INDUSTRIAL TRAINING
REPORT
TRAINEE
Name ISGEC
Branch Yamuna Nagar
Department MBD
Address ISGEC, NH-73A, YNR
ORGANIZATIONAL ADMINISTRATORS
Prologue 1
Acknowledgement 2
Chapter 1
ISGEC- A BRIEF PROFILE 3
Chapter 2
ISGEC- AN OVERVIEW 4
Chapter 3
PROJECT- CONSTRUCTION & INSPECTION OF PRESSES 8
3.1 Preparation Shop 8
Chapter 4
MECHANICAL PRESS 21
4.1 Principle 21
4.2 Advantages 21
After achieving the proper goal in life, an engineer has to enter in professional life. According to this life, he
has to serve an industry, may be public or private sector or self-own. For the efficient work in the field, he
must be well aware of the practical knowledge as well as theoretical knowledge.
To be a good engineer, one must be aware of the industrial environment and must know about management,
working in the industry, labor problems etc. so he can tackle them successfully.
Due to all the above reasons and to bridge the gap between theory and practical, our engineering curriculum
provides a practical training of 6 weeks. During this period, a student works in the industry and gets all type
of experience and knowledge about the working and maintenance of various types of machinery.
I have undergone my summer training (after 2nd yr.) at ISGEC HEAVY ENGINEERINGS LIMITED. This
report is based on the knowledge, which I acquired during my training period at the plant.
Gumesh Rana
09-ME-340
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ACKNOWLEDGEMENT
With a sense of great pleasure and satisfaction I present this industrial training report. Completion of this
report is no doubt a product of invaluable support and contribution of a number of people.
I present my sincere gratitude to my father MR. V.S. Rana (Sr. Mngr. MBD Planning), Mr. Rajendra
Agnihotry (Head, Training & Development), MR. Dhamender Sharma (PVD-QA), Mr. Bharti (Head,
Preparation shop) of ISGEC for being a constant guide, inspiration and a source of illumination throughout
this entire period. Without their support this would not have been possible.
Gumesh Rana
09-ME-340
2
Chapter 1
ISGEC-A BRIEF PROFILE
ISGEC (formally Indian Sugar and General Engineering Corporation) is an Indian multinational boilers,
Process plant, Sugar plant and agricultural equipment company headquartered in Noida, India. It is one of
Asia's largest Sugar Plant Machinery producers.
It produces various types of machines, including boilers, Steel casting, Presses and Sugar Machinery. It has
its manufacturing unit in Yamunanagar, Noida, Muzaffarnagar, Dahej and its products are sold in over 66
countries.
• ISGEC has been approved by Lloyds Register Asia (LRA) of quality assurance as an ISO-9001:
2000 company.
• The American Society of Mechanical Engineers (ASME) approves ISGEC for the use of ASME ‘U’,
‘U2’, R & S code stamps.
• Lloyds Register Asia as class-I Manufacturing of Fusion welded pressure vessels approves ISGEC
up to 200 mm thickness.
• Engineers India Ltd. (EIL) approves ISGEC for Manufacture of vessels and columns in carbon and
alloy steels up to 155mm thickness and in clad steel up to thickness of 130mm.
• Engineers India Ltd. approves ISGEC for Manufacture of Heat Exchangers up to maximum tube
sheet thickness of 300mm.
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Chapter 2
ISGEC-AN OVERVIEW
ISGEC the heavy engineering unit of Saraswati industrial ltd. was established in 1946 and is located at
Yamunangar, Haryana about 200kms from New Delhi. The annual turnover of ISGEC is US $ 50 million
and group turnover of the Saraswati Industial Syndicate ltd. Exceeds US $ 100 million.
