Internship Report

Submitted by

Amjad Mehmood, Faizan Ahmad, Mohsin Nazir

(University of Engineering and Technology, Lahore-54890, Pakistan)

Submitted to

Mr. Mudasir Chaudry

(Management Training Centre)

Incharge MTC

Mr. Ali Asghar

Dated: 15th July, 2015

Heavy Mechanical Complex (Pvt) Ltd Taxila: 47050 Pakistan

ii

Dedication

Dedicated to workers, staff members, supervisors and officers for their support and supervision

especially Mr. Ali Asghar (I/C MTC) and Mudasir Chaudhry for their guidance

A. Mehmood

F. Ahmad

M. Nazir

iii

PREFACE

Practical knowledge have become important in the industrial environment to produce products

for the service of mankind. The knowledge of manufacturing practices is highly essential for all

engineers for familiarizing themselves with modern concepts of manufacturing technologies. The

basic need is to provide practical knowledge of manufacturing processes to all the internee

students. Therefore, an attempt has been made through this internship to present the practical

knowledge. Considering the general needs of internee students and the fact that they hardly get

any exposure to hand tools, equipment’s, machines and manufacturing setups, this internship will

be very useful to them in their future.

At the end, we thank Ms. Ayesha Tayyab, Mr. Qaiser Naeem Butt, Mr. Shamshad Gill and Mr.

Abid Hussain for their special support and guidance.

A. Mehmood

F. Ahmad

M. Nazir

iv

Acknowledgement

We thankfully acknowledge the cooperation of Mr. Amjad Hussain (Instructor) as he helped

throughout our internship, with his kind cooperation; by which we had a complete exploration of

the practical experiences.

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Table of Contents

1. Introduction 1

Premises and Assets 1

Departments 1

Facilities 1

Products 2

Quality Certifications 2

Major Achievements 3

Technical Collaborations 3

Civic Amenities 4

2. Assembly Shop 6

Assembly 6

Fitting 7

Fits 7

3. Heat Treatment Shop 8

Heat Treatment 8

Heat Treatment Processes 8

4. Fabrication Shop 11

Fabrication 11

List of Machines 11

Raw Materials 11

Layout 12

Fabrication Techniques 13

Cutting 13

Forming Processes 13

Welding 15

Welding Defects 16

Surface Cleaning 18

Boiler 18

5. Production Planning and Control 20

Sales Order Numbering System 20

Core Planning 20

Project Planning 20

Material Management 20

Process Planning 21

Tool designing 21

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Dispatch Cell/Material Handling 21

Income tax Cost and Revenue 21

6. Steel Foundry 22

Casting Process 22

Advantages of Sand Casting 23

Limitations 23

Steel Melting Furnace 23

7. Non-Destructive Testing 24

Radiographic Testing 24

Ultrasonic Testing 24

Magnetic Particles Inspection 25

Liquid penetrant Testing 25

Eddy Current Testing 26

8. Basic Machine Shop 27

Production Planning Section 27

List of Machines 27

Machining 28

Classification of Machined Parts 28

Turning and Related Operations 28

Hobbing 28

Lathe Machine 29

Shaper Machine 30

Planar Machine 30

9. Technology Department 31

Feasibility Study 31

10. Material Testing Lab 32

Metallography 32

Mechanical Testing 32

Universal Testing Machine 32

Charpy Impact Testing Machine 33

Brinell Testing Machine 33

Rockwell Testing Machine 34

11. Inspection 35

APPENDIX: Schedule of Internship 37

[1]

Chapter No. 1

Introduction Heavy Mechanical Complex Pvt Ltd. Taxila is a State owned capital goods manufacturer which

brought Pakistan into the category of industrially advanced countries. Its performance is linked

with the policies and overall economy of the country

It was established in 1971 as a mechanical working company with the aim to shift emphasis from

manufacturing of consumer goods to capital goods, achieving optimum imports substitution in

plant, machinery and equipment, saving foreign exchange and achieving technological up

gradation. Its forgings and foundry section was established in 1977.

Premises and Assets

Total Factory Area: 226 Acres

Total Colony Area: 345 Acres

Total Area: 571 Acres

Covered Area in Factory: 46 Acres

Covered Area in Colony: 24 Acres

Total Covered Area: 70 Acres

Gross Assets: 2 billion PKR

Departments

• Sales and Marketing Department

• Design and Engineering Department

• Production Planning and Control Department

• Production Shops (HMC1 & HMC2)

• Quality Assurance Department

• Project Management Department

• Human Resources Department

• Finance and Budgeting Department

Facilities

• Fabrication

• Machining

• Heat Treatment

• Casting

• Forging

• Galvanizing

[2]

• Tool Making

• Assembly

• Design and Engineering with well-equipped Computer Aided Design (CAD) facility

• Well-equipped Quality Assurance Department with ISO 9001 Certification and

authorization to use ASME STAMPS, PP, S, U, U2

Products

• Sugar Plants

• Alcohol Plants

• Cement Plants

• Chemical and Petro Chemical Plants

• Oil and Gas Processing Plants

• Industrial Steam Boilers

• Thermal and Hydral Power Plants

• Road Construction Machinery

• Railway Equipment

• Over Head Traveling Cranes

• General Steel Structures

• Highly Sophisticated Castings and Forgings

• Items for Defence and Strategic Industry

Quality Certifications

ISO 9001

Scope

Design, engineering, manufacturing and commissioning of plants and machinery including

cement, sugar, thermal, hydro, chemical, oil and gas processing plants, agriculture machinery,

boilers, pressure vessels, heat exchangers, cranes, road construction machinery, steel structures,

plain and alloyed steel castings, free and automatic die forgings, steel billets and other similar

heavy engineering equipment.

ASME

ASME STAMPS

U: Pressure vessel according to ASME section VIII, Div. I

U2: Pressure vessel according to ASME section VIII, Div. II

S: Power Boilers

PP: Pressure Piping

[3]

LLOYDS

• First class manufacturer of fusion welded pressure vessels

• Registered as Qualified construction Company

Major Achievements

• Pioneer in getting ISO 9001 certification and helped other local industries to acquire

ISO 9001 certification

• Acquired Authorization from American Boiler Board to use ASME STAMPS for power

boilers, pressure vessels and pressure pipes

• Attained capability to design, engineer, manufacture machinery for turn-key supply of

higher module sugar and cement plants

• Pursue a dynamic marketing and engineering product diversification, policy as a

consequence diversified into energy sector (Thermal and Hydral Power Plants) and oil

& gas processing industry etc.

