ANINDUSTRIAL TRAINING REPORT

ONFORGING, CASTING, HEAT TREATMENT & MACHINING

Submitted in Partial fulfillment for the award of the Degree ofBachelor of Engineering

in MECHANICAL ENGINEERING

To

RAJIV GANDHI PROUDYOGIKI VISHWAVIDYALAYABHOPAL (M.P)

Under The Guidance of Mr. Sunder SubramaniamSr. Dy General Manager

Heavy Engineering Corporation LimitedDhurwa, Ranchi(Jharkhand)

Submitted BySHYAMAKANT SHARAN

0105ME121102

Department of Mechanical EngineeringOriental Institute of Science and Technology, Bhopal

Session: 2015-2016

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Industrial Training Certificate(Color Copy)

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ACKNOWLEDGEMENT

I take this opportunity to express my sincere gratitude to all those who have been helpful in the successful completion of my Industrial Training. I would like to show my greatest appreciation to the highly esteemed and devoted technical staff, supervisors of the Heavy Engineering Corporation Limited, Dhurwa, Ranchi(Jharkhand). I am highly indebted to them for their tremendous support and help during the completion my training.

My special goes to Mr. Sunder Subramaniam, Sr. Dy General Manager, HEC Ltd. for acceptance my request for providing Industrial Training and giving me an opportunity to be a trainee of Heavy Engineering Corporation Limited, Ranchi. I would like to thank to all those people who directly or indirectly helped and guided me to complete my training, including the following instructors and technical officers of various sections.

Nevertheless, I would like to place on record my deep sense of gratitude to Dr. V.K. Sahu, Director, Oriental Institute of Science and Technology, Bhopal and Prof. N. K. Mittal, Principal, Oriental Institute of Science and Technology, Bhopal who granted me the permission of Industrial training. I also wish to extend my thanks to Head of Department, Prof K K Dwivedi for his kind co-operation.

Last but not least, I would like to express my special gratitude towards my parents and friends for their constant encouragement.

SHYAMAKANT SHARAN

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TABLE OF CONTENTS

Title Page No.

Acknowledgement ………………………………………………….…….…i

Table of Contents…………………………………………………..……..…ii

Chapter 1: Introduction

1.1 Introduction of the Training Organization

1.2 Administrative System the Organization

1.3 Business Functions of the Organization

1.4 Services Provided by the Organization

1.5 Benefits from the Training

Chapter 2: Training Topic Name

2.1 Objectives

2.2 Analysis

2.3 Techniques

Chapter 3: Methodology

3.1 Introduction

3.2 Software and Tools Used

Chapter 4: Result and Analysis

4.1 Results

4.2 Scope

4.3 Future Work

Chapter 5: Conclusion

Bibliography…………………………………………………………….……iv

ii

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CHAPTER 1INTRODUCTION

Heavy Engineering Corporation Ltd., is one of the leading suppliers of capital equipment in India for steel, mining, railways, power, defense, space research, nuclear and strategic sectors. It also executes turn-key projects from concept-to-commissioning. Set-up in the year 1958, HEC has acquired expertise in its field through its more than half a century's experience.

With the seamless integration of its facilities, HEC is one of the largest integrated engineering complex. Sprawling in an area of around 2100,000 sq.m, HEC has facilities starting from steel melting, casting, forging, fabrication, machining, assembly and testing. It has its own in-house research and product development wing to deliver products suiting customers' specifications.

HEC is headquartered at Ranchi, the capital city of Jharkhand, in eastern part of India, and also has its manufacturing facilities located here. A well-suited location nearing to customer sites and proximity to the ports for import items, is an added advantage for its cost-effectiveness.

Founded primarily to facilitate manufacture of steel plant equipment indigenously, HEC has made immense contribution in setting-up, expansion and modernization of steel plants in India. In due course, HEC had diversified to different sectors and made commendable contributions towards manufacture and supply of import-substitute products. Bestowed with the onus of making the country self-reliant for heavy engineering equipment and services, HEC continues to contribute in the nation-building endeavor.