Infrastructure
• Lifting Capacity : Crane capacity- 200 MT
(Hydraulic Lifting arrangement for heavier loads up to 250 MT)
Forming
• Rolling : Thickness - 200 mm (8 inches)
Welding
• Narrow Gap Welding with seam tracking
• Twin wire and tandem head welding SAW, SMAW, TIG, and MIG etc. Over 850 WPS and 1000
PQR
Drilling
• Thickness up to 1000 mm ( 40 inches) using deep hole CNC Drilling machine
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Heat Treatment
• Four Gas Fired Furnaces
Size upto: 4500 mm x 4000 mm x 14500 mm
• Stress Relieving, Annealing, Quenching and Tempering as well as Solution Annealing of Stainless
Steels
Radiography
• Cobalt 60 for Radiography up to 200 mm (8 inches)
Testing
• Tensile testing including Elevated Temperature Testing up to 8000 C (14700 F)
• Ferrite Measurement
• IGC Testing
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PRODUCT RANGE
Diversity of ISGEC products range enables us to serve industry from Automobile and ship building to oil &
natural gas, defense, aeronautics and nuclear power. The group’s product range includes for;
• Hydraulic Presses, Mechanical Presses & Press brake. ISGEC has successfully commissioned
around 100 presses built include a 3700 tones hydraulic presses for defense and a 2500 tones
mechanical press.
• Process plant equipment (pressure vessels, heat exchangers, columns, storage and transport vessels,
reactors etc.) for fertilizer refinery, petrochemical and other industries.
• Industrial & power boilers(including pulverized fuel boilers up to 60 MW size bubbling as well as
circulating fluidized bed boilers up 200 TPH size).
• Custom made equipment for India’s nuclear establishments. ISGEC has supplied equipment during
last 15 years to Bhabha Atomic Research Center, Nuclear power Corporation, center of advanced
technology.
• Chlorine, Ammonia and other gases containers. ISGEC are the largest manufactures of chlorine in
the world.
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DIVISION OF ISGEC
The various divisions of ISGEC are as follows;
• PVD-I
• PVD-II
• PVD-III
• PVD-IV
• FABRICATION SHOP-I,II
• MACHINE SHOP-I,II
• ASSEMBLY SHOP
• QUALITY SHOP
3. FOUNDRY GROUP (FG)
Foundry group is the third important group of ISGEC and it is responsible for casting of large castings for
the big industries.
4. TUBE SHOP
Tube shop deals with tube manipulation and fabrication of tubing system used in economizers and super-
heaters.
5. CONTAINER SHOP
Container shop manufactures chlorine, ammonia and other gases containers.
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Chapter 3
PROJECT- CONSTRUCTION & INSPECTION OF PRESSES
The step by step procedure followed during the project & explanation of the same is as follows;
3.1Preparation Shop
This is where the raw material for production is brought in initial stage and it is identified as per the
specification. The scope of Preparation shop is to prepare material required by various other shops.
The tentative load or the amount of material required is set in starting of the financial year i.e. October. The
quantity depends upon the delivery date & the requirement of the customer,
The raw material is firstly identified & then is brought inside the shop where cutting operations are
performed by using manual Gas cutting & CNC machines on the material as per requirement for its
fabrication.
The two main requirements for cutting the material are drawing, and information about material.
The cutting machines are CNC which require some operator to feed the program and the cutting is done as
per the program. Most of the programs are made by the operators while some complex programs are made
by supervisors.
The programs are compiled in AutoCad & are feed directly to CNC through Burney LCD scanner.
A) Gas cutting
A cutting torch is used to heat metal to kindling temperature. A stream of oxygen is then trained on
the metal, and metal burns in that oxygen and then flows out of the cut as an oxide slag.
B) Plasma cutting
An inert gas is blown at high speed out of a nozzle; at the same time an electrical arc is formed
through that gas from the nozzle to the surface being cut, turning some of that gas to plasma. The
plasma is sufficiently hot to melt the metal being cut and moves sufficiently fast to blow molten
metal away from the cut.
3.2Fabrication Shop
Fabrication shop is one of the constituents of the machine-building division. Almost all sort of fabrication
work are done here. In this shop thick sheets of mild steel are cut, welded and bent according to the required
design. For the cutting of plates and sheets gas cutting technique is made use of. Then different cut parts are
joined together with the help of welding.
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Some of the welding techniques adopted are
• Semi Saw
The bending of sheets is preferred in hydraulic presses. For bending, a specific type and size of the die is
kept under the plate to be bent and then hydraulic pressure is applied above the plate. Extent of bending
depends upon the radius of curvature of arc formed by bend plate. Gouging is used for repairing faulty weld
joint.