Technical Collaboration

Table. 1.1 Technical Collaborations of HMC, Taxila

Product Company Country

Cement Plant and

Machinery

FULLER USA

KHD Germany

F. L. SMIDTH Denmark

FCB France

ONODA EN 66 Japan

Sugar Plant and Machinery POLIMEX-CEKOP Poland

WALKERS Australia

HEIN LEHMANN Germany

COMPLANT China

Alcohol Plants INTERIS France

Chemical/Petro Chemical CE-NETCO Singapore

TRITCHARD Corp. USA

[4]

TITAN PROTELTS Ltd. Canada

BABCOCK-KING UK

WILKINSON Malaysia

CHALLENGER USA

ESPACIALITY USA

Small Hydral Power Project SULZER ESCHER Switzerland

BIWATER UK

Boilers Industrial Utility COMPLANT China

THRONE INTL. UK

DEUTCHE BABCOCK Germany

TAKUMA Japan

Cranes R.STAHIL Germany

KONE Finland

Road Construction

Machinery COMPLANT China

BEUMAR Poland

SAKAI, TANAKA Japan

Auto Forging PARSON Turkey

Water Resistant Casting

and Grinding Media BRADLEY AND FOSTER UK

Civic Amenities

Residential Colony

• Family Accommodation: 1091

• Bachelor Accommodation: 342

• Flats: 30

• Mosques: 3

[5]

Schools

• Rehnuma Girls Higher Secondary School

• HMC Boys High School

• Junior Model School

Hospitals

• Male dispensary: 10 beds

• Female dispensary: 20 beds

Other facilities

• Shopping centre

• Officers Club

• Guest House

• Police Station

• Post Office

• Utility Stores

• Banks

• Play Grounds

• Subsidizing Electricity, gas and water supply, sewage, roads, horticulture etc. costing

Approx. 28 million per annum

Expenses on civic amenities are incurred by the company.

[6]

Chapter No. 2

Assembly Shop Assembly shop in HMC is responsible for all type of assemblies generally including assembly of

road rollers, overheard cranes, and mobile cranes, sugar and cement plant components etc.

Assembly

Assembly is a manufacturing process in which parts (usually interchangeable) are added to a

product in a sequential manner to create a finished product

Fitting

Fitting is the process of joining two mechanical parts to each other

Fits

The relation between two mating parts is called fit. Depending upon the actual limits of the hole

or shaft sizes, fits may be classified as clearance fit, transition fit and interference fit.

Clearance fit

Clearance fit is defined as a clearance between mating parts. In clearance fit, there is always a

positive clearance between the hole and shaft.

Interference fit

Interference fit is obtained if the difference between the hole and shaft sizes is negative before

assembly. Interference fit generally ranges from minimum to maximum interference.

Transition fit

Transition fit may result in either an interference or clearance, depending upon the actual values of

the tolerance of individual parts.

Fig. 2.1 Types of Fits

[7]

Fig. 2.1 (cont.) Types of Fits

System of Fits

In identifying limit dimensions for the three classes of fit, two systems are in use:

Hole Basis System

The size of the shaft is obtained by subtracting the allowance from the basic size of the hole.

Tolerances are then applied to each part separately. In this system, the lower deviation of the hole

is zero. The letter symbol indication for this is 'H'.

Shaft Basis System

The upper deviation of the shaft is zero, and the size of the hole is obtained by adding the allowance

to the basic size of the shaft. The letter symbol indication is 'h'.

[8]

Chapter No. 3

Heat Treatment Shop

Heat Treatment

Heat Treatment is process of heating a material to a specific temperature, then cooling at a specific

rate to achieve specific mechanical properties. Iron-Iron carbide Phase Diagram (Iron Carbon

Phase Diagram) is an important guide for heat treatment of different types of plain carbon steel.

Fig. 3.1 Iron Carbon Phase Diagram

Heat Treatment Processes

Annealing

Annealing is the process of slowly raising the temperature about 50ºC (90ºF) above the Austenitic

temperature line or line ACM in the case of Hypo eutectoid steels (steels with < 0.77%Carbon),

about 50ºC (90ºF) in case of eutectoid steel and 50ºC (90ºF) into the Austenite-Cementite region

in the case of Hypereutectoid steels (steels with > 0.77% Carbon).It is held at this temperature for

sufficient time for all the material to transform into Austenite or Austenite-Cementite as the case

may be. It is then slowly cooled at the rate of about 20ºC/hr. (36 ºF/hr.) in a furnace to about 50 ºC

(90 ºF) into the Ferrite-Cementite range. At this point, it can be cooled in room temperature air

with natural convection. The grain structure has coarse Pearlite with ferrite or Cementite

(depending on whether hypo or hyper eutectoid). The steel becomes soft and ductile.

[9]

Normalizing

Normalizing is the process of raising the temperature to over 60 º C (108 ºF), above line A3 or line

ACM Fully into the Austenite range. It is held at this temperature to fully convert the structure into

Austenite, and then removed from the furnace and cooled at room temperature under natural

convection. This results in a grain structure of fine Pearlite with excess of Ferrite or Cementite.

The resulting material is soft; the degree of softness depends on the actual ambient conditions of

cooling. This process is considerably cheaper than full annealing since there is not the added cost

of controlled furnace cooling. The main difference between full annealing and normalizing is that

fully annealed parts are uniform in softness (and machinability) throughout the entire part; since

the entire part is exposed to the controlled furnace cooling. In the case of the normalized part,

depending on the part geometry, the cooling is non-uniform resulting in non-uniform material

properties across the part. This may not be desirable if further machining is desired, since it makes

the machining job somewhat unpredictable. In such a case it is better to do full annealing.

Hardening

Flame Hardening

Flame hardening uses direct impingement of an oxy-gas flame onto a defined surface area. The

result of the hardening process is controlled by four factors: the design of the flame head; the

duration of heating; the target temperature to be reached; and the composition of the metal being

treated. The process is also effective at preheating bars, strip and various contours prior to forming

and forging. Flame Hardening Systems, Inc. manufactures a full range of equipment for efficiently

applying heat to a broad assortment of component parts. Basically there are four methods/types of

systems we build, depending on many factors.

Induction Hardening

A widely used process for the surface hardening of steel. The components are heated by means of

an alternating magnetic field to a temperature within or above the transformation range followed

by immediate quenching. The core of the component remains unaffected by the treatment and its

physical properties are those of the bar from which it was machined, whilst the hardness of the

case can be within the range 37/58 HRC.