OPERATING UNITS

1. HEAVY MACHINE BUILDING PLANT (HMBP)2. FOUNDRY FORGE PLANT (FFP)3. HEAVY MACHINE TOOLS PLANT (HMTP)4. PROJECTS DIVISION

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HEAVY MACHINE BUILDING PLANT (HMBP)The Plant has a fenced area of 5,70,000 sq.m and a floor area of nearly 2,00,000 sq.m. It is well equipped with sophisticated machine tools and handling equipments to undertake manufacture of heavy machinery and equipment of top quality. It is engaged in design and manufacture of equipments and components for Steel Plant, Mining, Mineral Processing, Crushers, Material Handling, Cranes, Power, Cement, Aluminium, Space Research, Nuclear Power etc.

FOUNDRY FORGE PLANT (FFP)It is the largest foundry and forging complex in India and one of the largest of its kind in the world. The area of the Plant is 13,16,930 sq.m accommodating 76,000 tonnes of installed machinery to cope up with the various operations effectively. This Plant is the manufacturer of heavy castings and forgings for various HEC make equipments related to Steel plant, Defence, Power, Nuclear energy etc. It also manufactures Forged Rolls for Steel Plants, Crank Shafts for Railway Loco etc.

HEAVY MACHINE TOOLS PLANT (HMTP)HMTP is the most modern and sophisticated of its kind in the country which produces machine tools in heavier ranges. The Plant covers an area of over 2,13,500 sq.m. It designs and manufactures medium & heavy duty CNC and conventional Machine Tools for Railways, Defense, Ordnance factories, HAL, Space and other strategic sectors.

PROJECTS DIVISIONDesign, Engineering and execution of Turnkey Projects related to Bulk Material handling, Steel Plant projects, Cement Plant and other sectors.

 Business Areas

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Steel & Metallurgical Plant equipment

Mining & Mineral Processing equipment

Machine Tools

Defense & Strategic Sector

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Heavy Castings & Forgings

STEEL PLANT EQUIPMENTS

 Blast Furnace  Coke Oven Batteries  Continuous Casting Machine  Steel Melting Converters  Forged Rolls  Other Equipments to Steel Sectors

 BLAST FURNACE

Blast Furnace (Volume 1719,2000,3200 CuM): Supplied to BSP, BSL ,VSP and exported to Turkey & Egypt. Supplies include:

 Technical Structure  Ch. Column & Plants  Cooling Plates  Charging Arrangements  Charging Distributors  Skip winch  Belt Control Winch  Valves  Rolling Stocks etc.  Cast House Machines  Pig Casting Machines etc.

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COKE OVEN BATTERIES

Coke Oven Battery (4.3 M to 7.0 M high) :Supplied to BSL, BSP VSP, DSP and Exported to Turkey, Egypt, USSR & Sri Lanka. Supplies include:

Coke Pusher Coal Charging Car Coke Guide Car Coke Quenching Car Red Hot Coke Car Travelling hoist Charging Hoist Charging Device Discharging Device Door, Frame, Flash plate and Sealing Frames Buckstays, Anchorages and Tie Rods Gas Collecting Mains and Cross Over Gas Mains Reversing Winch Skip Hoist Coal Tower Gates Primary Gas Cooler and Benzol Stripping Column Bend and Valve Assembly

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Coke Oven Machine for Bhilai Steel Plant

Remote Controlled Wagon Pusher Hot Coke Car

 CONTINUOUS CASTING MACHINE

Continuous Casting Machine/Plant : Supplied to RSP, BSL, BSP & VSP for Turnkey Project execution/equipment.