• Gas Cutting
Instructions
1. Select the optimum plasma cutting machine as per the supervisor’s instructions.
3. If cutting is through gauging, then leave 1.5mm from marking punch & start cutting.
General Instructions
1. Clean the surface before cut.
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Width in mm Size of nozzle in inch Oxygen pressure in Acetylene pressure in
kg/cm2 kg/cm2
• Cold Bending
1. Check machine and dye as per requirement.
5. Bend the job slowly and on completion check the size with the help of template.
6. Set priorities for fitting as per supervisor’s instructions and drawing or ND table given by Quality
Assurance.
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7. Fit job as per drawing or layout.
8. Mark job no., drawing no., mark no., serial no., and fabrication weight which must not exceed 5
tons,
• Painting a Job
1. Collect required information about job from supervisor.
2. Check for rust, oil or grease or any kind of dust material on job.
3. Before painting, check that job is grit blast or wire brushed as per job drawing.
• Hydro-testing
1. According to supervisor’s instructions, set job’s position keeping in mind the position of air packet.
2. Collect at least 2 pressure gauges as per the test pressure given in job drawing,
3. Range of pressure gauge must be between 1.5-4 times the test pressure.
5. Gauge must be placed at a place from where its reading is easy to read.
6. Tight all gauges and close all job openings before applying pressure.
7. Apply test pressure as per supervisor’s instructions and check for leakage and report the same.
• Welding
1. Collect information about the job and type of welding from supervisor.
2. Select appropriate machine and check for its calibration and connections.
3. Check WPS or shop welding record of job and check for your qualified position.
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5. Issue a maximum of 15 electrode and filler wire for MIG/TIG.
6. Weld according to WPS and test Route run OP of 10% part of groove size more than 10mm.
• Blast Cleaning
Stage I
1. Clean job from grease, oil, etc.
2. Blast job as per SA 2 ½ Swedish standard SIS055900. Check surface profile by comparing it with
standard full size photograph.
3. If blast cleaning is not possible, clean grease with the help of D-slagging gun or Wire brush.
Stage II
2. Job must be properly cleaned and dry. Never clean with the help of a cloth.
4. Use primer epoxy Zinc Chromate only, and ensure that it’s not more than 12 months old.
5. Ensure primer is in 2 packs and mix its plate and hardener as per instructions below.
A. For mixing Zinc Chromate use 3 parts of paste and 1 part of hardener, use epoxy thinner to dilute
the paste.
Pot life for such a primer is 3-4hrs use brush or spray gun to apply primer.
B. Keep in mind the time required by primer to dry. For Touch dry it is 1hr. For Handle dry is 4hrs.
And hard dry is 12hrs.
For Steel Structure
Same as for Oil tank above, except the use of Zinc Phosphate primer.
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2. Rough the primered surface with emery paper and clean dry with the help of cloth.
3. Each outer surface of job that is visible and is primered is coated with a layer of Putt. For the same,
Putty is prepared as below;
4. Take 9 parts paste and 1 part hardener. Use epoxy thinner to dilute the mixture. Stir a rod or stirrer.
Pot life is of 3-4hrs.
5. Apply the prepared Putty with the help of knife. Dents are filled up with the help of Putty. It takes
12hrs to dry.
9. Cover the entire machined surface with PVC tape, Grease, Oil, etc.
11. Use PU surface only and use 9 parts with 1parts Hardener and prepare that much only which can be
utilized within 4-6hrs. Give at least 4hrs after applying to dry.
2. Ensure the job free from any kind of dust particles, if so, clean the surface with help of surface
thinner,
6. Use 80 Grit Sanding disc in sander and plane those surfaces where putty is applied.
8. Use paint where PU surface has been applied and give paint time to dry.
11. Use Zinc phosphate primer on inside parts and those parts that touch ground.
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12.Uncover all the parts and clean them properly.
SAW is normally operated in the automatic or mechanized mode. The process is normally limited to the flat
or horizontal-fillet welding positions.
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Fig. 3.2 Pieces of slag from Submerged arc welding
Electrode
SAW filler material usually is a standard wire as well as other special forms. This wire normally has a
thickness of 1/16 in. to 1/4 in. (1.6 mm to 6 mm).
