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DEPARTMENT OF PRODUCTION ENGINEERING & INDUSTRIAL

MANAGEMENT

COLLEGE OF ENGINEERING, PUNE

(An Autonomous Institute of Govt. of Maharashtra)

INPLANT TRAINING-PROJECT
REPORT ON

“PRODUCTION AND QUALITY IMPROVEMENT”

AT

THERMAX Ltd BY

ANKIT JHA (111513031)

T. Y B. Tech

Production (Sandwich)
UNDER THE GUIDANCE OF

Dr. AJINKYA TANKSALE

Year 2017-18
DEPARTMENT OF PRODUCTION ENGINEERING &INDUSTRIAL
MANAGEMENT

COLLEGE OF ENGINEERING, PUNE

(An Autonomous Institute of Govt. of Maharashtra)

CERTIFICATE

This is to certify that Mr. Ankit Jha has carried out her Industrial In-plant Training
during his training at “THERMAX Ltd.” in partial fulfillment of the requirement of the V
Semester TY Course of Production Engineering (Sandwich), at the Department of
Production Engineering and Industrial Management, College of Engineering, Pune
411005 during the Academic term: 2017–18.

Date:

Place: Pune Dr. AJINKYA TANKSALE

(Guide)

Dr. Rajeev Prof. and Head,

Department of Production Engineering,

(External Examiner) & Industrial Management,

College of Engineering, Pune.


Abstract:

The target of the company is to increase the productivity and increase the accuracy.
This is done by reducing the set up cost and manual fatigue. Thus, production can
be achieved using jigs and fixture. For large scale machining of different jobs, a lot of
time is wasted in set up of the job and clamping the job. Trial and error method is
usually practiced until the job is properly aligned on the rotating table. In such a
situation a lot of time is being wasted to maintain alignment. Eventually it increases
the operator’s fatigue. Thus, guiding fixture increases productivity by eliminating
individual positioning, marking and frequent checking. The main advantage of the
fixture is interchangeability. The need of selective assembly is eliminated. The parts
of the fixture will fit properly and in the assembly and all similar components are
flexible. Also, a fixture reduces the repetitive nature required for marking and
checking because the locating, clamping and guiding of the job is done by the fixture
itself. The work guiding element is to guide the work in to the correct position. Hence
the requirement of skilled laborers is eliminated. A fixture is a production tool. The
main aim is to locate, hold and support the work securely so that the required
machining operations can be performed. It also increases the safety of the workman.
A fixture must be easily fastened with the table and the machine. As a result, the work
can be done. Fixture is largely used as a vice, milling, grinding, faceplate, boring to
locate the work piece. But it can also be used for other operations on most of the
standard machining tools like drilling machine and to hold work piece on saw
machine. Fixtures can also help to simplify the metalworking operations which are
performed on the special equipment. Fixtures are available in different shape and
sizes ranging from simple and cheap devices to very expensive and complicated
devices. Considering the advantages of jigs and fixtures, a fixture was designed to
cater to our needs.
AKNOWLEDGEMENTS:

I have taken efforts in this project. However, it would not have been possible without
the kind support and help of many individuals and organizations. I would like to extend
my sincere thanks to all of them.

I am highly indebted to Mr. Tushar Belhekar for his guidance and constant
supervision as well as for providing necessary information regarding the project &
also for his support in completing the project. I also want to express my gratitude to
Mr. Vitthal Nibe and my team mates in Quality and maintenance Department who
helped me in each step to make this project a success.

I would like to express my gratitude towards my parents & member of THERMAX


LTD. for their kind co-operation and encouragement which help me in completion of
this project. I am grateful to Dr. Ajinkya Tanksale my college mentor who supported
me for the whole concept of the project.

I would like to express my special gratitude to Mr. Sachin More and thanks to industry
persons for giving me such attention and time.
CONTENTS

