation

• Performed on a machine tool called a lathe

• Variations of turning that are performed on a lathe:

Facing

Contour turning

Chamfering

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Rotational Non-Rotational

Cutoff

Threading

Figure 1.2 - Turning operation

Facing

Tool is fed radially inward to create a flat surface.

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Chamfering

Cutting edge cuts an angle on the corner of the cylinder, forming a "chamfer".

Threading

Pointed form tool is fed linearly across surface of rotating work part parallel to axis of rotation at a large feed rate, thus creating threads.

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Lathe Machines

• Most lathe machines are horizontal but vertical lathe machines are also used for jobs with large diameter relative to the length and for heavy work

• The size of the lathe is designated by swing and maximum distance between centers

• Swing is the maximum workpart diameter that can be rotated in the spindle

• Maximum distance between centers indicate the maximum length of a workpiece that can be mounted between headstock and tailstock centers

• 350 mm x 1.2 m lathe means a swing of 350 mm and maximum distance between centers of 1.2 m

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Methods of Holding the Work in a Lathe

There are four common methods used to hold workparts in turning-to grasp the work, center and support it in position along the spindle axis, and rotate it:

• Holding the work between centers

• Chuck

• Collet

• Face plate

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Holding the Work Between Centers

3 jaw self centered Chuck

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Collet

Face Plate

Boring

• Boring is similar to turning. It uses a single-point tool against a rotating workpart

• Difference between boring and turning:

Boring is performed on the inside diameter of an existing hole

Turning is performed on the outside diameter of an existing cylinder

• In effect, boring is an internal turning operation

• Machine tools used to perform boring operations are called boring machines

• Boring machines

Horizontal or vertical - refers to the orientation of the axis of rotation of machine spindle

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Boring bar on tool post Boring bar between centres

Vertical Boring Mill

• Figure - A vertical boring mill –for large, heavy workparts

• Usually the workpart diameter is greater than its length

• Typical boring machine can position and feed several cutting tools

simultaneously

Drilling

• Machining operation used to create a round hole in a workpart

• Contrasts with boring which can only enlarge an existing hole

• Cutting tool called a drill or drill bit-a rotating cylindrical tool which has two cutting edges on its working end

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• Customarily performed on a drill press

Radial Drill

• Large drill press designed for large parts

• Head can be positioned at significant distance from the column to accommodate large work

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Milling

• A machining operation in which work is fed past a rotating tool with multiple cutting edges

• Axis of tool rotation is perpendicular to feed direction

• Creates a planar surface; other geometries possible either by cutter path or shape

• Owing to the variety of shapes possible and its high production rates, milling is one of the most versatile and widely used machining operations

• Other factors and terms:

Milling is an interrupted cutting operation-the teeth of the milling cutter enter and exit work during each revolution

Cutting tool called a milling cutter, cutting edges called "teeth"

Machine tool called a milling machine

Basic Types of Milling Operations

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(a) Peripheral milling (b) Face milling

Peripheral Milling vs. Face Milling

• Peripheral milling or plain milling:

Cutter axis is parallel to surface being machined

Cutting edges on outside periphery of cutter

• Face milling

Cutter axis is perpendicular to surface being milled

Cutting edges on both the end and outside periphery of the cutter

Types of Milling

• Peripheral Milling

Slab milling

Slotting

Side milling

Straddle milling

• Face milling

Conventional face milling

Partial face milling

End milling

Profile milling

Pocket milling

Surface contouring

Milling Machines

• Milling machines must provide a rotating spindle for the cutter and a table for fastening, positioning and feeding the workpart

• Types:

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Knee-and-column milling machine

Universal milling machine

Ram mill

Bed type milling machine

Planer type

Tracer mills

Tracer mills

CNC milling machines

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Horizontal knee-and-column milling machine Suitable for peripheral milling

Vertical knee-and-column milling machine

Suitable for face milling

Ram type knee-and-column machine; ram can

be adjusted in and out, and toolhead can be swiveled

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Universal milling machine

Simplex bed-type milling machine: rigid construction for mass production

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Hobbing

Hobbing is a machining process for making gears, splines, and sprockets on a hobbing machine, which is a special type of milling machine. The teeth or splines are progressively cut into the workpiece by a series of cuts made by a cutting tool called a hob. Compared to other gear forming processes it is relatively inexpensive but still quite accurate, thus it is used for a broad range of parts and quantities

It is the most widely used gear cutting process for creating spur and helical gears and more gears are cut by hobbing than any other process since it is relatively quick and inexpensive.