Machine equipped to cast :

Slab Thickness 180 mm - 210 mm

Slab Width 800 mm - 1300 mm

Length 600 mm 800 mm

Cutting Length at Slab Sizing Unit 2200 mm - 2800 mm

Specifications of Slab Caster :

Machine Radius 10 m

Machine Support Length 21 m

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Maximum Casting speed : For 180 mm thick slab 1.5 m/minFor 210 mm thick slab 1.3 m/min

Maximum Machine Speed 2.5 m/min

Annual Output 1 million tones

Grade of Steel Cast Low & Medium carbon steel

Bit Speed 0 - 150 rpm infinitely variable

Bit rated torque 950 Kg M at 100 rpm

Crawled Heavy duty individually drivenby electric motor

Air Compressor 28 M3/min at 7kg/cm2

Segments for Continuous Slab Caster Ladle Turret for RSP

 STEEL MELTING CONVERTERS

Steel Melting Converters : Supplied to BSL, BSP, VSP, DSP, RSP, Malvika steel plants, Indomag( Jindal) 5 nos Converters and 10 nos Mixers supplied.

L.D.Convertors 55T, 100T & 130 T

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Hot Metal Mixer 600T, 1300T

Self Propelled Transfer Car 130T

Steel Ladle transfer car 50T, 100T, 200T, 250T, 300T

Hot metal transfer car 100T, 140T

Slag Pot transfer car 16M3, 18M3

Ingot Mould car 160T, 180T

Ladles & Stands 40T to 100 T

120 T Hot Metal Ladle

Slag Ladle Car12

 FORGED ROLLS

Rolls: HEC is pioneer in manufacturing of Forged Rolls in India and is a regular supplier to major Steel plants of India. Dedicated facilities have been created for Induction hardened CRM rolls. Stringent quality control ensures High Quality Rolls.

Induction Hardened Forged Rolls:

Type Max Dia (mm) Max length(mm) Wt. (T) Hardness (shore)

HRM Rolls 1350 6000 35 45

CRM Rolls 600 6000 15 upto 100

Around 3800 nos. Rolls (CRM & HRM) supplied to various steel plants like :BSL, BSP, VSP, DSP, RSP, TISCO, Jindal, Steelco, Balco, Tinplate, Nippon Dendro etc.

120 T Hot Metal Ladle

 OTHER EQUIPMENTS TO STEEL SECTORS

Sinter Plant Equipment (75-312 sqm)

24 nos. supplied to BSL,BSP, VSP,Turkey, USSR.

General Purpose & Steel Plant Cranes

300 nos. supplied to BSL, BSP, VSP, (upto 450T capacity) RSP, TISCO, BHEL, CIL, Malvika steel

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Slag Cups Supplied to BSL, BSP, VSP, DSP, RSP, TISCO.

Machines Tools 150 nos supplied to BSL, BSP, VSP, RSP, TISCO, NINL

Rolling Mills of various types & sizes

19 nos. including 3600 MW wide plate mill

Mixer (600 to 1300 T) 10 nos.

Steel Melting Converter (55 to 300 T)

10 nos.

BULL GEAR Assembly (72T) Mill Stand for RSP

MINING EQUIPMENTS

 Electric Rope Shovels (5 CuM)  Electric Rope Shovel (10 CuM)

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 Draglines

ELECTRIC ROPE SHOVELS (5 CUM)

Rugged design suitable for mining Coal, Iron ore and other minerals in open cast mines. Easy to maintain and one of the most reliable shovel in this capacity range.

HEC supplied over 550 shovels for various mining organisations in India and treated as one of the most reliable mining shovels operating in Indian mining condition.

Important Parameters :

Bucket Size 5 CuM

Boom Length 10.5 M

Max. Digging Radius 14.4 M

Max. Digging Height 10.3 M

Max. Dumping Radius 12.65M

Max. Dumping Height 6.7 M

Hoist Force 45 T

 Crowd Force 20.5 T

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 Individual DC drives for main mechanisms - hoist, crowed and swing / travel system.  MG set with 250 KW squirrel cage induction motor as prime mover and 3 DC generators, one

each for hoist, crowed and swing / travel system.  Magnetic amplifier controlled.  Electrical supply 3.3 / 6.6 KV, 50Hz, 3�

 ELECTRIC ROPE SHOVELS (10 CUM)

Highly Productive & reliable machines for Mining Operation. Over 30 numbers supplied to Indian Coal Sector.