Tempering

Tempering is a process of heat treating, which is used to increase the toughness of iron-based

alloys. It is also a technique used to increase the toughness of glass. For metals, tempering is usually

performed after hardening, to reduce some of the excess hardness, and is done by heating the metal

to a much lower temperature than was used for hardening. The exact temperature determines the

amount of hardness removed, and depends on both the specific composition of the alloy and on the

desired properties in the finished product. For instance, very hard tools are often tempered at low

temperatures, while springs are tempered too much higher temperatures. In glass, tempering is

performed by heating the glass and then quickly cooling the surface, increasing the toughness.

[10]

Stress Releasing

Stress releasing is used to reduce residual stresses in large castings, welded parts and cold-formed

parts. Such parts tend to have stresses due to thermals cycling or work hardening. Parts are heated

to temperatures of up to 600-650 C (1112-1202 F), and held for an extended time (about 1 hour or

more) and then slowly cooled in still air.

Carburizing

Carburizing is a process used to harden low carbon steels that normally would not respond to

quenching and tempering. This is done for economic reasons (utilizing less expensive steel) or

design considerations to provide a tough part with good wear characteristics. Carburizing

introduces carbon into a solid ferrous alloy by heating the metal in contact with a carbonaceous

material to a temperature above the transformation range and holding at that temperature.

The depth of penetration of carbon is dependent on temperature, time at temperature, and the

composition of the carburizing agent. As a rough indication, a carburized depth of about 0.03 to

0.05 inches can be obtained in about 4 hours at 1700°F, depending upon the type of carburizing

agent, which may be a solid, liquid, or gas.

The primary object of carburizing is to secure a hard case and a relatively soft, tough core, only

low-carbon steels (up to a maximum of about 0.25% carbon), either with or without alloying

elements (nickel, chromium, manganese, molybdenum), are normally used. After carburizing, the

steel will have a high carbon case graduating into the low-carbon core. Once the carburization is

complete, the parts must be hardened and tempered to obtain the desired properties of both the core

and the case.

[11]

Chapter No. 4

Fabrication Shop

Fabrication

Fabrication is a process of building metallic Structures by cutting, bending and assembling process.

List of Machines

• Power Presses

• Roller Machines

• Radial Drill Machines

• Submerged Arc welding Machines

• Circular Saws

• Edge Planner

• Shearing Machine

• Parallel Flame Cutting Machine

• CNC Flame cutting machine

• De-coiling Machine

• Photocell Cutting Machine

• Brake Press

• Panel bending Machine

• Nibbling Machine

• Plasma Cutting Machines

• Tube welders

• Pipe Squeezing Machine

• Pipe Cutting and Bevelling Machine

• Tube Bending Machine

• TIG Welding Machine

• Welding Transformers

Raw Materials

Standard raw materials used by metal fabricators are:

• Flite metal Formed and expanded

• Tube stock

• Square stock

• Sectional metals (I beams, W beams, C-channel...)

• Castings

[12]

Layout

Marking out or layout is the process of transferring a design or pattern to a work piece, as the first

step in the manufacturing process. It is performed in many industries

Marking out consists of transferring the dimensions from the plan to the work piece in preparation

for the next step, machining or manufacture.

Typical Tools for Layout

Typical tools include:

Surface plate or marking out table

It provides a true surface from which to work.

Angle Plates

It assists in holding the work piece perpendicular to the table.

Scriber

It is the equivalent of a pen or pencil. It literally scratches the metal surface leaving behind a fine,

bright line.

Height Gauge or Scribing Block

It allows lines to be scribed at a preset distance, from the table’s surface.

Surface Gauge

An ungraduated comparison measuring tool that performs much the same function as the Vernier

height gage. It is often used in conjunction with a dial indicator and a precision height gauge.

Marking Blue

To provide a usable writing surface by covering any existing scratches and providing a contrasting

background.

Protractor

To assist in the transfer of angular measurements.

Tri-Square

To transfer 90° angles to the work piece.

[13]

Punches

It pricks or center punch to create permanent marks or dimples for drill bits to start in Ball peen

hammer used in conjunction with the punches to provide the striking blow needed.

Dividers or Measuring Compass

It is used for marking out circles of any desired radius.

Fabrication Techniques

To improve productivity of the process different types of production tools are used e.g. Fixtures,

Supports etc. these tools holds the work piece/Locate it or/and guide the tool, so reduce the time to

be used for locating or marking.

Cutting

The cutting part of fabrication is done via:

• Sawing

• Shearing (all with manual and powered variants)

• Oxy-Fuel Cutting (such as oxy-fuel torches or plasma torches)

• CNC cutters (using a laser, torch, or water)

• Semi-automatic cutting machines

• Electromagnetic cutting machines

• Plasma cutting machines

• Photocell cutting machines

• Parallel torch cutting machines

Forming Processes

The forming processes modify the work piece by deforming it i.e. without removing any material.

Forming is done with a system of mechanical forces and, especially for bulk metal forming, with

heat.

The Following is important forming processes:

• Bending

• Pre-Bending

• Roll Forming

• Drawing

• Deep Drawing

• Tube Expansion

• Tube Bending

• Coining

[14]

• Spinning

• Stamping

Bending

Bending is a manufacturing process that produces a V-shape, U-shape, or channel shape along a

straight axis in ductile materials, most commonly in sheet metal.

Pre-Bending

This process is performed before Roll Forming. A piece of sheet metal is bent slightly before it is

sent to a rolling machine for producing required curvature, this process is termed as pre- bending.

Roll Forming

Roll forming, also termed as rolling, is a continuous bending operation in which a long strip of

sheet metal (typically coiled steel) is passed through sets of rolls mounted on consecutive stands,

each set performing only an incremental part of the bend, until the desired cross-section profile is

obtained.

Drawing and Deep Drawing

Drawing is a sheet metal forming process in which a sheet metal blank is radially drawn into a

forming die by the mechanical action of a punch. It is thus a shape transformation process with

material retention. The process is considered "deep" drawing when the depth of the drawn part

exceeds its diameter.

Tube Expansion and Bending

In this process a tube is bended or expanded according to the desired Application.

Coining

Coining is a form of precision stamping in which a work piece is subjected to a sufficiently high

stress to induce plastic flow on the surface of the material.

Spinning

Metal spinning, also known as spin forming or spinning or metal turning, is a metalworking process

by which a disc or tube of metal is rotated at high speed and formed into an axially symmetric part.

Spinning can be performed by hand or by a CNC lathe.

Stamping

Stamping (also known as pressing) is the process of placing flat sheet metal in either blank or coil

form into a stamping press where a tool and die surface forms the metal into a net shape. Stamping

includes a variety of sheet-metal forming manufacturing processes, such as punching using a

machine press or stamping press, blanking, embossing, bending, flanging, and coining.