1. Company Profile. 5

1.1. Introduction. 5

1.2. Production Services Group (PSG). 8

1.3. Factory Management Group (FMG). 9

2. Plant – 5. 11

2.1. Plant Objectives. 11

2.2. Plant Processes. 11

2.2.1. Plate Marking. 13

2.2.2. Shell Fabrication. 15

2.2.3. Barrel Fabrication. 17

2.2.4. Capsule Fabrication. 17

2.2.5. Nozzle Hole Drilling. 18

2.2.6. Hydro Test. 19

2.2.7. Drum Assembly. 19

3. Plant – 12. 21

3.1. Product Range. 23

3.2. Coil Making. 23

4. Plant – 15. 27

4.1. Operations done in Plant-15. 27

5. Weld Inspection Method. 30

5.1. DP Test. 30

5.2. MPI Test. 32

1
6. Assignment No: 1. 37

7. Assignment No: 2. 50

8. Conclusion. 57

References. 58

2
List of Figures

Fig. 1. THERMAX. 5

Fig. 2. THERMAX Products. 6

Fig. 3. Shell Fabrication. 16

Fig. 4. Boiler Drum. 20

Fig. 5. Economizer. 26

Fig. 6. Die Penetration Test. 32

Fig. 7. Magnetic Particle Inspection Test. 36

Fig. 8. Dished End. 38

Fig. 9. Placing D/E at center of rotating table. 39

Fig. 10. Checking position of D/E on rotating table. 39

Fig. 11. Various aspects of fixture design. 41

Fig. 12. Fixture implemented on rotating table. 42

Fig. 13. D/E center guiding fixture. 43

Fig. 14. Fixture 2-D drawing. 43

Fig. 15. Cutting. 47

Fig. 16. Grinding. 47

Fig. 17. Drilling. 47

Fig. 18. Threading. 47

Fig. 19. Rectangular plate. 51

Fig. 20. D/E and man hole. 52

Fig. 21. Circular Burner. 53

Fig. 22. Design of fixture of burner for pre-heating. 55

3
List of Flow Charts

Flowchart 1: Stages of Drum Manufacturing. 12

Flowchart 2: Coil Making. 24

List of Tables

Table 1: Specification of Cutting Machine. 14

Table 2: Plant-12 Machinery. 22

Table 3: Material of Different parts of fixture. 45

Table 4: Job Constraints. 48

Table 5: Temperature of pre-heating required for different thickness. 53

Table 6: Man hours required to heat the blank of different diameters. 54

4
CHAPTER 1: COMPANY PROFILE

1.1. INTRODUCTION:

Thermax is a leading, global company specializing in the areas of generation and


conservation of energy and preservation of the environment. With an annual turnover
of US $500 million, the company provides integrated services and equipment in
Boilers and Heaters, Captive Power, Cooling, Water Waste Solution and chemicals.
It has joint ventures with Babcock & Wilcox and Energy Performance Services. The
company has a global reach, with 11 overseas offices and a domestic network of 12
sales & service offices.

1. Thermax – Babcock & Wilcox LTD:

For designing & manufacturing of high pressure, high capacity water tube
boilers & merger of energy division with it.

2. Thermax-energy Performance service LTD.:

This collaboration was made to support energy division & also for research
works in waste flue gas utilization techniques.

Fig 1. THERMAX

5
THERMAX LIMITED

ENERGY ENVIRONMENT

Absorption Chillers Air Pollution Control

Power Plant Equipment & Water & Waste


Services
Chemicals
Power

Boilers

UTILITY LARGE PACKAGE


BOILERS INDUSTRIAL

Fig 2. THERMAX PRODUCTS.

Thermax Limited, a leading player in energy and environment management, it


presented its audited financial results for 2005-06 announcing a 32 % revenue growth
to Rs.1464.9 crores. Exports increased 21% to Rs.307.6 crores. Consolidated
revenue for the group climbed 29 % to Rs.1606.2 crores. Thermax Ltd, Profit after
tax in 2005-06 at Rs.123.3 crores were up 77%. Earnings Per Share was Rs.9.69 on
face value of Rs.2/- per share. Operating profit margin increased 3.5% as the
transformation initiative started yielding results. Consolidated profit after tax for the
year was up 50 % to Rs.102.5 crores earning Per Rs.2/- Share was Rs.7.96 (last year
Rs.5.46).

Thermax has been rolling out a company-wide initiative to transform the way it does
business; aimed at significant increase in customer satisfaction and top line and
bottom line growth. The company is investing substantial resources in attaining
operational excellence – focusing on processes and systems that have a direct
impact on cost, quality, lead-time and on-time performance at every point of customer
engagement. The following is the detailed description of the whole organization. For
the proper & efficient working of an industry there always needs an able management
and proper departmental structure. A Company can stand only if, the
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interdepartmental relationships is good and there is a perfect rhythm in their
workability. Thermax is no exception for this statement its departments work with full
potential and with perfect cooperation of each other. Following are some of them.

a) Production- This department looks after the manufacturing of different products


of the company. All the production plants come under this department. This
department may be called as heart of the company. Its responsibility includes,

1. Manufacturing and assembly of a boiler unit.


2. Interplant loading and unloading of job accessories and spares.
3. Internal House-keeping in the plant.
4. Day to day planning of shop floor activities.

b) Maintenance - This department look after the proper working of machine, their
maintenance and their repair. It also looks for the maximum utilization of the
currently used machines.

c) Welding Engineering Department- this department look after the welding and
related activities:

1. To look after the Welding Training School (WTS).

2. To train newly recruited/apprentice welders.


3. To train present welders in new welding techniques.

4. To look after welding machine and shop floor welding activities.

5. To assist shop floor in complex welding designs and situations.


6. To introduce advanced welding technology with the help of MED &
Maintenance.

d) Quality Control/Assurance Department (QC/QA)-

This department performs the useful process of quality Control and its assurance,
from the customer as well as factory point of view:

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1. To audit, standardize, frame & implement ISO 9001(1994) quality standards
procedures
2. To inspect and test daily production (NON IBR jobs).
3. Take measure to improve current quality standards.
4. To meet customer’s quality requirements.
5. To train people regarding total quality philosophy.

e) Quality Control (IBR CELL) -Since boiler manufacturing is a specialized


process, its necessary to follow strictly IBR procedures for the production
processes, designing, quality measures etc. Thermax has taken care of them all
and this cell works for the same purpose. Its duties are as follows,

1. To check and offer boiler quality plates layouts, components and


accessories.
2. To check whether IBR procedures are followed or not.
3. To inspect critical welding areas and suggest changes/correction (if any).
4. To inspect whole boiler assembly and offer it to external IBR officers.
5. To get certified boiler design and testing capacities as per IBR acts.
6. To train people about IBR quality philosophy.