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Heat treatment Shop

Heat treatment is a method used to alter the physical and sometimes chemical properties of a material. The most common application is metallurgical. Heat treatments are also used in the manufacture of many other materials, such as glass. Heat treatment involves the use of heating or chilling, normally to extreme temperatures, to achieve a desired result such as hardening or softening of a material.. It is noteworthy that while the term heat treatment applies only to processes where the heating and cooling are done for the specific purpose of altering properties intentionally, heating and cooling often occur incidentally during other manufacturing processes such as hot forming or welding.

Heat treatment techniques include

Annealing. Hardening Tempering

Normalizing Stress releasing Carburizing Phosphating (phosphate coating is used to protect the surface from corrosion)

HMC has following Types of Furnace and facilities which are use in heat treatment section

HTS-1 Electric carbon furnace Electric box type furnace Flame hardening machine for surface hardening Chamber type Cleaner Electric tempering oil bath High temperature salt bath Low temperature salt bath Medium temperature salt bath High frequency induction heat treatment lab

Heat treatment of metals and alloys

Metallic materials consist of a microstructure of small crystals called "grains" or crystallites. The nature of the grains (i.e. grain size and composition) is one of the most effective factors that can determine the overall mechanical behavior of the metal. Heat

Treatment provides an efficient way to manipulate the properties of the metal by controlling rate of diffusion, and the rate of cooling within the microstructure.

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Surface hardening

Cause hardening

Full hardening

Annealing

Annealing is a technique used to recover cold work and relax stresses within a metal. Annealing typically results in a soft, ductile metal. When an annealed part is allowed to cool in the furnace, it is called a "full anneal" heat treatment. During annealing, small grains recrystalliz to form larger grains.

Normalizing

When an annealed part is removed from the furnace and allowed to cool in air, it is called a "normalizing" heat treatment. Normalizing: Carbon steel is heated to approximately 55 °C above Ac3 or Acm for 1 hour; this assures the steel completely transforms to austenite. The steel is then air-cooled, which is a cooling rate of approximately 38 °C (100 °F) per minute. This results in a fine pearlitic structure, and a more-uniform structure. Normalized steel has a higher strength than annealed steel; it has a relatively high strength and ductility .Typical annealing processes include, "normalizing", "stress relief" annealing to recover cold work, and full annealing.

Hardening and tempering (quenching and tempering)

To harden by quenching, a metal (usually steel or cast iron) must be heated into the austenitic crystal phase and then quickly cooled. Depending on the alloy and other considerations (such as concern for maximum hardness vs. cracking and distortion), cooling may be done with forced air or other gas (such as nitrogen), oil, polymer dissolved in water, or brine. The quenched hardness of a metal depends upon its chemical composition and quenching method. Cooling speeds, from fastest to slowest, go from polymer (silicon), brine, fresh water, oil, and forced air.

Tempering is a heat treatment technique for metals, alloys and glass. In steels, tempering is done to "toughen" the metal by transforming brittle martensite into bainite or a combination of ferrite and cementite.

Untempered martensite, while very hard and strong, is too brittle to be useful for most applications. A method for alleviating this problem is called tempering. Most applications require that quenched parts be tempered (heat treated at a low temperature, often three hundred degree Fahrenheit or one hundred fifty degrees Celsius) to impart some toughness. Higher tempering temperatures (may be up to thirteen hundred degrees Fahrenheit or seven hundred degrees Celsius, depending on alloy and application) are sometimes used to impart further ductility, although some yield strength is lost.

