SETH JAĐ PRAKASH MUKAND LAL INSTĐTUTE

OF ENGĐNEERĐNG & TECHNOLOGY

DEPARTMENT OF MECHANICAL ENGINEERING

NAME-SURNAME : Gumesh Rana.

DEPARTMENT : MECHANĐCAL ENGĐNEERĐNG

CLASS / NUMBER : ME-1209340

COURSE NAME : Mechanical Presses: Construction & Inspection

COMPANY : ISGEC Heavy Engineerings Limited(IHEL)

TRAINING PERIOD : 6th July 2011 to 16th August 2011

INDUSTRIAL TRAINING

REPORT

TRAINING REPORT

SETH JAĐ PRAKASH MUKAND LAL INSTĐTUTE OF

ENGĐNEERĐNG & TECHNOLOGY

DEPARTMENT OF MECHANICAL ENGINEERING

TRAINEE

Name and Surname Gumesh Rana

Class ME

ID Number 1209340

INDUSTRIAL ORGANIZATION for

TRAINING

Name ISGEC Branch Yamuna Nagar

Department MBD

Address ISGEC, NH-73A, YNR

ORGANIZATIONAL ADMINISTRATORS

Managing Director Mr. Aditya Puri

Director Mr. Arun Kathpalia

Whole Time Director Mrs. Nina Puri

Chair Person Mr. Ranjit Puri

Table of contents

Page no.

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

3.2 Fabrication Shop 8

3.2.1 Instructions for various works in Fabrication Shop 9

3.2.2 Welding Techniques Observed 14

3.3 Machine Shop 19

3.4 Assembly Shop 19

Chapter 4

MECHANICAL PRESS 21

4.1 Principle 21

4.2 Advantages 21

4.3 Features of Mechanical Press 21

4.4 Problems in Mechanical Press 24

4.5 Inspection of Presses 25

1

PROLOGUE

Practical knowledge means the visualization of the knowledge, which we read in our books. For this, we

perform experiments and get observations. Practical knowledge is very important in every field. One must

be familiar with the problems related to that field so that he may solve them and become a successful

person.

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

2

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

3

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.

4

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)

• Shop covered area: 43,000 Sq. Meter (51,427 Sq. yards)

• Total plant area: 250,000 Sq. Meter (298,998 Sq. yards)

� Forming

• Rolling : Thickness - 200 mm (8 inches)

� Welding

• Narrow Gap Welding with seam tracking

• Strip Cladding using single as well as double layer technique

• Automatic small diameter nozzle cladding.

• 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

5

� 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

• Local Stress Relieving by Electrical Resistance Method

• Stress Relieving by Internal Firing Method

• Stress Relieving of large jobs in Temporary Furnaces

� Radiography

• Cobalt 60 for Radiography up to 200 mm (8 inches)

� Testing

• Tensile testing including Elevated Temperature Testing up to 8000 C (14700 F)

• Impact Testing up to (-) 1960 C (-3200 F)

• Insitu Alloy Analyzer

• Metallurgical Microscope X-2000 with Photography facility

• Ferrite Measurement

• Recordable/ Mechanized Ultrasonic Testing

• Magnetic particle Testing

• Liquid Penetrant Testing

• Holiday Testing for Painting

• IGC Testing

• Complete laboratory supported by spectrometer

6

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.

7

DIVISION OF ISGEC

The various divisions of ISGEC are as follows;

1. PRESSURE VESSEL DIVISION (PVD)

Pressure vessel division is the oldest of ISGEC and it manufactures pressure vessels such as boilers, heat

exchangers etc. It is sub-divided into following shops;

• PVD-I

• PVD-II

• PVD-III

• PVD-IV

2. MACHINE BUILDING DIVISION (MBD)

Machine building division is very important division of ISGEC and it manufactures sugar mill machinery.

Press components and other Steel plant machinery. It is sub-divided into following shops;

• 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.