1.2. Production Services Group:

This group though not takes part in actual production but works for betterment of
industrial processes and relations. It includes,

a) Manufacturing Engineering Department (MED)- This one assist


manufacturing in their daily work and look after their daily needs for proper working.
Its working areas are

1. Providing shop floor drawings and designs.


2. Designing fixtures, jigs, special purpose m/c, clamp etc. as per
requirement.
3. To look after and maintain self-produced machines.
4. To check workability of presently used machines.
5. To help production department in their day to day activities.

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6. To deal with vendor regarding externally designed and manufactured
components.

b) Industrial Engineering Department- This concentrates on improving product


layout, standardizing norms based on improvements. The IED engineers are
actively involved in Standard man-hour (SMH) estimation for new jobs,
manufacturing budgeting; identification of area for cost reduction, preparation and
conduction of shop and off.

1.3. FACTORY MANAGEMENT GROUP (FMG):

Same as above, this group does not play role part in direct production but helps
production people to carry out their work in successful, safe and efficient manner.
It includes:

a) Civil Maintenance: This department maintain the civil structures and amenities
such as buildings, Ponds, garden, water supply, electricity supply, waste handling
and other factory civil works.

b) Industrial Safety: This department takes care of safety procedures to be


followed in plant, to enhance accidents free environment, to identify and eliminate
unsafe acts and conditions in factory premises, to nurture total safety policy in each
employee.

c) Waste Management Cell: This department works for the disposal of non-
performing assets and Factory arising lots. It also works for the waste/scrap
reduction and utilization.

d) ISO 14001: With a view to enhance perfect environmental conditions in the


factory premises this department was introduced in the company & its job is to frame

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and implement eco-friendly atmosphere and to eliminate any kind of wastage and
pollution creating elements.

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CHAPTER 2: PLANT- 5

2.1.

Following is a report of various manufacturing processes observed in Plant 5 of Boiler


and Heating (B&H) division at Thermax Limited. It aims to cover:

i. Sequence of the manufacturing processes.

ii. The material flow.

iii. Stages of manufacturing.

iv. Innovative machinery used to perform the same.

2.2.

The plant processes are subdivided into the following categories:

1. Plate preparation.

2. Shell fabrication.

3. Barrel fabrication.

4. Nozzle and internal attachment drilling.

5. Capsule fabrication.

6. Full welding.

7. Hydro test.

8. Drum Assembly.

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There subdivisions discussed in detail in the following report.

Flowchart 1: Plant 5 Stages of Drum Manufacturing.

Flowchart 1: Represents the sequence of manufacturing processes.


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2.2.1. Plate marking:

Shot blasted plate is the input material for the shell making. Plate marking process
involves laying out the reference line (RL), Bevel line (BL), Cutting line (CL) on the
shot blasted plate as per indicated on the engineering drawing. The reference line is
used to guide the rail of the gas-cutting machine. The cutting line indicates the end
plane of the plate. The bevel line indicates the line of initiation of bevel provided to
the plate. If the plate thickness is greater than 40mm, a pre-pinch allowance is given
to the plate and the corresponding distance is added on both sides of the plate before
it is gas cut. Oxy acetylene flame is used to Gas-Cut the plates at the designed bevel
angle. For plates, thicker than 20mm LPG gas cutting is used else Oxy-Acetylene gas
cutting is performed.

Formula used for plate marking:

Length of Shell = Mean Diameter (ID + THK) x (22/7) + Pre-pinching


allowance + Test plate allowance

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Specification of KOIK IK-12 Elite portable cutting machine:

Material Thickness 3 to 6 mm 12 to 18 mm 25mm 50mm

Cutting nozzle size A8 A12 A16 A16

Oxygen pressure kg/cm2 2.5 2.5 2.8 3.5

DA Pressure kg/cm2 3.15 0.15 0.15 0.15

Cutting speed cm/min 21 45 68 21

Table 1: Specification of cutting machine.

Punch on plate:

WH064100: Job number.

HT NO-085506: Heat number.

A heat number is an identification coupon number that stamped on material


plate after it remove from the foundry and rolled at still mill.

First digit corresponds -furnaces number.

2nd digit -year when material was melted.

Last four digit-melt number.

PL NO-5264111: Plate number.

SA 516 G70: Grade number.

DRG NO.: Drawing number.

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2.2.2. Shell Fabrication:

The final product of Plate preparation is the cut and bevelled plate of required
dimensions. The first step of shell fabrication is the Rolling process. The length of the
plate is calculated with reference to the required diameter of the shell. Himalaya
Rolling machine, which has a capacity to roll a maximum of 90mm plate, is housed
in plant 5. It has three rollers. The upper roller is stationary while the two rollers below
can be moved radially towards the stationary roller, thus resulting in rolling action on
the plate. Key features of the Himalaya Rolling machine:

Make: Himalaya.

Min Thickness of plate required for rolling: 10mm.

Max Thickness of plate than can be effectively rolled: 90mm.

Length of plate, that can be accommodated for rolling: 2.5m.

Diameter of each roller: 760mm.

The plate is rolled in the Himalaya bending machine and depending on the
requirement of pre-pinching, it may be pre-pinched and re rolled into the required
diameter. On completion of rolling process, the rolled plate is heated and tacked
using arc welding to prevent opening of the closed roll.

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Fig 3: Shell Fabrication

 The tacked roll is set on the Inner SAW welding machine. Test plates are
attached to the rolled plate and the shell undergoes longitudinal inner SAW
welding.

