15ME390L INDUSTRIAL TRAINING

A REPORT

Submitted by
MANU SHARMA, REG No:- RA1611002010665
in submission for assessment and award
of Grade

BACHELOR OF TECHNOLOGY
IN

MECHANICAL ENGINEERING
OF

FACULTY OF ENGINEERING & TECHNOLOGY

Mahatma Gandhi Rd, Potheri, S.R.M. Nagar , Kattankulathur,

Kancheepuram District
TAMIL NADU 603203

JANUARY 2019
 SRM INSTITUTE OF SCIENCE AND TECHNOLOGY

(Under Section 3 of UGC Act, 1956)

BONAFIDE CERTIFICATE

Certified that this report titled “15ME390L INDUSTRIAL

TRAINING ” is the bonafide work of “MANU SHARMA”, who carried out
the training in (ISGEC HEAVY ENGINEERING LIMITED ). Certified
further, that to the best of my knowledge the work reported herein does not
form any other training report on an earlier occasion on this or any other
candidate.

SIGNATURE

(CLASS IN CHARGE:- MR S.SUNDAR (MECH))

COMPANY CERTIFICATE
 ACKNOWLEDGEMENT

"A DREAM DOESN'T BECOME REALITY THROUGH MAGIC, IT TAKES

DETERMINATION AND HARD WORK "

To start with, I wish to express my sincere gratitude to Mr.DN. Mishra and Mr. Dharmendra
Sharma for providing me an opportunity to undergo 4 week Industrial Training at Isgec,
Yamuna Nagar, Haryana.

I give my great sense of privilege in submitting this project work, for which I am grateful
and indebted to Mr.DN Mishra (Training Officer) for allowing me to undergo my training
and to do this project at Isgec. I sincerely acknowledge his help, efforts and cooperation as
well as timely guidance, which helped me to complete my project.

I express my sincere gratitude to my industry guide Mr. DN Mishra (Head- Industrial

Engineering),fordable guidance, continuous support and co-operation throughout my project,
without which the present work would not have been possible. I would also like to thank the
entire team of Isgec, for the constant support and help in the successful completion of my
project.

I convey my heartiest thanks to all those officers and employees of Isgec who have given
me their full co-operation and devoted their valuable time, for rendering me their needy
services, guidelines during the course of imparting me practical training and with whose
sincere and precious helps, I have been able to complete my practical training successfully.
 CONTENTS

CHAPTER NO. TITLE PAGE NO.

1. INTRODUCTION

1.1 ABOUT THE ORGANISATION 1

1.2 FACILITIES AVAILABLE 3

2. DESCRIPTION OF INDUSTRIAL TRAINING

2.1 WHAT IS DIRECT REDUCED IRON 5

2.1.1 THERMODYNAMIC RELATION 5

2.2 COAL BASED DIRECT REDUCTION 7-8

ROTARY KILN PROCESS

2.3 RAW MATERIALS 9

2.3.1 OPTIMUM SPECIFICATION 9

2.3.2 CHEMICAL REACTIONS 10

2.3.3 BLOCK DIAGRAM OF 11-13

PROCESS IN KILN

3 USE OF SPONGE IRON 14

4 CONCLUSION 15
 INRODUCTION

Isgec is the engineering. Unit of SISL (Saraswati Industrial Syndicate Limited) established in
1946. Over the years Isgec diversified into the manufacturer of heavy engg, Equipment.

Collaboration with John Thompson in UK established a joint company by the name of Isgec
John Thompson which was subsequently merged with SIS (Saraswati Industrial Syndicate) in
1960 as a unit. The unit located at Delhi supplies the boilers & auxiliary equipments on
turnkey basis. Isgec process division also located at Delhi provides engg, procurement and
construction services for sugar plants.

Isgec at present offers a wide range of products for diverse applications including pressure
vessels, heat exchangers, Reactors, columns, hydraulic 7 mechanical presses, CNC, Press
brakes, Ton containers for liquefiable gases, steel plant, machinery iron & steel castings as
well as turnkey sugar plants.

It is a US$ 300 million turnover public company established 75 years back in India.
The group technical capabilities are supported by a highly trained cadre of 460 qualified
engineers, covering a wide gamut of specifications – thermal, metallurgical, mechanical,
electrical, instrumentation, civil & project management

APPROVALS

 Isgec Heavy Engineering Ltd. 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 130mm
thickness.
 Engineers India Ltd. approves Isgec for Manufacture of Heat Exchangers up to
maximum tube sheet thickness of 300mm.

 China Safety Quality License

INFRASTUCTURE
1. Isgec has a sprawling works covering an area of about 25 hectares including covered
production area of around 35,000 square meters.

2. It has the capacity to handle jobs weighing upto 100 tonnes (single piece).

3. Extensive facilities for hot & cold rolling, machining, welding, heat treatment and
stringent quality controls to ensure strict compliance to international standards.