Important Parameters :

Bucket Size 10 CuM

Max. Digging Radius 17.12 M

Max. Digging Height 13.03 M

Max. Dumping Radius 14.61 M

Max. Dumping Height 14.27 M

Av. Cycle 28 sec

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Hoist Motor 477 kw

Crowd Motor 97 kw

Propel Motor 190 kw

Swing Motor 2x97 kw

Power supply 3.3/6.6 Kv, 3�, 50Hz

MG set - for DC supply to main mechanism motors.

DRAGLINES

HEC is the first Indian company to manufacture walking Dragline of 24 CuM Bucket capacity. 12 nos of Draglines of 24 /96 and 3 nos of 20 / 90 Draglines supplied by HEC to Indian Mining industry.

Important Parameters :

Bucket capacity 24 to 34 CuM

Boom length 74.6 to 95.6 m

Boom angle 300 / 380

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Operating radius 64 to 88 m

Dump height 25.5 to 48.1 m

Digging depth 46.2 to 74.5 m

Base diameter 15.25 m

Bearing area 182.65 sq.m

Average bearing pressure 0.95 kg / sq.cm.

Walking shoe bearing area (for2) 95.2 sq.m.

Walking speed (appx) 0.24 kmph

Hoist & Drag powered by 1300 HP motors, 2 for each systems.

Devised with MG set, all motions are powered by adjustable armature DC generators.

2 MG sets each driven by 1750 HP synchronous motor.

MG set - for DC supply to main mechanism motors.

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MACHINE TOOLS

 Vertical Turning & Milling Machine  Lathe  Roll Grinding Machine  Deep Hole Boring Machine  Horizontal Boring Machine  Radial Drilling Machine  Planning Machine  Plano Milling Machine  Special Purpose Railway Macine Tools

 VERTICAL TURNING & MILLING MACHINE

6 Axis CNC Double Column Vertical Turning & Milling Machine (BV 40 / 50 NM) supplied to Vikram Sarabhai Space Research Centre

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3 Axis CNC Single Column Vertical Turning & Milling Machine (BVS 55 / 70 NM)

2 Axis CNC Vertical Turning Machine(Mono-block type BV 5 - 16 NS)

CNC Double Column Machine Specification:

 Table Diameter : 3 to 5 meter  Max turning diameter 4 to 6 meter  Max turning height 3.1 to 4.2 meter  Max wt. of work piece 30 to 80 MT

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Vertical Turning MachineCNC Single Column Machine Specification:

 Table Diameter : 2 to 5.5 meter  Max turning diameter 4 to 7 meter  Max turning height 1.6 to 2.85 meter  Max wt. of work piece 20 to 50 MT

LATHE

CNC Centre Lathe (LC 100 N)CNC Centre Lathe Specification:

 Swing over Carriage 650 - 1000 mm  Distance between centres 3 - 6 metre  Max. wt of work piece 8 - 15 MT  CNC System - Fanuc / Siemens (2 axes)  Centralised lubrication  8 station programmable turret  2 Stage high efficiency transmission head stock  Spring clamped - Hydraulic unclamped tail stock

CNC Roll Turning Lathe with 4 Guideways (LTR 160 N / 8M), Swing over bed : 1600 mm

CNC Roll Turning Lathe specification:

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 Swing over Carriage 650 - 1600 mm

 Distance between centres 3 - 10 metre

 Max. wt of work piece 8 - 50 MT

 CNC System - Fanuc / Siemens (2 axes)

Conventional Lathe Conventional Lathe

ROLL GRINDING MACHINE

Roll Grinding Machine specification:

 Max. dia to be ground : 575 - 1600 mm  Distance between centers 2 / 3 to 6 / 7 M  Max. weight of roll 3 to 6 T  Rigid design for better efficiency & accuracy  Accurate concave & convex grinding  Electronic / mechanical feed counter for pre-selection of cross feed  Built in dynamic balancing device  Automatic feed at reversing points  Automatic cut off device for grinding wheel  Automatic wheel wear compensation