 It is followed by back gauging process. The back-gauging process involves


changing the outer V- groove into a U- groove by grinding. BG is done to
increase the weld deposition volume and thus impart strength to the weld.

 After BG, the shell proceeds to outer SAW weld and flush grinding. Die
penetrant test is performed after the SAW weld is completed to ensure crack
and defect free weld.

 The test plates are now removed and passed on for destructive and non-
destructive testing to check the weld quality and strength.

 The shell is now ready and is re-rolled and handed over for Radiographic
inspection to ensure proper weld condition.

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2.2.3. Barrel Fabrication:

 Ready shell is the input to this manufacturing section.

 Two or more shells are placed along side and the total length of the barrel is
inspected and verified if it matches to the requirements.

 The longitudinal seams of two adjacent shells are never aligned, but possess a
specified angle offset for safety reasons.

 The shells are aligned with respect to each other and tacked, so that there is
no relative motion between the shells during rotation of the barrel during further
welding processes.

 This process is followed by a sequence of inner circumferential weld,


circumferential back gauging, outer circumferential SAW.

2.2.4. Capsule Fabrication:

 Capsule is recognized when dish-ends are attached to barrels.

 Dish-ends are manufactured by drawing flat plates into hemispherical shapes


of required diameters.

 Dish ends are initially marked with manhole positions and then gas cut.

 Manhole is set upon the gas cut portion of the dish-end. Depending upon the
requirement the man-hole height inside the dish end is set and the manhole is
tacked on the Dish-end.

 The manhole and dish-end undergo an inner SAW welding followed by back
gauging and an Outer SAW weld.

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 The welds are flush grinded and the area adjacent to the welds is finished for
making the surface suitable for an Ultrasonic test.

 The welds are inspected by ultrasonic testing and thus defect free welding is
ensured.

 The dish-ends are given appropriate bevel angle and are joined to the
barrel with same procedure as that used in barrel fabrication for
circumferential welding to complete the capsule fabrication process.

2.2.5. Nozzle Hole drilling:

 The capsule is setup on the rollers and quadrant marking is done on the
capsule.

 With reference to the quadrants, the nozzles are marked on the capsule.

 Juristic machine is used for nozzle drilling on the capsule

 The holes are de-burred and inspected using GO and NOGO plug gauges

 Hole measurement is performed using Vernier callipers and gauged using plug
gauges.

 Nozzles are attached to the nozzle holes and inspected Nozzles are fillet
welded and finished

 This is followed by stress relieving and radiographic inspection.

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2.2.6. Hydrotest:

 The drum is now subjected hydro testing.

 Preparing the capsule for hydro testing includes sealing all the capsule
openings with hydro blanks plates. The hydro blanks are welded to the nozzles
on the capsule.

 Capsule is filled with water and is subjected to 1.5 times the working pressure.

 The expansion is noted, and these values are tallied with the standard
readings.

 If the expansion is within the permissible limits, the capsule is passed by the
QC inspector and promoted to the next stage of the process.

2.2.7. Drum Assembly:

 During final assembly of Capsule, the nozzle blanks are cut, and the end of
the nozzles are grinded and finished to facilitate on site welding.

 The drum is now shot blasted and painted before final assembly.

 This is followed by a final Quality Check and handed over.

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Fig 4. Boiler Drum.

Plant 5 also possesses All Weld Area which deals with manhole cover making,
nozzle stub making.

It is specially dedicated to the nozzle making which includes pipe cutting, lathe
operations like facing to adjust nozzle length, turning to adjust nozzle diameter.

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CHAPTER 3: Plant -12

The report on this shop aims to cover the

 Manufacturing processes involve in coil manufacturing (economizer,


Evaporators coils) convection tubes, in bed tubes, fire heaters, exhaust gas
boiler part manufacturing, oil and gas skids.

 Materials used in the plants

 Machinery used for special manufacturing requirements

The following table enlists various machines Plant 12 and their significance:

Sr. No Machinery Quantity Remark

1 Bending Machine 2 Max bend angle :1800

OD range: 21 to 76

2 Welding Transformer 32 TIG, Kempli

Master cool 10

3 Tube strengthening Machine 1

4 Tube expansion Machine 1 Saynak Hydraulics

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5 Projection Welding machine 3

6 Electric Abrasive Machine 4

7 Lathe 1

8 Power Hack Saw cutting Max OD: 220mm

Machine Max Thickness:

1. Chudasma Precision 1 50mm

Tools, Harihar

2. Ganga Precision 1

Industries, Coimbatore

9 Chamfering Machine

1. Dolphin Special 2

Machine Technologies,

Chennai

2. Thakoor Technologies 1

Table 2: Plant 12 Machinery

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3.1. Product Range:

1. Super heater coils

a) Bi-drum type boilers.

b) Process Integrated Boilers (PIB).

c) CFBC.

2. Economiser

3. Evaporator Coils

4. Exhaust Gas Boiler (EGB)

a) Draught Natural Circulation

b) Draught recirculation

5. Fire heaters

6. Headers

7. In bed tubes (IBT)

8. Boiler bank tubes (BBT)

9. Convection Tubes (CBT)

10. Oil and gas Skids

3.2. Coil Making:

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Flow Chart 2: Coil Making

Explanation:

3.2.1. Tube cutting:

Tubes of required OD and thickness are procured and cut at appropriate


lengths required for coil making

3.2.2. Tube end chamfering:

The cut tube ends are chamfered using chamfering machine. This process
serves as an edge preparation process before welding.
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3.2.3. Layout marking:

Layout is drawn with reference to the engineering drawing. This process


facilitates arrangement of pipes for correct coiling.