[15]

WELDING

Welding is a fabrication or sculptural process that joins materials, usually metals or thermoplastics,

by causing coalescence. This is often done by melting the work pieces and adding a filler material

to form a pool of molten material (the weld pool) that cools to become strong joint, with pressure

sometimes used in conjunction with heat, or by itself, to produce the weld. This is in contrast with

soldering and brazing, which involve melting a lower-melting-point material between the work

pieces to form a bond between them, without melting the work pieces.

Shielded Metal Arc Welding (SMAW)

Shielded metal arc welding (SMAW), also known as manual metal arc (MMA) welding or

informally as stick welding, is a manual arc process that uses a consumable electrode coated influx

to lay the weld. An electrician the form of either alternating or current from welding is used to form

an electric between the electrode and the metals to be joined. As the weld is laid, the flux coating

of the electrode disintegrates, giving off vapors that serve as shielding and providing a layer of

slag, both of which protect the weld area from atmospheric contamination.

Because of the versatility of the process and the simplicity of its equipment and operation, shielded

metal arc welding is one of the world's most popular welding processes. It dominates other welding

processes in the maintenance and repair industry, and though flux welding is growing in popularity,

SMAW continues to be used extensively in the construction of steel structures and in industrial

fabrication. The process is used primarily to weld iron and steels (including stainless but aluminum,

nickel and copper alloys can also be welded with this method.

Defects

As SMAW is manual welding process so it has no uniformity (for larger welds) and there is also

equality difference in welding (someplace thick and some other place thin). To remove this defect

SAW welding is used.

Submerged Arc Welding (SAW)

Submerged arc welding (SAW) is a common arc process. Originally developed by the Linde -

Union Carbide Company. It requires a continuously fed consumable solid or tubular flux cored)

electrode. The molten weld and the arc zone are protected from atmospheric Contamination by

being “submerged” under a blanket of granular fusible flux consisting of Lime, silica, manganese

oxide, calcium and other compounds. When molten, the flux becomes conductive, and provides a

current path between the electrode and the work.

This thick layer of flux completely covers the molten metal thus preventing spatter and sparks as

well as suppressing the intense ultraviolet radiation and fumes that are a part of the shielded metal

arc welding (SMAW) process. SAW is normally operated in the automatic or mechanized mode,

however, semi-automatic (hand-held) SAW guns with pressurized or gravity flux feed delivery are

available.

The process is normally limited to the flat or horizontal-fillet welding positions (although

horizontal groove position welds have been done with a special arrangement to support the

flux).Single or multiple (2 to 5) electrode wire variations of the process exist. SAW strip-cladding

utilizes a flat strip electrode (e.g. 60 mm wide x 0.5 mm thick). DC or AC power can be used, and

combinations of DC and AC are common on multiple electrode systems. Constant voltage welding

are most commonly used; however, constant current systems in combination with a voltage sensing

wire-feeder are available.

[16]

Gas Tungsten Arc Welding (GTAW)

Gas tungsten arc welding (GTAW), also known as tungsten inert gas (TIG) welding, is an arc

welding process that uses a non-consumable tungsten electrode to produce the weld. The weld area

is protected from atmospheric contamination by shielding (usually an inert such as argon), and

fillers normally used, though some welds, known as autogenously welds, do not require it.

A constant-current supply produces energy which is conducted across the arc through a column of

highly ionized gas and metal vapors known as plasma GTAW is most commonly used to weld thin

sections of stainless steel and non-ferrous metals such as aluminum, magnesium, and copper alloys.

The process grants the operator greater control over the weld than competing procedures such as

shielded and gas 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 uses a slightly

different welding torch to create a more focused welding arc and as a result is often automated

Gas metal arc welding (GMAW), sometimes referred to by its subtypes metal inert gas (MIG)

welding or metal active gas (MAG) welding, is a welding process in which an electric arc forms

between a consumable wire electrode and the work piece metal(s), which heats the work piece

metal(s), causing them to melt, and join.

Along with the wire electrode, a shielding gas feeds through the welding gun, which shields the

process from contaminants in the air. The process can be semi-automatic or automatic. A constant

voltage, direct current power source is most commonly used with GMAW, but constant current

systems, as well as alternating current, can be used. There are four primary methods of metal

transfer in GMAW, called globular, short-circuiting, spray, and pulsed-spray, each of which has

distinct properties and corresponding advantages and limitations.

Originally developed for welding aluminum and other non-ferrous materials in the 1940s, GMAW

was soon applied to steels because it provided faster welding time compared to other welding

processes. The cost of inert gas limited its use in steels until several years later, when the use of

semi-inert gases such as carbon dioxide became common. Further developments during the 1950s

and 1960s gave the process more versatility and as a result, it became a highly used industrial

process.

Today, GMAW is the most common industrial welding process, preferred for its versatility, speed

and the relative ease of adapting the process to robotic automation. Unlike welding processes that

do not employ a shielding gas, such as shielded metal arc welding, it is rarely used outdoors or in

other areas of air volatility. A related process, flux cored arc welding, often does not use a shielding

gas, but instead employs an electrode wire that is hollow and filled with flux.

TYPES OF WELDING DEFECTS

Cracks

Cracks are produced due to properties difference of materials and wrong pre-heating.

Incomplete Penetration

This type of defect is found in any of three ways:

• When the weld bead does not penetrate the entire thickness of the base plate.

[17]

• When two opposing weld beads do not interpenetrate.

• When the weld bead does not penetrate the toe of a fillet weld but only bridges across

it.

Welding current has the greatest effect on penetration. Incomplete penetration is usually caused by

the use of too low a welding current and can be eliminated by simply increasing the amperage.

Other causes can be the use of too slow a travel speed and an incorrect torch angle. Both will allow

the molten weld metal to Roll in front of the arc, acting as a cushion to prevent penetration. The

arc must be kept on the leading edge of the weld puddle.

Distortion

Welding methods that involve the melting of metal at the site of the joint necessarily are pronto

shrinkage as the heated metal cools. Shrinkage then introduces residual stresses and distortion.

Distortion can pose a major problem, since the final product is not the desired shape. To alleviate

certain types of distortion the work pieces can be offset so that after welding the product is the

correct shape.

Gas Inclusion

Gas inclusions are a wide variety of defects that includes

• Porosity

• Blow holes

• Pipes

The underlying cause for gas inclusions is the entrapment of gas within the solidified weld. Gas

formation can be from any of the following causes: high sulfur content in the work piece or

electrode, excessive moisture from the electrode or work piece, too short of an arc, or wrong

welding current or polarity.

Undercut

Most structural failures originate from weld joint because it is the source of discontinuity or defects.