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DEEP HOLE BORING MACHINE

CNC Deep Hole Boring Machine specification:

 Max. Solid drilling diameter 200 mm  Max. Trepanning diameter 350 mm  Max. Counter boring diameter 350 mm  Max. Boring depth 12000 mm  Swing over bed 1400 mm  Mx. Wt. Job 15 MT

CNC Deep Hole Boring Machine BDH 140 N

HORIZONTAL BORING MACHINE

CNC Horizontal Boring Machine specification:

 Boring spindle diameter 100 mm  Max spindle travel 900mm  Head stock vertical travel (Y-axis) 1120 mm  Moving column type design  Highly rigid construction  Automatic clamping/unclamping of ISO-60 tooling facility  Circulating lubrication system for H/S & Feed gear box.

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Horizontal Boring Machine (BH-100 N)

RADIAL DRILLING MACHINE

Specifications:

 Max. dia Drilled in steel 80 - 100 mm  Min. distance of axis of spindle to column 530 mm  Max. distance of axis of spindle to column 2520 / 3070 and 3620 / 4470 mm

Radial Drilling Machine(DR 8A)

 PLANNING MACHINE

Specifications:

 Planing width 1400 - 2000 mm  Planing length 3000/ 4000 - 12000 mm  Planing height 900 - 2000 mm  Max. work weight per meter of planning length 2 MT  CNC System Fanuc / Siemance (2 Axis)

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Double Column Planning Machine (PD 16)

 PLANO MILLING MACHINE

Double Column Plano Milling Machine Specifications:

 Max. Milling width 1250 - 2000 mm  Max. Milling length 10000 - 12000 mm  Max. Job height 1250 - 2000 mm

Plano Milling Machine

SPECIAL PURPOSE RAILWAY MACINE TOOLS

CNC Under Floor Wheel Lathe:

 Gauge 1676 mm  Max./Min. tread dia 1250 / 700 mm  Uncoupled axle distance 1600 mm  Coupled axle distance 1500 - 2650 mm  Max. Axle load 25 MT  Max. Axle load 1889 - 2750 mm

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CNC Under Floor Wheel Lathe (LUW 176 N)

CNC Surface Wheel Lathe:

 Gauge 1676 mm  Max./Min. tread dia 1250 / 700 mm  Max. axle distance 2750 mm  Min. axle distance 1850 mm  Max. weight of wheel set 3.5 MT

CNC Surface Wheel Lathe (LW 200 N)

CASTINGS & FORGINGS

 Steel Castings  Steel Forgings  Grey Iron Castings  Non-Ferrous Castings

STEEL CASTINGS

Heavy Steel castings of piece weight 65 Ton finished wt. (as cast wt. upto 90 Ton) (facility of liquid metal upto 120 T)

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Typical steel castings products are:

 Slag cups for Steel Plants ( 11/15/16/18 CuM )  Roll chocks  Roll mill housings  Cement plant tyre (upto 45T piece weight and 6m dia )  Cyclotron Magnet poles

Bottom Housing of Pinion Stand (Steel Casting, 65 T) Spindle Stand

Mill Housing (Steel Casting) 20 CuM Slag Cup

 STEEL FORGINGS

Forgings of various grades of alloy material up to piece weight of 65 Ton finished wt. Complete with heat treatment and machining. (click for forging facilities).

 Forged Rings up to diameter : 4.2 M  Die forgings

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75 T Ingot under Forging Spindle for Hot Strip Mill (Steel Forging)

Forged Ball (1.35 M diameter) Ring Forging (4.2 M diameter)

GREY IRON CASTINGSIron castings of piece weight 70 Ton finished wt.