Precipitation hardening

Some metals are classified as precipitation hardening metals. When a precipitation hardening alloy is quenched, its alloying elements will be trapped in solution, resulting in a soft metal. Aging a "solutionized" metal will allow the alloying elements to diffuse through the

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microstructure and form intermetallic particles. These intermetallic particles will nucleate and fall out of solution and act as a reinforcing phase, thereby increasing the strength of the alloy. Alloys may age "naturally" meaning that the precipitates form at room temperature, or they may age "artificially" when precipitates only form at elevated temperatures. In some applications, naturally aging alloys may be stored in a freezer to prevent hardening until after further operations - assembly of rivets, for example, may be easier with a softer part.

Induction heating

Induction heating is the process of heating an electrically conducting object (usually a metal) by electromagnetic induction, where eddy currents are generated within the metal and resistance leads to Joule heating of the metal. An induction heater (for any process) consists of an electromagnet, through which a high-frequency alternating current (AC) is passed. Heat may also be generated by magnetic hysteresis losses in materials that have significant relative permeability. The frequency of AC used depends on the object size, material type, coupling (between the work coil and the object to be heated) and the penetration depth.

Induction heating allows the targeted heating of an applicable item for applications including surface hardening, melting, brazing and soldering and heating to fit. Iron and its alloys respond best to induction heating, due to their ferromagnetic nature. Eddy currents can, however, be generated in any conductor, and magnetic hysteresis can occur in any magnetic material. Induction heating has been used to heat liquid conductors (such as molten metals) and also gaseous conductors (such as gas plasma). Induction heating is often used to heat graphite crucibles (containing other materials) and is used extensively in the semiconductor industry for the heating of silicon and other semiconductors

Induction furnace

An induction furnace uses induction to heat metal to its melting point. Once molten, the high-frequency magnetic field can also be used to stir the hot metal, which is useful in ensuring that alloying additions are fully mixed into the melt. Most induction furnaces consist of a tube of water-cooled copper rings surrounding a container of refractory material. Induction furnaces are used in most modern foundries as a cleaner method of melting metals than a reverberatory. Metals melted include iron and steel, copper, aluminum, and precious metals. Because it is a clean and non-contact process it can be used in

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Customer

Sale and marketing

Design deppt

PPC

Fabrication CTC

Fabrication shop

Material issue to fab shop

Job planning for fab shop

Deliver to dispatch cell

Check the work

a vacuum or inert atmosphere. Vacuum furnaces make use of induction heating for the production of specialty steels and other alloys that would oxidize if heated in the presence of air.

FABRICATION SHOP

HMC fabrication shop has full capacity to fabricate every part which is used in boiler, gas tanks, teem boiler, roar roller parts etc; HMC has following machine in fabrication shop.

Parallel cutting machine. Trennjaeger circular saw. CNC cutting Machine Angle cutting machine Boom Column sub march welding machine Photo cell cutting machine Semi automated machine Non ferrous steel cutting machine

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Circular saw small size and large size. Straight rolling machine Rerolling machine Plasma cutting machine 100ton press machine 160ton brack press machine 3000ton press machine Membrane water wall welding machine etc

Fabrication is the process of forming, casting, machining and welding of metals.

Fabrication, when used as an industrial term, applies to the building of machine, structures and other equipment, by cutting, shaping and assembling components made from raw materials. Small businesses that specialize in metal are called fabrication shop. Steel fabrication shops and machine shops have overlapping capabilities, but fabrication shops generally concentrate on the metal preparation, welding and assembly aspect while the machine shop is more concerned with the machining of parts.

Metal fabrication

Metal fabrication is a value added process that involves the construction of machines and structures from various raw materials. A fabrication shop will bid on a job, usually based on the engineering drawings.

Raw materials

Standard raw materials used by metal fabricators are

plate metal

welding wire co gas argon gas Cutting torches silica etc

The raw material has to be cut to size. This is done with a variety of tools.