2. Arc voltage
3. Travel speed
5. Polarity and current type (AC or DC) & variable balance AC current
Weld Layer Electrode Size Current (A) Voltage (V) Speed (IPM)
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Advantages
1. High operating factors in mechanized applications.
3. Sound welds are readily made (with good process design and control).
4. High speed welding of thin sheet steels up to 5 m/min (16 ft/min) is possible.
9. Welds produced are sound, uniform, ductile, corrosion resistant and have good impact value.
10. Single pass welds can be made in thick plates with normal equipment.
11. The arc is always covered under a blanket of flux, thus there is no chance of spatter of weld.
Limitations
1. Limited to ferrous (steel or stainless steels) and some nickel based alloys.
4. Flux and slag residue can present a health & safety concern.
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Fig. 3.3 GMAW Circuit diagram. (1) Welding torch, (2) Workpiece, (3) Power source, (4) Wire feed unit,
(5) Electrode source, (6) Shielding gas supply
Equipment
Welding gun
The typical GMAW welding gun has a number of key parts—a control switch, a contact tip, a power cable,
a gas nozzle, an electrode conduit and liner, and a gas hose. The control switch, or trigger, when pressed by
the operator, initiates the wire feed, electric power, and the shielding gas flow, causing an electric arc to be
struck. The contact tip, normally made of copper and sometimes chemically treated to reduce spatter, is
connected to the welding power source through the power cable and transmits the electrical energy to the
electrode while directing it to the weld area. The gas nozzle is used to evenly direct the shielding gas into
the welding zone—if the flow is inconsistent, it may not provide adequate protection of the weld area.
Fig. 3.4 GMAW torch nozzle cutaway image. (1) Torch handle, (2) Molded phenolic dielectric (shown in
white) and threaded metal nut insert (yellow), (3) Shielding gas diffuser, (4) Contact tip, (5) Nozzle output
face
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Wire feed unit
The wire feed unit supplies the electrode to the work, driving it through the conduit and on to the contact
tip. Most models provide the wire at a constant feed rate, but more advanced machines can vary the feed
rate in response to the arc length and voltage.
Electrode
Electrode selection is based primarily on the composition of the metal being welded, the process variation
being used, joint design and the material surface conditions. All commercially available electrodes contain
deoxidizing metals such as silicon, manganese, titanium and aluminum in small percentages to help prevent
oxygen porosity. Some contain denitriding metals such as titanium and zirconium to avoid nitrogen
porosity. Depending on the process variation and base material being welded the diameters of the electrodes
used range from 0.7 to 2.4 mm but can be as large as 4 mm.
Shielding gas
Shielding gases are necessary for gas metal arc welding to protect the welding area from atmospheric gases
such as nitrogen and oxygen, which can cause fusion defects, porosity, and weld metal embrittlement if they
come in contact with the electrode, the arc, or the welding metal. The choice of a shielding gas depends on
several factors, most importantly the type of material being welded and the process variation being used.
Pure inert gases such as argon and helium are only used for nonferrous welding; with steel they do not
provide adequate weld penetration (argon) or cause an erratic arc and encourage spatter (with helium).Pure
carbon dioxide, on the other hand, allows for deep penetration welds but encourages oxide formation, which
adversely affect the mechanical properties of the weld. Its low cost makes it an attractive choice, but
because of the reactivity of the arc plasma, spatter is unavoidable and welding thin materials is difficult. As
a result, argon and carbon dioxide are frequently mixed in a 75%/25% to 90%/10% mixture. Shielding gas
mixtures of three or more gases are also available. Mixtures of argon, carbon dioxide and oxygen are
marketed for welding steels. Other mixtures add a small amount of helium to argon-oxygen combinations,
these mixtures are claimed to allow higher arc voltages and welding speed.
Advantages
1. Because of continuously fed electrode, MIG welding process is much faster as compared to TIG or
stick electrode welding.
3. Thick and thin, both types of work pieces can be welded effectively.
6. No flux is used. MIG welding produces smooth, neat, clean and spatter free welded surfaces which
require no further cleaning. This helps reducing total welding cost.
