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MANAGEMENT
INPLANT TRAINING-PROJECT
REPORT ON
AT
THERMAX Ltd BY
T. Y B. Tech
Production (Sandwich)
UNDER THE GUIDANCE OF
Year 2017-18
DEPARTMENT OF PRODUCTION ENGINEERING &INDUSTRIAL
MANAGEMENT
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:
(Guide)
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 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
2. Plant – 5. 11
3. Plant – 12. 21
4. Plant – 15. 27
5.1. DP Test. 30
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. 5. Economizer. 26
3
List of Flow Charts
List of Tables
4
CHAPTER 1: COMPANY PROFILE
1.1. INTRODUCTION:
For designing & manufacturing of high pressure, high capacity water tube
boilers & merger of energy division with it.
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
Boilers
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
6
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.
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:
This department performs the useful process of quality Control and its assurance,
from the customer as well as factory point of view:
7
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.
This group though not takes part in actual production but works for betterment of
industrial processes and relations. It includes,
8
6. To deal with vendor regarding externally designed and manufactured
components.
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.
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.
9
and implement eco-friendly atmosphere and to eliminate any kind of wastage and
pollution creating elements.
10
CHAPTER 2: PLANT- 5
2.1.
2.2.
1. Plate preparation.
2. Shell fabrication.
3. Barrel fabrication.
5. Capsule fabrication.
6. Full welding.
7. Hydro test.
8. Drum Assembly.
11
There subdivisions discussed in detail in the following report.
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.
13
Specification of KOIK IK-12 Elite portable cutting machine:
Punch on plate:
14
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.
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.
15
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.
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.
16
2.2.3. Barrel Fabrication:
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.
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.
17
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.
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.
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
18
2.2.6. Hydrotest:
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.
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.
19
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.
20
CHAPTER 3: Plant -12
The following table enlists various machines Plant 12 and their significance:
OD range: 21 to 76
Master cool 10
21
5 Projection Welding machine 3
7 Lathe 1
Tools, Harihar
2. Ganga Precision 1
Industries, Coimbatore
9 Chamfering Machine
1. Dolphin Special 2
Machine Technologies,
Chennai
2. Thakoor Technologies 1
22
3.1. Product Range:
c) CFBC.
2. Economiser
3. Evaporator Coils
b) Draught recirculation
5. Fire heaters
6. Headers
23
Flow Chart 2: Coil Making
Explanation:
The cut tube ends are chamfered using chamfering machine. This process
serves as an edge preparation process before welding.
24
3.2.3. Layout marking:
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
Ball test, die penetrant test etc. are performed on the coil.
25
3.2.8. Weld joint RT:
Welded joints are radio graphically tested and proper welding is ensured.
Fig 5. Economizer.
26
CHAPTER 4: Plant -15
Assembly Shop:
6. Nozzle setup.
27
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.
b. It is by this process that it becomes possible to make the job eligible for
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.
28
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.
Note:
Heavy jobs are allotted to plant 15 and relatively smaller jobs are forwarded to plant
5 due to space and crane constraints.
29
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.
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:
32
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.
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.
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
Performance Test: Satisfactory on Ketose Ring, Std. Defect Plate & ASME /
ASTM Shims
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
Non-corrosive to the job and the film can be easily removed using WC-
Remover
5.2.5. Procedure:
3. Connect the Magnetic yoke to the power connection and ensure proper
and safe functioning
35
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
36
ASSIGNMENT NO: 1
2. PROBLEM STATEMENT:
3. OBJECTIVES:
Mistake proofing.
37
4. INTRODUCTION:
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.
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.
38
Fig 9: Placing D/E at the Centre of Rotating Table (before implementation of
fixture).
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.
Fixture design deals with the establishment of the basic fixture concepts
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:
Clamping surfaces
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
42
\
43
9. MATERIAL SELECTION:
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.
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.
44
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.
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.
6 Nut-Bolt standard
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.
Cutting
Flush grinding
Drilling
Tapping
Welding
46
Fig 15: Cutting Fig 16: Grinding
47
11. JOB CONSTRAINTS:
Parameters Constraints
Weight 1 to 2 tons
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.
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.
49
ASSIGNMENT NO: 2
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:
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.
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.
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.
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:
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).
58