Cutting

The raw material has to be cut to size. This is done with a variety of tools. The most common way to cut material is by Shearing (metalworking); Special band saws designed for cutting metal have hardened blades and a feed mechanism for even cutting. Abrasive cut-off saws, also

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known as chop saws, are similar to miter saws but with a steel cutting abrasive disk. Cutting torches can cut very large sections of steel with little effort.

Forming

Hydraulic brake presses with v-dies are the most common method of forming metal. The cut plate is placed in the press and a v-shaped die is pressed a predetermined distance to bend the plate to the desired angle. Tube bending machines have specially shaped dies and mandrels to bend tubular sections without kinking them. Rolling machines are used to form plate steel into a round section.

Machining

Fabrication shops will generally have a limited machining capability including; metal lathes, mills, magnetic based drills along with other portable metal working tools.

Welding

Welding is the main focus of steel fabrication. The formed and machined parts will be assembled and tack welded into place then re-checked for accuracy. A fixture may be

Used to locate parts for welding if multiple weldments have been ordered. The welder then completes welding per the engineering drawings, if welding is detailed or per his own judgment if no welding details are provided.

Special precautions may be needed to prevent warping of the weldments due to heat. These may include re-designing the weldments to use less weld, welding in a staggered fashion, using a stout fixture, covering the weldments in sand during cooling, and straightening operations after welding.

Straightening of warped steel weldments is done with an Oxy-acetylene torch and is somewhat of an art. Heat is selectively applied to the steel in a slow, linear sweep. The steel will have a net contraction, upon cooling, in the direction of the sweep. A highly skilled welder can remove significant war page using this technique.

Final assembly

After the weldments have cooled it is generally sand blasted, primed and painted. Any additional manufacturing specified by the customer is then completed. The finished product is then inspected and shipped.

TYPE OF WELDINGS

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Stick welding Tig welding Mig welding etc

Shielded Metal Arc Welding (SMAW) is frequently referred to as stick or covered electrode welding. Stick welding is among the most widely used welding processes. The flux covering the electrode melts during welding. This forms the gas and slag to shield the arc and molten weld pool. The slag must be chipped off the weld bead after welding. The flux also provides a method of adding scavengers, deoxidizers, and alloying elements to the weld metal.

Tungsten inert gas (TIG) welding,

Gas tungsten arc welding (GTAW), also known as tungsten inert gas (TIG) welding, is an arc welding process that uses a no consumable tungsten electrode to produce the weld. The weld area is protected from atmospheric contamination by a shielding gas (usually an inert gas such as argon), and a filler metal is normally used, though some welds, known as autogenously welds, do not require it. A constant-current welding power supply produces 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 light metals such as aluminum, magnesium, and copper alloys. The process grants the operator greater control over the weld than competing procedures such as shielded metal arc welding and gas metal arc 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.

BOILER FABRICATION

In the energy sector HMC has supplied over 30,000 tons of fabricated equipment and parts to different power plants. Major strength is HMC's capabilities for manufacturing utility boilers pressure parts. For this purpose some of the major machines are:

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3 roller bending machines for making drums Booster pipe bending machine for making super heater Reheated and economizer coils Specialized machine for machining and welding of headers and complete train of

machines for manufacture of membrane walls in panel and bent form

HMC has the capability to manufacture following type of boilers:

Natural circulation steam generators Heat recovery steam generators Fluidized bed combustion boilers

Besides Boiler Island, HMC have also capabilities and expertise for manufacture of balance of plant equipment / parts such as:

Condensers L.P. heater H.P. heater parts Water treatment plant Deaerator and feed water tank Pressure vessels Oil storage tanks Cooling water system Heat exchangers Steel structure Elevator hoist and cranes Piping Other misc. items

With a team of well experienced engineers and technicians, HMC is well prepared to carry out all site construction work which includes:

Site fabrication Erection / installation and commissioning Civil works (if part of complete construction work, package)

HMC is also providing services for repair / maintenance and BMR of existing power plant for its boilers, turbines, condensers, heaters and other equipment.