4. More than 125 sophisticated machines and machine tools are installed in various
production bays. Apart from these, more than 100 welding machines (for various
processes including SMAW, SAW, MIG, TIG and flash butt welding and under
operation).

5. Isgec has own captive power generation of 3650 KV through DG sets.

 Product range

FIELD SERVICES

 Site construction and commissioning

 Operation and Maintenance
 Retrofitting and revamping

PRESSURE VESSEL AND HEAT EXCHANGERS

PRESSES

 Straight Side Presses - Mechanical

 Straight Side Presses- Hydraulic

 'H' Frame Presses - Mechanical

BOILERS

 Dump Grate Boilers

 Travelling Grate Boilers

 Atmospheric Fluidised Bed Combustion Boilers (AFBC)

 Circulating Fluidised Bed Combustion Boilers (CFBC)

 Oil / Gas Fired Boilers

 Waste Heat Recovery Boilers

 Deaerators

 Spares

DIVISION OF ISGEC
ISGEC has been divided into three divisions 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:-

a) PVD-I
b) PVD-II
c) PVD-III
d) 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:-

a) FABRICATION SHOP-I,II
b) MACHINE SHOP-I,II
c) ASSEMBLY SHOP
d) 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.

6. CONTAINER SHOP
Container shop manufactures chlorine, ammonia and other gases containers.

Material flow in shops of MBD division

Preparation shop

Fabrication shop

Machine shop

Assembly shop

 Preparation shop- To provide raw material (plates) to various divisions, after

flame cutting to shape and size, as required in drawings, for various jobs.

 Fabrication shop- Material to be fabricated is sent to fabrication shop. All of

the fabrication is done in this shop.
 Machine shop- Job after fabrication is sent to machine shop. This shop is fully
equipped with new technology machines.

 Assembly shop- The component from machine shop and fabrication shop are
sent in assembly shop for assembly.
 INTRODUCTION OF PROJECT

Heat Exchangers
1.1 INTRODUCTION
A heat exchanger is a device that is used to transfer thermal energy (enthalpy)
between two or more fluids, between a solid surface and a fluid, or between solid
particulates and a fluid, at different temperatures and in thermal contact. In heat
exchangers, there are usually no external heat and work interactions. Typical
applications involve heating or cooling of a fluid stream of concern and evaporation
or condensation of single- or multicomponent fluid streams. In other applications, the
objective may be to recover or reject heat, or sterilize, pasteurize, fractionate, distill,
concentrate, crystallize, or control a process fluid. In a few heat exchangers, the fluids
exchanging heat are in direct contact. In most heat exchangers, heat transfer between
fluids takes place through a separating wall or into and out of a wall in a transient
manner. In many heat exchangers, the fluids are separated by a heat transfer surface,
and ideally they do not mix or leak.
Such exchangers are referred to as direct transfer type, or simply recuperators. In
contrast, exchangers in which there is intermittent heat exchange between the hot and
cold fluids—via thermal energy storage and release through the exchanger surface or
matrix— are referred to as indirect transfer type, or simply regenerators. Such
exchangers usually have fluid leakage from one fluid stream to the other, due to
pressure differences and matrix rotation/valve switching. Common examples of heat
exchangers are shell-and tube exchangers, automobile adiators, condensers,
evaporators, air preheaters, and cooling towers. If no phase change occurs in any of
the fluids in the exchanger, it is sometimes referred to as a sensible heat
exchanger.
There could be internal thermal energy sources in the exchangers, such as in electric
heaters and nuclear fuel elements.
Combustion and chemical reaction may take place within the exchanger, such as in
boilers, fired heaters, and fluidized-bed exchangers. Mechanical devices may be used
in some exchangers such as in scraped surface exchangers, agitated vessels, and
stirred tank reactors. Heat transfer in the separating wall of a recuperator generally
takes place by conduction. However, in a heat pipe heat exchanger, the heat pipe not
only acts as a separating wall, but also facilitates the transfer of heat by condensation,
evaporation, and conduction of the working fluid inside the heat pipe. In general, if
 the fluids are immiscible, the separating wall may be eliminated, and the interface
between the fluids replaces a heat transfer surface, as in a direct-contact heat
exchanger.

The goal of heat exchanger design is to relate the inlet and outlet temperatures,
the overall heat transfer coefficient, and the geometry of the heat exchanger, to the
rate of heat transfer between the two fluids. The two most common heat exchanger
design problems are those of rating and sizing. We will limit ourselves to the design
of recuperators only. That is, the design of a two fluid heat exchanger used for the
purposes of recovering waste heat.

COMPONENTS OF HEAT EXCHANGER

Shell-and-Tube Heat Exchangers Construction Details

The shell-and-tube heat exchanger is named for its two major components – round tubes mounted
inside a cylindrical shell.

The shell cylinder can be fabricated from rolled plate or from piping (up to 24 inch diameters). The
tubes are thin-walled tubing produced specifically for use in heat exchangers.