3.2.4. Coil bending:

The tubes are bent at required angles on tube bending machine.

3.2.5. Coil Setup:

The bent tubes are now arranged on the layout plate. This ensures proper tube
arrangement. The tube ends are clamped together, and a final coil setup is ready

It is inspected, and dimensions are verified.

3.2.6. Coil Weld:

The coil is now full welded.

3.2.7. BT, PT:

Ball test, die penetrant test etc. are performed on the coil.

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3.2.8. Weld joint RT:

Welded joints are radio graphically tested and proper welding is ensured.

3.2.9. Support Setup Weld:

3.2.10. Paint and Hand over:

Fig 5. Economizer.

26
CHAPTER 4: Plant -15

Assembly Shop:

4.1. Operations done in Plant 15:

1. Barrel to dish end setup.

2. Barrel to dish end inner SAW.

3. Barrel to dish end outer SAW.

4. Capsule Radiography test.

5. Nozzle drilling on Juristic machine.

 Nozzles marking are done prior to loading the job on juristic


machine.
 G and N codes are used to program the juristic machine to
carry out the radial drilling operation on the job.

6. Nozzle setup.

7. Down comer opening on shell.

8. Down comer setup.

9. Nozzle and down comer welding.

 All the radially drilled holes are deburred.


 The dimensions are checked using GO and NOGO gauges.
 Bore gauges are also used for gauging the holes. Dial gauges
are used to inspect the grooves

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 Dimensions are noted down after measurements using Vernier
Calliper.
 After the nozzle inspection and Quality check, the job is
forwarded for nozzle setup.
 Radial drilling is followed by nozzle setup
 After the inspection of the setup, the job is forwarded for full
welding.

10. External attachment marking and setup.

11. External attachment welding.

12. Full welding dress up and Non-Destructive Test.

13. Hydro blank welding.

a. Hydro blanks are welded to the nozzles to cover them.

b. It is by this process that it becomes possible to make the job eligible for
hydro test

14. Stress Relieving.

15. NDT after SR.

16. Hydro test.

a. After hydro blank welding, the job is filled with water and
pressurized to 1.5 times the working pressure and the
corresponding strains (elongations) are noted.

b. These elongations are compared to standard values and


based on the analysis; the quality of the job is decided.

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17. Hydro blank cutting.

After hydro test and approval from the Quality check officer, the hydro blanks are
cut, and the job is ready to be handed over.

18. Nozzle trimming and edge preparation.

Note:

Operations 1 to 5, these operations are like those performed in plant.

Heavy jobs are allotted to plant 15 and relatively smaller jobs are forwarded to plant
5 due to space and crane constraints.

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CHAPTER 5: Weld Inspection Method:

5.1. DP test:

Die Penetrant test: DP test is a widely applied and low-cost inspection method used
to locate surface-breaking defects in all non-porous materials. DP inspection is used
to detect casting, forging and welding surface defects such as hairline cracks, surface
porosity, leaks in new products, and fatigue cracks on in-service components.

5.1.1. Principle:

DPI is based upon capillary action, where low surface tension fluid penetrates 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 non-fluorescent (visible).

5.1.2. Procedure:

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. Note that if media blasting is used, it may "work over" small discontinuities
in the part, and an etching bath is recommended as a post-blasting treatment.

30
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 tested, and
the size of flaws sought. As expected, smaller flaws require a longer penetration
time.

3. Application of Developer:

After excess penetrant has been removed, a white developer is applied to the sample.
Several developer types are available, including: non-aqueous wet developer, dry
powder, water-suspend able, and water-soluble. Choice of developer is governed by
penetrant compatibility (one can't use water-soluble or -suspend able developer with
water-washable penetrant), and by inspection conditions. NAWD is commercially
available in aerosol spray cans, and may employ acetone, isopropyl alcohol, or a
propellant that is a combination of the two. Developer should form a semi-transparent,
even coating on the surface.

4. Inspection:

The inspector will use visible light with adequate intensity (1100 lux is typical) for
visible dye penetrant or Ultraviolet (UV-A) radiation, along with low ambient light for
fluorescent penetrant examinations. Inspection of the test surface should take place
after 10- to 30-minute development time, depends of product kind. 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

31
indications as they form because the characteristics of the bleed out are a significant
part of interpretation characterization of flaws.

Fig 6: Die Penetrant test

5.2. MPI Test

The aim to perform this test is to locate and inspect surface and closely located sub
surface defects on the job. The primary but crucial instances of usage of MPI as
observed at Thermax Plant 5 include inspection of Longitudinal and circumferential
welds on the shells.

5.2.1. Principle:

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The principle of the method is that the specimen is magnetized to produce magnetic
lines of force, or flux, in the material. If these lines of force meet a discontinuity, such
as a crack, secondary magnetic poles are created at the faces of the crack. The
presence of a surface or subsurface discontinuity in the material allows the magnetic
flux to leak, since air cannot support as much magnetic field per unit volume as
metals. Ferrous particles are then applied to the part. The particles may be dry or in
a wet suspension. If an area of flux leakage is present, the particles will be attracted
to this area. The particles will build up at the area of leakage and form an indication.
This helps highlight and facilitates locating the surface or subsurface discontinuity.