BOILER COMPONENTS Super Heaters One of the most important accessories of a boiler is a superheated. It affects improvement and economy in the following ways.

The superheated increases the capacity of the plant.

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Material purchase

Third party verify material

Marking & cutting layout

Pre bending

Rolling LW fit up

Third party verify material

Welding

Re rolling

Radiography Stress releasing

Hydraulic testing

Third party test

Eliminates corrosion of the steam turbine.

Reduces steam consumption of the steam turbine.

ECONOMISERS

This is feed-water heaters in which the heat from waste gases is recovered to raise the temperature of feed-water supplied to the boiler. They offer the following advantages:

Fuel economy Longer life of the boiler Increase in steaming capacity Finned Tube Economizers C.I. Gilled Tube Economizers Plain Tube Coil Economizers

Steam Generating Tubes

These are tubes in the Boiler where water is evaporated to steam and are also called Steam Generating Tubes. These Tubes also form the Walls of the Boiler and are hence called Water Walls or Water Wall Panels. These Tubes have very complicated shapes to allow Inspection openings and burner throats and fabrication require bending Machines.

Boiler Fabrication Techniques. HMC has 3.5 meter rolling capacity. And it can manufacture 2 ton to 80 ton boiler.

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NON DESTRUCTIVEVE TESTING(NDT)IT INCLUDE DIFFERENT OPEREATIONS

INDICATION

INTERPRETATION

FALSE

RELEVENT

NON RELEVENT

EVALUATION

ACCEPT

REJECT

NON DESTRUCTIVE EVALUATION FACILITIES:

1- X-ray radiography

2- Gamma rays radiography

3- Ultrasonic

4- Magnetic particle inspection

5- Liquid penetrant method

6- Eddy current spectroscopy

RADIOGRAPHY TESTING METHOD:

Radiography testing is most universally used NDT method for the detection of gas porosity in weldments. The radiographic image of a round porosity will appear as oval shaped spots with smooth edges, while elongated porosity will appear as oval shaped spots with the major axis sometimes several times longer than the minor axis. Foreign material such as loose scale flux or splatter will affect validity of test results.

ULTSONIC TESTING:

Ultrasonic testing equipment is highly sensitive, capable of detecting micro separations.

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Surface finish and grain size will affect the validity of test results.

EDDY CURRENT TESTING METHOD:

Normally confined to thin wall welded pipe and tube

Penetration restricts testing to a depth of more than one quarter inch

LIQUID PENETRANT TESTING METHOD:

Normally confined to in process control of ferrous and non ferrous welds

Liquid penetrant testing like magnetic particle is restricted to surface evaluation

Extreme caution must be exercised to prevent any cleaning material and liquid penetrant materials from becoming entrapped and contaminating the rewelding operation

MAGNETIC PARTICLE TESTING METHOD:

Not normally used to detect gas porosity. Only surface porosity would be evident. Near surface

porosity would not be clearly defined since indications are neither strong nor pronounced.

MATERIAL TESTING LABThere are three sections of the lab;

1- Chemical section

2- Metallographic

3- Mechanical

CHEMICAL SECTION:

The chemical section lies in the steel foundry. So, it mainly concerns with the determination of the chemical composition of steel. However, samples from cast iron foundry are also brought here to determine the chemical composition.

EMISSION SPECTROMETER:

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In emission spectrometer, a 2”*2” sample is used. Arc is produced by using a tungsten electrode. Argon gas is used for shielding. The atoms got excited. When they return to their ground state, they emit radiations. Each element emits radiations of some specific wavelength. So, from the wavelength element and its percentage can be calculated.

WET ANALYSIS:

The chemical composition can also be determined by wet analysis. Different chemicals are used in different proportions. The color achieved at the end is a measure of element and its percentage.

Other facilities include;

1. Spectrophotometer 2. Carbon apparatus

MECHANICAL SECTION

HMC has a capability to test for metal mechanical properties like hardness, strength, shearing, crushing, impact bend test etc.