 Centrifugal CastingTypical Iron castings products are

 Coke Oven door bodies, door frames and flash plated for Coke Oven upto 7 m height.  Base plate for Blast furnace stove  Grate bars

NON-FERROUS CASTINGS

 Non-Ferrous Castings of piece weight upto 4 Ton (Click for forging facilities)  Centrifugal Casting  Copper based castings upto 2 Ton piece weight  Aluminium based castings up to 300 Kg. piece weight

Typical Iron castings products:

 Hollow Shaft for Stripper Crane Bushes, machine components etc.  

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 CRUSHING EQUIPMENTS

 Primary Gyratory Crusher  Cone Crusher  Four Roll Crusher  Reversible Hammer Crusher  Rod Mill  Other Crushing and Mineral Processing Products

PRIMARY GYRATORY CRUSHER

Designed for heavy duty services and stable product size. Supplied over 12 nos for Coal and Iron ore crushing.

Important Parameters :

PGC 1500

Feed opening 1500 mm

Nominal Discharge 160-200 mm

Capacity (CuM/hr) 1450

Main Drive Motor 400 kw

Weight of Crusher 428 T (with out electrics)

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 Wide range of models with receiving opening ranging from 1350 to 1500 mm

 Adjustment provision for discharge setting to compensate wear & tear of concaves & mantel.

 Spider suspension of main shaft assembly.

 Optional duel prime movers

 Different models available for various output range.

CONE CRUSHER

Cone Crushers both for Secondary & Tertiary Crushing suitable for ore dressing for application in ferrous and non-ferrous metallurgical works, cement plants and construction material plants.

Important Parameters :

SHC 2200

Feed opening 130 mm

Discharge Opening 5-15 mm

Recommended deed size 100 mm

Output (CuM/hr) 75 - 220

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Main Drive Motor 250 kw

Weight of Crusher 82 T (with out electrics)

FOUR ROLL CRUSHER

For fine crushing of coke etc. for Sintering and other applications. Two stage crushing made possible in one unit. Available in various capacity range.

Important Parameters :

900 x 700

Recom. Feed size upto 40 mm

Diameter of Rolls 900 mm

Width of Rolls 700 mm

Main Drive Motor 45 kw

Other Drive 15/23 kw

Weight of machine 28.5 T (with out electrics)

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 Centralised grease lubrication

REVERSIBLE HAMMER CRUSHER

Applicable for secondary & tertiary crushing of medium hard materials such as gypsum, limestone etc. and bituminous coal. Designed for achieving very high reduction ratio. Available in various models with capacity ranging from 80 to 550 T / Hr. (Coal).

Important Parameters :

155 x 1500

Diameter of Rotor 1500 mm

Width of Rotor 1500 mm

Recommended Mx. feed size 120 mm

Product size(coal) 0-3 mm

Capacity 350-550 T/hr.

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Main Drive Motor 800 kw

Other Drive 15/23 kw

 Weight of machine 28 T (with out electrics)

REVERSIBLE HAMMER CRUSHER

Applicable for secondary & tertiary crushing of medium hard materials such as gypsum, limestone etc. and bituminous coal. Designed for achieving very high reduction ratio. Available in various models with capacity ranging from 80 to 550 T / Hr. (Coal).

Important Parameters :

155 x 1500

Diameter of Rotor 1500 mm

Width of Rotor 1500 mm

Recommended Mx. feed size 120 mm

Product size(coal) 0-3 mm

Capacity 350-550 T/hr.

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Main Drive Motor 800 kw

Other Drive 15/23 kw

 Weight of machine 28 T (with out electrics)

ROD MILL

Applicable for secondary & tertiary crushing of medium hard materials such as gypsum, limestone etc. and bituminous coal. Designed for achieving very high reduction ratio. Available in various models with capacity ranging from 80 to 550 T / Hr. (Coal).

Important Parameters :

Drum diameter 2700 to 3600 mm

Drum length 3100 to 5500 mm

Air Swept Coal Pulveriser is primarily of ball mill family and is designed for pulverising coal to prepare boiler feed.