The most visible weld defect we can easily find in visual inspection is undercut. Undercut is usually

due to over current in electric arc welding. Over current causes wide melting zone in base metal

but not enough weld fusion metal to replace the gap. High lapping speed also leaves the gap poorly

filled with weld fusion metal and produces undercut. To avoid undercut, welder and welding

inspector must observe initial weld lap to see whether the current setting is appropriate. Post

welding inspection can be tricky since welder can cover undercut by running another lap using

lower grade welding electrode and low current. Undercut is dangerous because it amplifies the

stress flow due to reduction in section area and stress concentration of the notch form Undercut

and overlap.

Incomplete Fusion

Other welding defect is incomplete fusion which is due to undercurrent. Arc welding uses

concentrated high-temperature electric arc to melt both base metal and welding electrode. These

melted base metal and electrode mix and fuse together into weld pool which subsequently bonds

adjoining base metals. If the welding current is set too low, ideal melting Temperature cannot be

achieved and base metal doesn’t melt completely. Furthermore, weld Pool material is not adequate

[18]

and gap between adjoining base metals is not properly filled. This will leave empty holes inside or

outside weld joints.

Surface Cleaning

It is done to preserve the surface from corrosion etc.

Following are the types of Surface Cleaning Process:

• Shot Blasting

• Sand Blasting

• Chemical Cleaning (pickling)

Boiler

Boiler is one of the major products of Heavy Mechanical Complex, Taxila. It has the vast

experience of manufacturing small as well as large Power and Industrial Boilers.

There are two types of boilers:

• Fire tube boiler (Smoke Tube Boiler)

• Water tube Boiler (spelled water-tube)

Fire tube boiler (Smoke Tube Boiler)

A fire-tube boiler is a type of boiler in which hot gases from a fire pass through one or (many)

more tubes running through a sealed container of water. The heat of the gases is transferred through

the walls of the tubes by thermal conduction, heating the water and ultimately creating steam.

Fig. 4.1 Fire Tube Boiler

Water tube Boiler

A water tube boiler (also spelled water-tube and water tube) is a type of boiler in which water

circulates in tubes heated externally by the fire. Fuel is burned inside the furnace, creating hot gas

which heats water in the steam-generating tubes. In smaller boilers, additional generating tubes are

separate in the furnace, while larger utility boilers rely on the water-filled tubes that make up the

walls of the furnace to generate steam.

[19]

Fig. 4.2 Water Tube Boiler

Third Party Inspection

In all type of pressure vessels an inspection company (termed as third party) accredited by boiler

boards or international standardizing organizations e.g. ASME also inspects the vessel time to time

during manufacturing this inspection is known as third party inspection.

[20]

Chapter No. 5

Production Planning and Control (PPC)

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.

The last two digits denotes the serial number of order of a particular type.

For example, a job order given as111504 is read as follows

11: product group for sugar spares

15: represents 2014-15 as the fiscal year

04: specifies the fourth order for the current year that is fourth order of sugar spares in 2015.

Core Planning

Core planning section has following works.

Master schedule planning.

Order Activity plans.

Monitoring of all the schedules.

Project Planning

To ensure receipt of all drawings and documentation from design.

To issue the material purchase requirement.

To prepare the requirements of materials to be issued.

To prepare and issue job orders and prepare the follow up.

Material Management (MMG)

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.

[21]

Process Planning

Preparation of following documents:

Detail parts list

Route card (machining and fabrication) if required

Cutting plans

Time sheets

Tool designing

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.

Dispatch Cell/Material Handling

To receive finish goods from shops/material handling sections.

To draw the standard items/equipment from stores for dispatch to costumer/sites.

To organize preservation/packing. Mostly painted with red oxides to prevent from

corrosion.

Maintain detailed dispatch records of finished goods, equipment, standard items against

each contract.

Organize transportation.

Ensure complete and accurate documentation along with each dispatch.

To prepare the dispatch plans and ensure compliance.

Income tax Cost and Revenue (ICR)

To defend in litigation/adjudication and contravention

To organize industrial survey.

To obtain the consumption certificates and release of guarantee.

[22]

Chapter No. 6

Steel Foundry A foundry is a workshop that produces metal castings. Metals are cast into shapes by melting them

into a liquid, pouring the metal in a mold, and removing the mold material or casting after the metal

has solidified as it cools. The most common metals processed are aluminum and cast iron.

Casting Process

Casting process contain the following steps:

Pattern Making

Pattern making is the first stage for developing a new casting. The pattern, or replica of the finished

piece, is typically constructed from wood but may also be made of metal, plastic, plaster or other

suitable materials. These patterns are permanent so can be used to form a number of moulds.

Pattern making is a highly skilled and precise process that is critical to the quality of the final

product. Many modern pattern shops make use of computer-aided design (CAD) to design patterns.

Mould Making

The mould is formed in a mould box (flask), which is typically constructed in two halves to assist

in removing the pattern. Sand moulds are temporary so a new mould must be formed for each

individual casting. A cross-section of a typical two-part sand mould. The bottom half of the mould

(the drag) is formed on a moulding board. Cores require greater strength to hold their form during

pouring. Dimensional precision also needs to be greater because interior surfaces are more difficult

to machine, making errors costly to fix.

Melting and Pouring

Many foundries, particularly ferrous foundries, use a high proportion of scrap metal to make up a

charge. As such, foundries play an important role in the metal recycling industry. Internally

generated scrap from runners and risers, as well as reject product, is also recycled. The charge is

weighed and introduced to the furnace. Alloys and other materials are added to the charge to

produce the desired melt. In some operations the charge may be preheated, often using waste heat.

In traditional processes metal is superheated in the furnace. Molten metal is transferred from the

furnace to a ladle and held until it reaches the desired pouring temperature.

Fettling, Cleaning and Finishing

After the casting has cooled, the gating system is removed, often using band saws, abrasive cut-off

wheels or electrical cut-off devices. A ‘parting line flash’ is typically formed on the casting and

must be removed by grinding or with chipping hammers. Castings may also need to be repaired by

welding, brazing or soldering to eliminate defects.

[23]

Advantages of Sand Casting

Use is widespread; technology well developed.

Materials are inexpensive, capable of holding detail and resist deformation when heated.

Process is suitable for both ferrous and non-ferrous metal castings.

Handles a more diverse range of products than any other casting method.

Produces both small precision castings and large castings of up to 1 ton.

Can achieve very close tolerances if uniform compaction is achieved.

Mould preparation time is relatively short in comparison to many other processes.

The relative simplicity of the process makes it ideally suited to mechanization.

High levels of sand reuse are achievable

Limitations

Typically limited to one or a small number of moulds per box.