5.2.2. Observations:

Usage of aerosol sprays is preferred due to the easy of handling, portability and
reliability. Aerosol applied particles are like wet systems; they are sold in premixed
aerosol cans like hair sprays. It is common industry practice to use specifically
designed oil and water-based carriers for magnetic particles.

A device, Magnetic yoke is a hand-held device that induces a magnetic field between
two poles. It is used to generate the magnetic field on the testing component, e.g. it
is used to generate magnetic field along the weld to be tested. Common applications
are for outdoor use, remote locations, and weld inspection.

 Magnetic Particles in suitable carrier liquid are supplied in aerosol


containers in ready to use form, which does not need any preparation.

 Pre-adjusted concentration of particles as per International specifications


and the other parameters with reference to sensitivity etc. are assured
through Laboratory testing.

33
 Controlled mixture of extremely fine & high permeability ferro-magnetic
particles facilitates highest sensitivity.

 These products are available in two colours namely Black and Red.

 White contrast WC-23 is a contrast coat to enhance the sensitivity of the


test. It has coating thickness less than 10 microns on single application.
(The film thickness provided does not affect the magnetic field on the job
under test)

5.2.3. Main Features of magnetic particle spray:

 Extremely fine magnetic particles of very high magnetic permeability for high
Sensitivity.

 Supplied in Aerosol packages: 550 ml Capacity Net Can with Net Content 425
ml.

 Particle Concentration: 3.0 to 4.0 ml. per litre of Carrier Liquid (As per
Specifications

 Avg. Particle Size: 6 microns

 Performance Test: Satisfactory on Ketose Ring, Std. Defect Plate & ASME /
ASTM Shims

 Carrier Liquid: High flash (95 Deg.C) Petroleum Oil

5.2.4. White contrast spray WC-23:

34
Significance of using WC-23:

 Provides bright coat almost instantly thus preparing the surface for MPI

 Serves the purpose of a barrier so that the fine magnetic particles cannot
bridge the gap of the defects which otherwise can reduce the leakage field and
thus the possibility of detectability of the defect

 It results in an extremely thin and even coat. Hence does not reduce sensitivity
of MPI

 Matt finish with contrast ratio as high as 95%

 Can also be used for fluorescent MPI

 Operator friendly but using PPE is highly recommended

 Non-corrosive to the job and the film can be easily removed using WC-
Remover

 WC-23 supplied in aerosols contains hydrocarbons as propellants and hence


is ozone friendly.

5.2.5. Procedure:

1. Clean the surface to be inspected

2. Application of White contrast

3. Connect the Magnetic yoke to the power connection and ensure proper
and safe functioning

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4. Spray the magnetic particle spray over a small portion of the weld
section to be inspected

5. Immediately energise the magnetic yoke and move it along the weld
section sprayed with magnetic particles in the direction of the weld

6. Continue this procedure along the full length of the weld

7. Inspect the weld and determine if any accumulation of magnetic


particles is observed along the weld. (Usage of a light torch while
inspection is recommended)

8. The accumulation is distinctively seen as black lines on a white


contrasting back ground

Fig 7: Magnetic Particle Inspection.

36
ASSIGNMENT NO: 1

1. TITLE - DESIGN AND FABRICATION OF FIXTURE TO REDUCE SET-UP


TIME.

2. PROBLEM STATEMENT:

To reduce the set-up time in D/E to manhole setup.

3. OBJECTIVES:

 Locate & hold job in a given orientation

 Reduce set-up time

 Reduce operator fatigue

 Easy to learn & operate

 Mistake proofing.

37
4. INTRODUCTION:

a) D/E set-up activity at saw process: Plant-5

Dished end is the end part of capsule in boiler. Hemispherical, semi ellipsoidal, tori
spherical are three types of ASME (American Society of Mechanical Engineer)
pressure vessel Dished Ends. There are various attachments on the dished end like
nozzles, manholes, safety valve etc. as per boiler type. Manhole is provided on
dished end for a worker to enter and used for maintenance and cleaning. It is actual
oval access door at the top of dished end.

b) At the work station: D/E to Manhole outside SAW process

As shown in figure. For this process D/E (dished end) need to place exactly at the
center of rotating table. This whole activity was performing by worker without using
any fixture. Activities like checking, marking, and handling were consuming lot of time.
So, to adjust location of D/E on rotating table was taking lot of time. Therefore, fixture
is provided to reduce set-up time.

Fig 8: Dished End

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Fig 9: Placing D/E at the Centre of Rotating Table (before implementation of
fixture).

Fig 10: Checking position of D/E on rotating table (before implementation of


fixture).

5. Design Criteria for Fixtures:

A work holding device is a tool that establishes a relationship between the work piece
and the machine tool. Every work holding device is designed to securely support,
locate, and hold the work piece as it sustains machining forces, as shown in Figure
1. However, many variables affect the design of an effective customized fixture for
any given machining operation.

39
The responsibility of the designer is to create a fixture that is sturdy, easy to use, and
inexpensive. An effective fixture also reduces nonproductive time spent on tasks
other than machining. In small shops, the designer may also be the person who builds
the fixture. However, larger shops often employ individuals that are solely responsible
for the design of the fixture. The designer plays a crucial role in maintaining quality
while increasing production.