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 OTHER CRUSHING AND MINERAL PROCESSING PRODUCTS

 Jaw Crushers  Two roll Crushers  Sinter Crushers  Apron feeders

CRANE

HEC designs and manufactures heavy duty Electric Over Head (EOT) cranes for application in Steel Plant, Engineering sector, Space Research etc. The highest capacity crane designed & manufactured so far is 450 T Ladle Crane for handling hot liquid metal.

Typical EOT Cranes:

 EOT Cranes for workshops and engineering sector up to 400 t capacity  Ladle Crane for handling Hot metal Ladles in Steel and metallurgical plant up to 450 t  Rotating Trolley Crane  Tundish Handling Crane  Magnet Grab Crane  Slab handling Tong Crane for steel plant application  Four girder double Trolley semi portal Scrap Charging Crane  Cantilever Roof mounted Tower Crane

Special Features:

 Digital AC Vector Drive for smooth control and creep speed  Regenerative Active Front End (AFE) Converters for energy efficient operation  Interface to automation systems eg. Coil Yard management system  Planetary Gear system for continuous hoisting & lowering at half speed in case of failure of

one drive system  Double wire rope, double upper Block and double bottom pulley block system to facilitate

emergency hoist operation without tilting the load in case of failure of one rope system/one pulley system

 Emergency Braking system on Hoist Rope Drum to prevent free fall of load  AC operators cabin and electrical panel room.  Weighing system with VHF communication to ground station  Anti collision system  Radio remote control

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 Automatic Track and wire rope lubrication systemSupplies made to:

 Bharat Heavy Electricals Limited, Hardwar  Bhilai Steel Plant  Tata Iron & Steel Co., Jamshedpur  Bokaro Steel Limited, Bokaro Steel City, Bokaro  Visakhapatnam Steel Project, Visakhapatnam  Bhilai Steel Plant, Bhilai  Jayant Coal Handling Plant, Northern Coal Fields Ltd., Jayant  Durgapur Steel Plant, Durgapur  Rourkela Steel Plant, Rourkela  Isro, Sriharikota  Konark Met Coke Limited  Tamil Nadu Electricity Board  Neelachal Ispat Nigam Limited  Tiazhpromexport Moscow For Bulgaria  TSVETMETPROMEXPORT, Moscow For Cuba

Capacity-wise Break up:

Capacity

Nos.

Up to 50 t 102

50 t to 100 t 113

100 t to 200 t 83

250 t 3

320 t 4

400 t 1

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450 t 7

Capacity: 400 /60 T, Span : 32 M installed at a height of 46 M to handle GSLV and PSLV at ISRO, Sriharikota.

Hoist Drum of diameter 3.3 M and length 7.5 M weighing 35 T.

Fabrication of 4 Girder Ladle Crane (180 T capacity) 450 T capacity Ladle crane in Assembly Line

(a)Assembly of Rotating Trolley of a 25 T and 33 M span EOT Crane (b)18 T Capacity Tong

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TURN-KEY PROJECTS

Turn-key Project Execution:2 HEC Executes various projects in the core sectors from concept to commissioning in different sectors like mining, power, steel plants, cement engineering etc.

Fields of specialization:

 Material Handling Plant  Coal Handling Plants  Coal Washeries  Low Temperature Carbonisation Plant and Gas Treatment Plants  Tar distillation Plant & Processing Plants  Direct Reduction Plants from Iron Ore  Sinter Plants  Continuous Casting Plants for Billets, Slabs and Blooms  B.O.F. & Gas cleaning Plant  Lime Calcination Plants  Rolling Mills  Cement Plants.

Wagon tippler Wagon Tippler Complex

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  Track Hopper Complex

Stacker cum reclaimer in operation Conveyor Gallery

BC 228A, B, 231 to PB Building

Coal Handling Plant at PARICHHA Thermal Power Station (UPSEB)

Strip Caster Mill for Mdni, Hyderaba Coal Handling Plant at BINA, N.C.L. (C.I.L.)