Sand: metal ratio is relatively high.

High level of waste is typically generated, particularly sand, bag house dust and spent shot.

Steel Melting Furnace

Molten metal is prepared in a variety of furnaces, the choice of which is determined by the quality,

quantity and throughput required.

Electric Induction Furnaces

Electric induction furnaces are the most common type used for batch melting of ferrous, copper

and super alloys. This method involves the use of an electrical current surrounding a crucible that

holds the metal charge. Furnace sizes range from < 100 kg up to 15 tons. For production of super

alloys and titanium, melting may be undertaken in a vacuum chamber to prevent oxidation.

[24]

Chapter No. 7

Non-Destructive Testing (NDT) Lab Non-destructive testing (NDT) is a wide group of analysis techniques used in science and industry

to evaluate the properties of a material, component or system without causing damage. The terms

Non-destructive examination (NDE), Non-destructive inspection (NDI), and Non-destructive

evaluation (NDE) are also commonly used to describe this technology. Because NDT does not

permanently alter the article being inspected, it is a highly-valuable technique that can save both

money and time in product evaluation, troubleshooting, and research on Destructive testing (NDT)

Methods:

Radiographic Testing (RT)

Ultrasonic Testing (UT)

Magnetic Particle Testing

Liquid Penetration Testing

Eddy Current Testing

Radiographic Testing

Radiographic Testing (RT), or industrial radiography, is a non-destructive testing (NDT) method

of inspecting materials for hidden flaws by using the ability of short wavelength electromagnetic

radiation (high energy photons) to penetrate various materials. The followings steps are involved:

Job is divided into sections

Separate room is used for testing

After developing process, illuminators of different ranges are used to see the defects that

are capture through the film.

Developing of Film

This process is consisting of following steps

Developer: alkaline changes the exposed salt to black metallic silver 5-6 minutes

Stop bath: It neutralizes the developer and stop the developing process.

Fixer: At this step, the effects of faults are fixed.

Water tank: It cleans the film from chemicals.

PF. Solution: It prevents water to make spot.

Ultrasonic Testing

Ultrasonic testing (UT) is a family of non-destructive testing techniques based on the propagation

of ultrasonic waves in the object or material tested.

A typical UT inspection system consists of several functional units, such as the pulser/receiver,

transducer, and display devices. A pulser/receiver is an electronic device that can produce high

voltage electrical pulses. Driven by the pulser, the transducer generates high frequency ultrasonic

energy. The sound energy is introduced and propagates through the materials in the form of waves.

When there is a discontinuity (such as a crack) in the wave path, part of the energy will be reflected

back from the flaw surface. The reflected wave signal is transformed into an electrical signal by

[25]

the transducer and is displayed on a screen. In the applet below, the reflected signal strength is

displayed versus the time from signal generation to when an echo was received. Signal travel time

can be directly related to the distance that the signal traveled. From the signal, information about

the reflector location, size, orientation and other features can sometimes be gained.

Probe types

Normal beam probes: radiate their sound wave perpendicular to specimen surface.

TR probes: separate crystal for receiving and transmitting waves

Angle beam probes: probes that radiate their sound wave at an angle.

Advantages

It is sensitive to both surface and subsurface discontinuities.

The depth of penetration for flaw detection or measurement is superior to other NDT

methods.

Only single-sided access is needed when the pulse-echo technique is used.

It is highly accurate in determining reflector position and estimating size and shape.

Limitations

Surface must be accessible to transmit ultrasound.

Skill and training is more extensive than with some other methods.

It normally requires a coupling medium to promote the transfer of sound energy into the

test specimen.

Materials that are rough, irregular in shape, very small, exceptionally thin or not

homogeneous are difficult to inspect.

Cast iron and other coarse grained materials are difficult to inspect due to low sound

transmission and high signal noise.

Magnetic Particles Inspection

Magnetic particle Inspection (MPI) is an NDT process for detecting surface and slightly subsurface

discontinuities in ferromagnetic materials such as iron, nickel, cobalt, and some of their alloys. The

process puts a magnetic field into the part. The piece can be magnetized by direct or indirect

magnetization.

Magnet ink is used as magnetic powder which is attracted to local pole sat defects. Mostly the

white powdering is done on the job to increase the contrast before magnetizing.

Liquid penetrant Testing

Penetrant testing (PT), is a widely applied and low-cost inspection method used to locate surface-

breaking defects in all non-porous materials (metals, plastics, or ceramics).

Principle

[26]

DPI is based upon capillary action, where fluid having low surface tension penetrates into clean

and dry surface-breaking discontinuities. Penetrant may be applied to the test component by

dipping, spraying, or brushing. After adequate penetration time has been allowed, the excess

penetrant is removed and a developer is applied. The developer helps to draw penetrant out of the

flaw so that an invisible indication becomes visible to the inspector. Inspection is performed under

ultraviolet or white light, depending on the type of dye used - fluorescent or no fluorescent (visible).

Inspection steps

Pre-cleaning

Application of Penetrant

Excess Penetrant Removal

Application of Developer

Inspection

Mostly cleaner for the penetrant which used are solvent and water emulsifier.

Eddy Current Testing

Continuous wave eddy current testing is one of several non-destructive testing methods that use

the electromagnetism principle. Conventional eddy current testing utilizes electromagnetic

induction to detect discontinuities in conductive materials.

A specially designed coil energized with alternating current is placed in proximity to the test

surface generating changing magnetic-field which interacts with the test-part producing eddy

current in the vicinity.

[27]

Chapter No. 8

Basic Machine Shop In the development of every nation industries are very important and for industries machinery’s

key factor. To check the development of any industry check it’s machinery. The machine shop of

HMC contains various types of machines.

Production Planning Section (PPS)

This section is known as the main branch of machine shop. Working is Given Below:

Job order receiving from PPS

Drawing set receiving from PPS

Cutting plan received (if required)

Material receiving

Drawing/Job order Planning

Loading

Machining

Inspection

Movement

o Assembly Shop

o Dispatch Cell

o Fabrication Shop

List of Machines

Lathe machine (Three jaws and four jaws chucks, turret)

Planer machine

Shaper Machine

Milling machine

Cylindrical Grinding Machine

Drilling machine

HDL (Heavy duty lathe)

BVT (Boring vertical turret lathe machine)

Gear hobbling machine

Gear shaper machine

Straight bevel machine

Horizontal lathe machine

Radial drilling machine

[28]

Slotting machine

Double housing planner

Face plate machine

Column drilling machine

Machining

A material removal process in which a sharp cutting tool is used to mechanically cutaway material

so that the desired part geometry remains.