This class will walk you through the construction of the plate fixture shown in Figure
2 to teach you fundamental work holding design principles.

6. Fixture Design Fundamentals:

Fixture planning is to conceptualize a basic fixture configuration through analyzing all


the available information regarding the material and geometry of the workpiece,
operations required, processing equipment for the operations, and the operator. The
following outputs are included in the fixture plan:

Fixture design deals with the establishment of the basic fixture concepts

Fixture layout is an embodiment of the concepts in the form of a spatial configuration


of the fixture,

Fixture element design is concerned with the concrete details of the locators, clamps
and supports

Tool body design produces a structure combining the fixture elements in the desired
spatial relationship with the machine tool.

40
7. Fixture Design:

Fixture planning is to conceptualize a basic fixture configuration through analyzing all


the available information regarding the material and geometry of the work piece,
operations required, processing equipment for the operations, and the operator. The
following outputs are included in the fixture plan

 Fixture type and complexity

 Number of work pieces per fixture

 Orientation of work piece within fixture

 Locating datum faces

 Clamping surfaces

 Support surfaces, if any

Fig 11: Various Aspects of Fixture Design.

41
Generation of fixture layout is to represent the fixture concepts in a physical form.
The following outputs are included in the fixture layout:

 Positions of locators
 Positions of clamps
 Positions of supports, if any
 Type of locators
 Type of clamps
 Type of supports
 Clamping forces and sequence

8. DESIGNS ON SOLID WORK:

Fig 12: Fixture Implemented on Rotating Table.

42
\

Fig 13: D/E Center Guiding Fixture.

Fig 14: Fixture 2-D drawing.

43
9. MATERIAL SELECTION:

Material selection is one of the foremost functions of effective engineering design as


it determines the reliability of the design in terms of industrial and economical
aspects. A great design may fail to be a profitable product if unable to find the most
appropriate material combinations. So, it is vital to know what the best materials for
a particular design are. How we are going to get an idea about the best materials for
a design? In this aspect engineers use several facts of materials to come to the most
reasonable decision. They are mainly concentrated on the properties of the materials
which are identified as the potential materials for that specific design.

The points that are taken into consideration for designing a product are as following:

a) Fixture must be so strong that the deflection in the fixture should be as less as
possible. The deflection that is mentioned includes the forces of clamping of work
piece to the machine table. The material for guide way (base plate) of the fixture
should be selected to sustain weight of the job.

b) Another important design consideration is the clamping which should be fast


enough and require less amount of effort.

c) They should also have the arrangement for easy removal as well.

d) The clamps and support points which are to be adjusted in due course of time
should be preferred of same size. It will be better if the clamps and adjustable support
points can be operated from the front of the fixture.

e) Sliding block is used to provide sliding motion between guide way slot and holding
post. Material for sliding block should be selected such that it should provide smooth
sliding motion and as well as it should have self-lubricant property.

Therefore, cast iron material selected for sliding block.

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f) Material for holding post selected by taking into consideration of points like

Easily available, low cost, mechanical properties (like strength, hardness).as per this
carbon steel material is selected for holding post.

e) Standard bolt selected of size 18M.

k) The design must possess enough rigidity and robustness to prevent vibration else
it may lead to undesired movement of the work piece and tools.

l) Minimum cost should be incurred during the fabrication of the project and the design
should be as simple as possible. In such a way it will help even a lay man to operate
the device.

m) Materials generally used are formulated in Table

Sr. No. Part Name Material

1 Base plate Cast iron

2 Guide way Cast iron

3 Trapezoidal Block Carbon steel

4 Holding Post Carbon steel

5 Lock Nut Carbon steel

6 Nut-Bolt standard

Table 3: Material of Different Parts

45
10. MANUFACTURING PROCESS:

Manufacturing process are the steps through which raw materials are transformed
into a final product. The manufacturing process begins with the product design, and
materials specification from which the product is made. These materials are then
modified through manufacturing processes to become the required part.

Manufacturing processes used are as follows:

 Cutting

 Flush grinding

 Drilling

 Tapping

 Welding

46
Fig 15: Cutting Fig 16: Grinding

Fig 17: Drilling Fig 18: Threading

47
11. JOB CONSTRAINTS:

Parameters Constraints

Diameter 900mm to 1700mm

Weight 1 to 2 tons

Thickness 40mm to 100mm

Shape Hemispherical and


Semi-ellipsoidal

Table 4: Job Constraints

Here the job of Hemispherical and Semi-ellipsoidal shape can be machined with
constraints as shown in Table. It has no arrangement for machining a circular type of
job. However, development can be done on this product to make it suitable for
machining a circular type of job and flat job with any thickness.

12. COSTING OF FIXTURE:

 Cost of man power: -

Cost of 1 worker per day is 333Rs. Total working days are. Therefore, total cost of 1
worker is 666Rs. 2 workers were required. Therefore, cost of manpower is1332Rs.

 Cost of material:

As materials were taken from scrap and total weight of 1 fixture is 30kg. Three fixtures
were made so total weight of 3 fixtures is 90kg.

48
Rate of scrap is 28Rs/kg. Therefore, total cost of material is = 28*90

=2520Rs.

 Cost of manufacturing processes:

Total manufacturing cost is approximate is 600Rs.

 Cost of painting and punching:

Total cost of painting and punching is 100Rs

 Total cost = 1332+2520+600+100

Total cost =4552Rs.