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Wagon loading station / BINA CHP/NCL RETORTS FOR Low Temperature Carbunisation Plant ,DANKUNI / CIL

Rotory Wagon Tippler / IISCO,Burnpur Pilot Sponge Iron Plant / R&D / SAIL

Chhatak Cement Plant / BangladeshSpecial Focus:

3 Concept to Commissioning for Bulk material Handling and steel plant projects

 Feasibility studies & Site selection  Basic Engineering with Process Flow Sheets, Energy and Material Balance  Detail Specification of Plant and Process Equipment  Manufacturing, Erection, Testing & Commissioning of Plant & Equipment

SERVICES PROVIDED BY THE ORGANIZATION

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Major Achievements

 Over 550 thousand tons of equipment manufactured and supplied to Steel Sector.  Significant contribution in setting up of Bokaro and Vizag. Steel plant.  Equipment supplied for expansion of Bhilai Steel Plant.  Supplied to almost all the Steel plants of India.  Supplied over 580 Excavators (of 4.6 /5 /10 CuM capacity)  Supplied 12 numbers of 24 CuM Draglines.  Supplied over 10 numbers of Heavy Duty Gyratory 1500 TPH crushers.

 Manufactured over 300 numbers of Cranes.  Supplied over 900 Machine Tools.

500th Excavator ready for dispatch (2008)

/// Cyclotron Magnet PolesHEC successfully manufactured Magnet Poles and associated components for VECC (Department of Atomic Energy) and supplied in the year 2002.

 exceptionally low carbon steel. variation in carbon content within 0.07% and other elements within 0.10%.

 ultra clean steel, free from alloying & tramp elements and gaseous contents.  very high homogeneity level.  control of grain size and micro structure to ensure best magnetic permeability.  free from non-metallic inclusions and other ultrasonic defects.  precision machining of complex geometry shapes.

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Pole Tip Assembly Cyclotron Magnet Assembly

/// High Impact Steel for DMRL

 Two grades of steel 249 A (ABA) and 249 AB2 developed for application in NAVY.  Excellent Mechanical properties of the material achieved which is the manifestation of its

internal soundness and cleanliness of steel composition.  Impact test result achieved 170 Joules / cm2  Commercial production of the established grade of steel started.  A mile stone achievement in Indian metallurgy

/// Contribution to Nuclear Energy

 HEC has successfully manufactured special forging of nuclear gradel.  The ultra clean liquid steel has been developed with close control of chemical composition &

impurities.  HEC has now established the technological processes and controls needed to make forgings

for nuclear power sector.  CNC Vertical Turning & Boring machine for Durgapur Wheel and Axle Plant

15 nos. of machines were manufactured with Automatic Wheel Handling System to cater the production of 1 lakh wheels per year from rough forging to finish stage. These wheels are being supplied to INDIAN RAILWAYS for direct mounting on axles. The machines were equipped with FANUC 12 T with Auto Tool Changer.

 CNC Deep Hole Boring machineThe machine was designed & developed with Sinumerik 810 M.GA3. The machine was commissioned in 1994 at Field GUN Factory, Kanpur for deep hole drilling/trepanning of large size gun barrels. It's performance was appreciated by the user.

 CNC Planing machine for Copper Mould machiningDesigned for machining Concave / Convex profile on the copper mould to be used on continuous casting machine. The machine was developed with FANUC 0-MC CNC System for Rourkela Steel Plant, in the year 1995.

 Heavy Duty CNC Roll Turning Lathe for Rolling Mills

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4 nos. of machines were developed & manufactured for rough & finish machining of Rolls with very high skin hardness. These machines with a use of FANUC 0-TD CNC System were supplied & commissioned at Bokaro steel Plant in the year 1997.

 Wheel Lathe for Tramways  Conversion of Hydromotor to DC Feed Drive for Horizontal Boring machine  Twin Horizontal Boring machine system for Co-Co Bogie machining for CLW  HEC has successfully developed High Strength Low Alloy Steel Grade DMR-249A and 249B

for Naval Application  HEC has taken up developmental work of large size rings of special material for ISRO.

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BIBLIOGRAPHY

1. http://www.hecltd.com/ 2. https://en.wikipedia.org

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