Most common application includes 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

Rotational - cylindrical or disk-like shape

Achieved by rotation motion of the work part e.g. turning and boring.

Non-rotational (also called prismatic) - block-like or plate-like

Achieved by linear motion of the work part e.g. milling, shaping, planning and sawing

Turning and Related Operations

Turning

A single point cutting tool removes material from a rotating work piece to generate cylindrical

shape. The tool is fed linearly in a direction parallel to the axis of rotation Performed on a machine

tool called a lathe.

Facing

Tool is fed radially inward to create a flat surface.

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 rotational a

large feed rate, thus creating threads.

Hobbing

Hibbing is a machining process for making gears, splines, and sprockets on a hobbling machine,

which is a special type of machine. The teeth or splines are progressively cut into the work piece

by a series of cuts made by cutting 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 hobbling than any other process since it is relatively quick and inexpensive.

[29]

Types of Gears

Spur Gears

Helical Gears

Worm Wheel

Sprocket

Bevel Gear

Spiral Bevel

Rack and Pinion

Cutters Used for Gear Cutting

Mechanical Cutter

Hob Cutter

Disc type Cutter

Taper shank Cutter

Sprocket Cutter

Blades

Lathe Machine

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 centres. Swing is the maximum work part diameter that can be rotated

in the spindle.

Fig. 8.1 Lathe Machine

[30]

Shaper Machine

A shaper is a type of machine tool that uses linear relative motion between the work piece and a

single-point cutting tool to machine a linear toolpath. Its cut is analogous to that of a lathe, except

that it is (archetypally) linear instead of helical. (Adding axes of motion can yield helical toolpaths,

has also done in helical planning.) A shaper is analogous to a planer, but smaller, and with the cutter

riding a ram that moves above a stationary work piece, rather than the entire work piece moving

beneath the cutter. The ram is moved back and forth typically by a crank inside the column;

hydraulically actuated shapers also exist.

Planar Machine

A planer is a type of metalworking machine tool that uses linear relative motion between the work

piece and a single-point cutting tool to machine a linear toolpath. Its cut is analogous to that of a

lathe, except that it is (archetypally) linear instead of helical. A planer is analogous to a shaper, but

larger, and with the entire work piece moving on a table beneath the cutter, instead of the cutter

riding a ram that moves above a stationary work piece. The table is moved back and forth on the

bed beneath the cutting head either by mechanical means, such as a rack and pinion drive or a

leadscrew, or by a hydraulic cylinder.

[31]

Chapter No. 9

Technology Department

Technology department has two major functions:

Provide feasibility study or quantitative details of a project before taking the order

Technology Preparation for workshops

HMC I & II has different Technology departments e.g. Technology I and Technology II.

Technology I is responsible for fabrication, machining and assembly.

Technology II is responsible for casting and forging.

Technology department designs the entire process for completion of a project including all major

as well as minor details.

Feasibility Study

Sales and marketing department receives a quotation about any project.

It sends a letter to technology department and asks for its feasibility study.

Then Technology department prepares a feasibility report to sales and marketing

department.

Further, the report is sent to accounts department for cost analysis.

Then, it is sent back to Sales and marketing Department, which replies the quotation or

receives the order.

[32]

Chapter No. 10

Material Testing Lab

Material testing laboratory is divide into three sections:

Metallographic

Mechanical testing

Chemical analysis (ferrous, non-ferrous, refractory materials)

Metallography

Metallography is the study of the physical structure and components of metals, typically using

microscopy In HMC metallographic section the microscope with the following magnification is

available.

100x 450x 1000x 2000x

Mechanical Testing

In this section the tests being performed are:

Tensile Tests

o Tensile strength

o Yield strength

o Elongation

o Reduction in area

Bend Tests

Impact Tests

Crushing Test

Hardness

Shear Test

Universal Testing Machine (UTM)

A universal testing machine (UTM), also known as a universal tester, materials testing machine or

materials test frame, is used to test the tensile strength and compressive strength of materials. It is

named after the fact that it can perform many standard tensile and compression tests on materials,

components, and structures.

The set-up and usage are detailed in a test method, often published by a standards organization.

This specifies the sample preparation, fixturing, gauge length (the length which is under study or

observation), analysis, etc.

The specimen is placed in the machine between the grips and an extensometer if required can

automatically record the change in gauge length during the test. If an extensometer is not fitted,

[33]

the machine itself can record the displacement between its cross heads on which the specimen is

held. However, this method not only records the change in length of the specimen but also all other

extending / elastic components of the testing machine and its drive systems including any slipping

of the specimen in the grips.

Once the machine is started it begins to apply an increasing load on specimen. Throughout the tests

the control system and its associated software record the load and extension or compression of the

specimen.

Charpy Impact Testing Machine

Charpy impact testing involves striking a standard notched specimen with a controlled weight

pendulum swung from a set height. The standard Charpy-V notch specimen is 55mm long, 10mm

square and has a 2mm deep notch with a tip radius of 0.25mm machined on one face. The specimen

is supported at its two ends on an anvil and struck on the opposite face to the notch by the

pendulum. The amount of energy absorbed in fracturing the test-piece is measured and this gives

an indication of the notch toughness of the test material.

The pendulum swings through during the test, the height of the swing being a measure of the

amount of energy absorbed in fracturing the specimen. Conventionally, three specimens are tested

at any one temperature and the results averaged.

Charpy tests show whether a metal can be classified as being either brittle or ductile. This is

particularly useful for ferritic steels that show a ductile to brittle transition with decreasing

temperature. A brittle metal will absorb a small amount of energy when impact tested, a tough

ductile metal absorbs a large amount of energy. The appearance of a fracture surface also gives

information about the type of fracture that has occurred; a brittle fracture is bright and crystalline,

a ductile fracture is dull and fibrous.

The percentage crystallinity is determined by making a judgement of the amount of crystalline or

brittle fracture on the surface of the broken specimen, and is a measure of the amount of brittle

fracture.

Lateral expansion is a measure of the ductility of the specimen. When a ductile metal is broken,

the test-piece deforms before breaking, and material is squeezed out on the sides of the compression

face. The amount by which the specimen deforms in this way is measured and expressed as

millimeters of lateral expansion.

When reporting the results of a Charpy test, the absorbed energy (in J) is always reported, while

the percentage crystallinity and lateral expansion are optional on the test report. It should be

emphasized that Charpy tests are qualitative, the results can only be compared with each other or

with a requirement in a specification - they cannot be used to calculate the fracture toughness of a

weld or parent metal.

Brinell Testing Machine

The Brinell hardness test method as used to determine Brinell hardness, is defined in ASTM E10.