49
ASSIGNMENT NO: 2

1. TITLE – DESIGN OF BURNER HOLDER TO REDUCE THE TIME REQUIRED


FOR PRE-HEATING THE DISHED END BLANK.

2. Problem Statement:

Time required for preheating the dished end blank is more which wastes the time
of the workers and slows down the work.

3. Objectives:

 Reduce time required for pre-heating.


 Reduce time wastage of workers.
 Easy to learn and operate.
 To make it adjustable with different diameters of dished end.

4. Introduction:

Dished end blank (D/E) is nothing but a circular plate cut from a rectangular plate.
This D/E blank after cutting goes to pressing machine to eventually make dished
end which is a part of the capsule drum to be made. D/E can be of various
thickness depending on the thickness of the job. D/E blank also has various
diameters depending on the size of the job.

50
Fig 19. Rectangular Plate.

Before the D/E blank is cut it is first heated. This is called as pre-heating. Pre-heating
is done to provide quality cut to the D/E blank. If the blank is not heated properly it
causes production of mill scales. Mill scale, often shortened to just scale, is the flaky
surface of hot rolled steel, consisting of the iron ox Dished end blank (D/E) is nothing
but a circular plate cut from a rectangular plate. This D/E blank after cutting goes to
pressing machine to eventually make dished end which is a part of the capsule drum
to be made. D/E can be of various thickness depending on the thickness of the job.
D/E blank also has various diameters depending on the size of the job. Since D/E
has various thickness it requires pre-heating. But pre-heating should be done for only
a given period. If the part is not heated properly it can lead to formation of mill scales.
Mill scale, often shortened to just scale, is the flaky surface of hot rolled steel,
consisting of the iron oxides iron(II) oxide (FeO), iron(III) oxide (Fe2O3), and iron(II, III)
oxide (Fe3O4, magnetite). Too much pre-heat will result in a rounded top edge as well
as significant increase in slag. Slag, by-product formed in smelting, welding, and

51
other metallurgical and combustion processes from impurities in the metals or ores
being treated.

Fig 20. D/E blank after pressing and man hole.

Gases used in pre-heating are Natural Gas and cutting Oxygen. Sometimes
Acetylene is also used instead of Natural Gas.

D/E blank is heated only when the thickness of the blank to be cut is less than 25mm.
Because the PUG machine used to cut the blank can cut blanks of thickness less
than 25mm flawlessly. Blanks with thickness greater than 25mm require pre-heating.
Temperature up to which the blank is heated ranges from 100-150 degree Celsius.
This temperature range again depends on the thickness of the blank.

52
Table 5: Temperature of pre-heating required for different thickness.

Fig 21. Circular Burner.

When the thickness is greater than 25mm the blank needs to be heated first. This is
done by using a burner. As you can see in the above figure, that burner is used to
pre-heating. Naturally due to its orientation it cannot heat the whole blank at one time.

53
So, we need to keep that burner at one part of the circle of the blank until the part
gets heated. Similarly, we shift the burner to another part when one part gets heated.
Heating one part requires 10-20 min of time. Hence time required to heat the whole
blank with the help of the above burner requires more time. More time of the workers
is wasted as they can utilise this time to do another work. Also, it slows the further
manufacturing process as it is one of the main parts of the capsule drum.

Table 6: Man hours required to heat the blank of different diameters.

5. Fixture Design of Burner for Pre-heating:

Since time required to heat the blank is more we need to design something that
will reduce the time and heat the blank. It should also be adjustable so that it can
cover different diameters of the blank.

54
Fig 22. Design of fixture of Burner for pre-heating.

Above figure shows the design of the fixture which can be used to hold the burner
and heat the blank. The design consists of eight racks of 1m each arranged in a
circular fashion on a circular pipe of diameter 2.5m. Each rack will contain one
burner. Hence, total eight burners can be arranged in the above design. These
racks have six slots. These slots are provided to make the burner adjustable. The
burner will be held by these slots. The burner can be moved on these slots and
the diameter can be adjusted. The burners will be given input from the 1:8 port
which be held in the middle of the circle. The D/E blanks comes in different
diameters which ranges from 800mm to 3200mm. All these blanks can be covered
by this fixture as the minimum and maximum length of the diameter which the
burner can heat is 750mm and 3500mm respectively.

55
6. Advantages of the Fixture:

 Lesser time will be required to pre-heat big dished ends.


 DPR will increase.
 No highly skilled labor required.
 Lesser time to complete the job, hence higher productivity.

56
CHAPTER 8: CONCLUSION

Assignment 1:

With the help of this fixture set-up time required for the D/E to manhole outside SAW
welding is reduced from 30-35 min to 10-15 min. This fixture is easy to understand &
use. Along with locating, this fixture is used to prevent rotating bed from heating. As
scale is provided over the guide ways help to set the different diameter D/E easily.

Assignment 2:

With the help of this fixture the time required to pre-heat the D/E blank will be reduced
from 2-2.5 hours to 15-30 min. This fixture is easy to use. This fixture will increase
the productivity and increase the daily production rate of the workers. Production of
further jobs will also increase.

57
References:

1. thermaxglobal.com.
2. Flow Process Chart of Plant-5.
3. System of Procedure of Plant-5.
4. Wikipedia.
5. Report by Shashank Desai (Maintenance Department, Thermax).

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