HMC mechanical testing lab has following facilities…

FACILITIES:

30 ton universal testing machine (UTM)

60 ton UTM

10 ton UTM

100 ton UTM

Charpy impact testing machine

Brinell hardness tester 2 pieces

Rockwell hardness tester 2 pieces

Vicker hardness tester TESTS:

Tensile

Bend

Shear

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Compression/crushing

METALLOGRAPHY:

Here, the macrostructure and microstructure is determined. A number of microscopes are placed here in lab having different

magnifications such as;

100 X

450 X

1000 X

2000 X

A hardness tester with 450 X

PATTERN SHOP

The purpose of pattern shop is to make wooden or metallic components for casting process.

TYPES OF PATTERN:-

One piece or solid pattern

Two piece or split pattern

Three piece pattern

Loose piece pattern.

Self core pattern.

Sweep pattern.

Skeleton pattern.

Match plate pattern.

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Connecting pattern.

Master pattern

TYPES OF CORE PRINTS:-

Top print.

Bottom print.

Side print.

Tail print.

Hang print.

Balancing print.

TYPES OF CORE BOX :-

Box type core box.

Shake out type core box.

Gang type core box

MACHINES IN PATTERN SHOP:-

Band saw.

Joint planner.

Thickness planner.

Disc and spindle sander.

Wooden lathe machine.

Wooden milling machine.

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Forging Shop

In HMC there are two forging shop that differs in capacity and type of job.

They are also facilitated with heat treatment processes.

Forging shop I:

In this shop die forging is done.

Die forging:

In this type of forging method specific dies are used to produce the specific job for this allowance is very low.

Requirements:

For die forging we need:

Furnace Hammers In HMC forging shop 1 has following facilities: 150kg hammering machine 300kg hammering machine 750kg hammering machine 800 ton hydraulic press with 3 ton manipulator 25 to counter blow Trimming press Crew presser 63 ton power press 400 ton press 1250 ton press Swelling crane of 1 ton capacity

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Forging shop II

In this shop free forging is done. Free forging is method of producing jobs without using dies. In free forging large allowance is present. HMC have following facilities in this shop:

1 ton hammer 2 ton hammer 3 ton hammer

Forge: It is the ability of the material to undergo deformation under compression without rapture. Any material or alloy which can be brought to plastic stage through heating can be forged the extent to which the material can be forged is governed by its compositions as well as temperature of the forging. Selection of the forging material depend upon certain mechanical prosperities inherent in the material like strength, malleability, resistance to fatigue , durability, shock or bending machinability . Some forgeable materials are listed below:

Pure aluminum Pure magnesium Pure copper Aluminum alloys Magnesium alloys Copper alloys Carbon and low alloy steels Stainless steel Nickel alloys

INSPECTIONQUALITY INSPECTION

It is one of the most responsible and sensible department of the complex. If some part fails outside in the field, it is not the mistake of the production department but of quality inspector who passed it. So, the repute of any industry depends to a great extent on this department. This department checks each and every material which comes in or goes out of the factory, i.e.

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from the raw material to the final product. There is at least one quality inspector always present in a shop for the stage inspection and the final inspection. If something exceeds the tolerance, they have the right to reject it. They have different tools with them for the measurements. Some of them are;

Inside micrometer

Outside micrometer

Mercer gage

Vernier caliper

Bevel protector etc.

Recommendations

We would like to give some recommendations to improve the quality of work and save time along the health of the workers because during our visit we observed that the workers are not playing with their own lives which are a great loss of man power. To eradicate it we recommend following things:

Safety should be made necessary for each and every one especially for the fabrication shopTheir should be check and balance of these safety stepsTrained labor must have junior or fresh labor because in the future they can take their seats.Environment should be made clean and healthy by planting plants and keeping the surface cleanTo increase the rate of work the repeated jobs should be given to that person who had worked on it but this should be made necessary for that person that he will convey his knowledge to his sub-ordinates.

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