Most commonly it is used to test materials that have a structure that is too coarse or that have a

surface that is too rough to be tested using another test method, e.g., castings and forgings. Brinell

testing often use a very high test load (3000 kgf) and a 10mm wide indenter so that the resulting

indentation averages out most surface and sub-surface inconsistencies.

The Brinell method applies a predetermined test load (F) to a carbide ball of fixed diameter (D)

which is held for a predetermined time period and then removed. The resulting impression is

measured across at least two diameters – usually at right angles to each other and these result

[34]

averaged (d). A chart is then used to convert the averaged diameter measurement to a Brinell

hardness number. Test forces range from 500 to 3000 kgf.

A Brinell hardness result measures the permanent width of indentation produced by a carbide

indenter applied to a test specimen at a given load, for a given length of time. Typically, an

indentation is made with a Brinell hardness testing machine and then measured for indentation

diameter in a second step with a specially designed Brinell microscope or optical system.

The resulting measurement is converted to a Brinell value using the Brinell formula or a conversion

chart based on the formula. Most typically, a Brinell test will use 3000 kgf load with a 10mm ball.

If the sample material is aluminum, the test is most frequently performed with a 500 kgf load and

10mm ball. Brinell test loads can range from 3000 kgf down to 1 kgf. Ball indenter diameters can

range from 10mm to 1mm.

Generally, the lower loads and ball diameters are used for convenience in “combination” testers,

like Rockwell units, that have a small load capacity. The test standard specifies a time of 10 to 15

seconds, although shorter times can be used if it is known that the shorter time does not affect the

result.

Rockwell Testing Machine

The Rockwell hardness test method, as defined in ASTM E-18, is the most commonly used

hardness test method. The Rockwell test is generally easier to perform, and more accurate than

other types of hardness testing methods. The Rockwell test method is used on all metals, except in

condition where the test metal structure or surface conditions would introduce too much variations;

where the indentations would be too large for the application; or where the sample size or sample

shape prohibits its use.

The Rockwell method measures the permanent depth of indentation produced by a force/load on

an indenter. First, a preliminary test force (commonly referred to as preload or minor load) is

applied to a sample using a diamond indenter. This load represents the zero or reference position

that breaks through the surface to reduce the effects of surface finish.

After the preload, an additional load, call the major load, is applied to reach the total required test

load. This force is held for a predetermined amount of time (dwell time) to allow for elastic

recovery. This major load is then released and the final position is measured against the position

derived from the preload, the indentation depth variance between the preload value and major load

value. This distance is converted to a hardness number.

Preliminary test loads (preloads) range from 3 kgf (used in the “Superficial” Rockwell scale) to 10

kgf (used in the “Regular” Rockwell scale) to 200 kgs. Total test forces range from 15kgf to 150

kgf (superficial and regular) to 500 to 3000 kgf (macro hardness).

A variety of indenters may be used: conical diamond with a round tip for harder metals to ball

indenter’s ranges with a diameter ranging from 1/16” to ½” for softer materials.

[35]

Chapter No. 11

Inspection Inspection is a process in which the material is just visually Checked by using many apparatus like

Vernier Caliper, Micro meter screw gauges, Tapes, Compasses etc. When this is done, then a report

is prepared containing all the references with respect to that the material was passed out from the

inspection stage and this is a necessary step to assure the quality of the product. And is done where

the status of the manufacturing industry is to be maintained and the Quality of the manufactured

product is too kept up to the standards.

The working process starts with agreement between purchaser and manufacture, the manufacture

provides Preformat Invoice (PI) to the purchaser which explains the equipment specification and

related price. Then the purchaser issues the Purchase Order (PO) which confirming the preformat

invoice. Before start of manufacturing, the purchaser must provide equipment inspection and test

plan (ITP) to the manufacture. The ITP identifies all inspection points for purchaser inspector.

Then the manufacture needs to prepare the project quality control plan based of this inspection and

test plan. The manufacture notifies purchaser inspector in advance to attend to her factory for

witnessing the inspections and tests. The communication and coordination channel between

manufacture, purchaser inspector and purchaser are agreed in the Pre-inspection meeting

(PIM).Based the international practice manufacture sends her notification to the purchaser, and

purchaser reviews the notification and after her approval sends to the inspector.

Then the inspector will be attended in the in manufacture shop to witness the test or inspection.

The purchaser inspector will send his/her inspection visit report to the purchaser. Purchaser can

assign his/her own inspector which is her own direct employee or hire a third party inspection

agency to carry out inspection.

Inspection and test plan has tabular format and its content extracted from construction code. In

each row of the table there is quality control and inspection requirement and determine which party

is responsible for control and inspection. There are three parties in ITP:

Manufacturer

Third Party Inspector (TPI)

Client or purchaser.

Final Inspection before manufacturing section consists of Pre-Inspection Meeting (PIM) and

review of quality control documents which need to be approved before start of manufacturing.

There are 3 or 4 important terminologies in the ITP which determines the responsibility of each

party. These are:

Hold point (H)

Hold on the production till TPI Inspector perform inspection and supervise the required test, as

general; attendance to the PIM meeting, raw material inspection and identification, Post Weld Heat

Treatment Review, Hydrostatic Test, Performance Test, Run-Out Test and Final Inspection are

Hold points. Normally manufactures shall notify TPI Inspector 7 working days in advance.

Witness Point (W)

Manufacture shall notify client and TPI Inspector but there is no hold on the production, client can

waive this inspection based on his discretion and inform TPI Inspector.

[36]

Spot Witness (SW)

For items with spot witness manufacture shall notify TPI inspector as fulfilling the monitoring for

example one random visit for whole UT Tests or one or two visit for whole surface preparation

work for painting.

Review (R)

Review means Review document, which includes the review of quality control records, test reports

and etc. When TPI Inspector make visit for hold or witness point, the inspector can review the

related documents.

[37]

APPENDIX

Schedule of Internship Start: June 17th, 2015

End: July 15th, 2015

S. No. Date Training Workshop/Program

1 June 17th, 2015 Introduction to HMC

2 June 18th, 2015 Assembly Shop

3 June 19th, 2015 Heat Treatment and TTC

4 June 20th-25th, 2015 Fabrication Shop

5 June 26th-27th, 2015 PPC/Dispatch Cell

6 June 29th- July 3rd, 2015 Steel Foundry

7 July 4th, 2015 NDT Lab

8 July 6th-10th, 2015 Basic Machine Shop

9 July 11th, 2015 Technology Department

10 July 13th, 2015 Material Testing Lab

11 July 14th-15th, 2015 Inspection