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7. Higher arc travel speeds associated with MIG welding reduce distortion considerably.
Disadvantages
1. The process is slightly more complex as compared to TIG or stick electrode welding because a
number of variables (like electrode stick out, torch angle, welding parameters, type and size of
electrode, welding torch manipulation, etc.) are required to be controlled effectively to achieve good
results.
3. Since air drafts may disperse the shielding gas, MIG welding may not work well in outdoor welding
applications.
4. Weld metal cooling rates are higher than with the processes that deposit slag over the weld metal.
2. SWIFT Lathe
ML-14
4. SACEM- MSMG
The shop is divided in two zones of area one is the pit area and the other is outer area. Presses greater in size
and height are assembled in the outer area and those normal in size in the pit area. The final assembly
involves very precise work and therefore requires more skilled workers and experienced supervisors.
Each press is assembled according to the requirement of the customer. The assembly requires two broad
machine parts
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• Parts fabricated by ISGEC i.e. the frame and some other components.
• Parts being imported from outside that are parts like modules and brake and gear system and oil
lubrication unit.
The link frame presses are assembled with the help of tie rods which join the bottom head, uprights and top
head together. The tie rod helps to assemble them in proper positions. When the frame is ready the slide is
moved inside it and placed with the help of jigs etc. all other parts are assembled as per requirement with
the help of drawing. Once the press is complete it is tested again and again for any kind of defect before it is
dispatched.
The assembly is a complex process and involves hours of continues work the steps involved are discussed
below
5. After the assembly is over each part is punched of marked for identification and for making the work
of site workers easy.
6. After assembly the presses are tested for any fault and any faulty material is either removed or
corrected.
7. After the inspection is over the press is dismantled and is ready to be dispatched.
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Chapter 4
MECHANICAL PRESS
4.1 Principle
The power is transmitted from motor to flywheel with the help of flat or V-belt. Most commonly V-belt is
used because in case of flat belt, losses due to slip are present. When clutch are not engaged with the
flywheel drive shaft does no rotate. When air is supplied to the clutch brake assembly then at a particular
pressure of air, the liner of clutch-brake engages with flywheel and drive shafts starts rotating. There are
teeth cut on the other end of the shaft, which mesh with the larger gear mounted on the eccentric shaft. So
when pinion shaft rotates, the motion is transferred to the eccentric shaft through connecting rod or pitman,
which is mounted on the eccentric part of the shaft. In this way, rotating motion of the motor is converted in
to reciprocation motion of the slide.
4.2 Advantages
• Faster production rate than hydraulic press.
• Ease of maintenance.
• Suitable for operation viz. punching, blanking and trimming in which there is sudden release of load
at the end of cutting stroke.
• Press over loading is possible. Safe guard against over load is required.
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Need for a Die Cushion
1. To prevent slip and wrinkling during forming from a blank.
The pneumatic die cushion is mostly widely used. Standard air pressure in a pneumatic die cushion is 4-
5kg/cm2. When it is necessary to raise the pressure in a pneumatic die cushion up to three cylinders can be
used in tandem.
A hydro-pneumatic die cushion can only be used for a single stage. The blank holder pressure and knock
out pressure are the same in the pneumatic die cushion; however, in a hydro pneumatic die cushion the
knock out pressure is only about one sixth of the blank holder pressure.
All the mechanical presses are provided with a flywheel to store energy. During the idle position of the
stroke, flywheel rotates continuously on the main shaft and power to slide is transmitted through a clutch.
Clutches are of positive friction and eddy current types.
A brake is an important part of a press. It assists the clutch thereby ensuring positive and safe operation of
the press. A faulty brake can cause a major break down of the press. When the press starts the clutch must
engage only after the brake has been released and conversely, when the press stops the brake must operate
only after the clutch has been disengaged, the time lapse in each case is called time lag.
The control of provided clutches is usually limited to stop and start only. Mechanical controls are available
so that the press cycle may be either continuous. This clutch has many other special features to be designed
in to the system to suit almost any circumstances.
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4.3.3 Various Modes of Run
Inch mode
Inch controls is mainly used for setting up the tools and allows the press to run only when inch button is
pressed. When inch button is released press stops. It is the most common mode of operation.
Continuous mode
In this mode press run for predefined number of cycles. The press must be equipped with automatic feeder.
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A knockout device is normally fitted to the slide of the press, however, in a forging press it is fitted to
the head size.
4.4.2 Slide
• Pump taking continuous stroke, check for;
leakage from any pipe.
porosity during welding.
internal leakage.
4.4.3 Upright
• Sitting problem occur due to machining inaccuracy.
• Timing error
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4.4.5 Crown
• Abnormal heating of motor.
• No pumping.
4.5.1 Principles
DPI is based upon capillary action, where surface tension fluid low 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, a
developer is applied. The developer helps to draw penetrant out of the flaw where an invisible indication
becomes visible to the inspector. Inspection is performed under ultraviolet or white light, depending
upon the type of dye used - fluorescent or non-fluorescent (visible).
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Fig.4.2 1. Section of material with a surface-breaking crack that is not visible to the naked eye.
2. Penetrant is applied to the surface. 3. Excess penetrant is removed.
4. Developer is applied, rendering the crack visible.
1. Pre-cleaning
The test surface is cleaned to remove any dirt, paint, oil, grease or any loose scale that could either keep
penetrant out of a defect, or cause irrelevant or false indications. Cleaning methods may include solvents,
alkaline cleaning steps, vapor degreasing, or media blasting. The end goal of this step is a clean surface
where any defects present are open to the surface, dry, and free of contamination.
2. Application of Penetrant
The penetrant is then applied to the surface of the item being tested. The penetrant is allowed dwell time to
soak into any flaws (generally 5 to 30 minutes). The dwell time mainly depends upon the penetrant being
used, material being testing and the size of flaws sought. As expected, smaller flaws require a longer
penetration time. Due to their incompatible nature one must be careful not to apply solvent-based penetrant
to a surface which is to be inspected with a water-washable penetrant.
4. Application of Developer
After excess penetrant has been removed a white developer is applied to the sample. Several developer
26
types are available, including: non-aqueous wet developer, dry powder, water suspendable, and water
soluble. Choice of developer is governed by penetrant compatibility (one can't use water-soluble or
suspendable developer with water-washable penetrant), and by inspection conditions. When using non-
aqueous wet developer or dry powder, the sample must be dried prior to application, while soluble and
suspendable developers are applied with the part still wet from the previous step. Developer should form a
semi-transparent, even coating on the surface.
The developer draws penetrant from defects out onto the surface to form a visible indication, commonly
known as bleed-out. Any areas that bleed-out can indicate the location, orientation and possible types of
defects on the surface. Interpreting the results and characterizing defects from the indications found may
require some training and/or experience, the indication size is not the actual size of the defect.
5. Inspection
The inspector will use visible light with adequate intensity (100 foot-candles) for visible dye penetrant.
Ultraviolet (UV-A) radiation of adequate intensity (1,000 micro-watts/cm2 is common), along with low
ambient light levels (less than 2 foot-candles) for fluorescent penetrant examinations. Inspection of the test
surface should take place after a 10 minute development time. This time delay allows the blotting action to
occur. The inspector may observe the sample for indication formation when using visible dye. It is also
good practice to observe indications as they form because the characteristics of the bleed out are a
significant part of interpretation characterization of flaws.
6. Post Cleaning
The test surface is often cleaned after inspection and recording of defects, especially if post-inspection
coating processes are scheduled.
• The main advantages of DPI are the speed of the test and the low cost.
• The main disadvantages are that it only detects surface flaws and it does not work on
very rough surfaces. Also, on certain surfaces a great enough color contrast cannot be
achieved or the dye will stain the work piece
• ISO 3059, Non-destructive testing - Penetrant testing and magnetic particle testing -
Viewing conditions
27
• ISO 3452-3, Non-destructive testing - Penetrant testing - Part 3: Reference test blocks
• ASME Boiler and Pressure Vessel Code, Section V, Art. 6, Liquid Penetrant
Examination
• ASME Boiler and Pressure Vessel Code, Section V, Art. 24 Standard Test Method for
Liquid Penetrant Examination SE-165 (identical with ASTM E-165)
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