Other components include: the channels (heads), tubesheets, baffles, tie rods & spacers, pass
partition plates and expansion joint (when required). Shell & tube heat exchanger designs and
constructions are governed by the TEMA and ASME codes.
 Introduction to welding process

Introduction
Welding is a process in which two or more parts are joined permanently at their touching
surfaces by a suitable application of heat and/or pressure. Often a filler material is added to
facilitate coalescence. The assembled parts that are joined by welding are called a weldment.
Welding is primarily used in metal parts and their alloys.
Welding processes are classified into two major groups:
1. Fusion welding:
In this process, base metal is melted by means of heat. Often, in
fusion welding operations, a filler metal is added to the molten pool to facilitate the
process and provide bulk and strength to the joint. Commonly used fusion welding
processes are: arc welding, resistance welding, oxyfuel welding, electron beam
welding and laser beam welding.

2.Solid-state welding:
In this process, joining of parts takes place by application of
pressure alone or a combination of heat and pressure. No filler metal is used.
Commonly used solid-state welding processes are: diffusion welding, friction
welding, ultrasonic welding.

3.Arc welding and similar processes

Arc welding is a method of permanently joining two or more metal parts. It consists of
combination of different welding processes wherein coalescence is produced by heating with
an electric arc, (mostly without the application of pressure) and with or without the use of
filler metals depending upon the base plate thickness. A homogeneous joint is achieved by
melting and fusing the adjacent portions of the separate parts. The final welded joint has unit
strength approximately equal to that of the base material. The arc temperature is maintained
approximately 4400°C. A flux material is used to prevent oxidation, which decomposes
under the heat of welding and releases a gas that shields the arc and the hot metal.The second
basic method employs an inert or nearly inert gas to form a protective envelope around the
arc and the weld. Helium, argon, and carbon dioxide are the most commonly used gases.

4.Shielded-Metal Arc (SMAW) or Stick Welding

This is an arc welding process wherein coalescence is produced by heating the workpiece
with an electric arc setup between a flux-coated electrode and the workpiece. The electrode is
in a rod form coated with flux. Figure M6.1.1 illustrates the process.
Figure M6.1.1: Shielded-Metal Arc (SMAW)

4.Submerged Arc Welding (SAW)

This is another type of arc welding process, in which coalescence is produced by heating the
workpiece with an electric arc setup between the bare electrode and the work piece. Molten
pool remains completely hidden under a blanket of granular material called flux. The
electrode is in a wire form and is continuously fed from a reel. Movement of the weld gun,
dispensing of the flux and picking up of surplus flux granules behind the gun are usually
automatic.

5.Gas-Metal Arc Welding (GMAW)

In this process an inert gas such as argon, helium, carbon dioxide or a mixture of them are
used to prevent atmospheric contamination of the weld. The shielding gas is allowed to flow
through the weld gun. The electrode used here is in a wire form, fed continuously at a fixed
rate. The wire is consumed during the process and thereby provides filler metal. This process
is illustrated in Figure M6.1.2.
Figure M6.1.2: Gas-Metal Arc Welding
6.Gas-Tungsten Arc Welding (GTAW)
This process is also known as tungsten–inert gas (TIG) welding. This is similar to the Gas-
Metal Arc Welding process. Difference being the electrode is non consumable and does not
provide filler metal in this case. A gas shield (usually inert gas) is used as in the GMAW
process. If the filler metal is required, an auxiliary rod is used.

7.Plasma Arc Welding (PAW)

This process is similar to TIG. A non-consumable electrode is used in this process. Arc
plasma is a temporary state of gas. The gas gets ionized after the passage of electric current
and becomes a conductor of electricity. The plasma consists of free electrons, positive ions,
and neutral particles. Plasma arc welding differs from GTAW welding in the amount of
ionized gas which is greatly increased in plasma arc welding, and it is this ionized gas that
provides the heat of welding. This process has been illustrated in Figure M6.1.3.

8.Oxyfuel Gas Welding (OFW)

This process is also known as oxy-acetylene welding. Heat is supplied by the combustion of
acetylene in a stream of oxygen. Both gases are supplied to the torch through flexible hoses.
Heat from this torch is lower and far less concentrated than that from an electric arc.

9.Electron-Beam Welding (EBW)

Electron beam welding is defined as a fusion welding process wherein coalescence is
produced by the heat obtained from a concentrated beam of high velocity electron. When
high velocity electrons strike the workpiece, kinetic energy is transformed into thermal
energy causing localized heating and melting of the weld metal. The electron beam
generation takes place in a vacuum, and the process works best when the entire operation and
the workpiece are also in a high vacuum of 10-4torr or lower. However, radiations namelyray,
infrared and ultraviolet radiation generates and the welding operator must be protected.
10.Laser Beam Welding (LBW)
Laser beam welding is defined as a fusion welding process and coalescence is achieved by
utilizing the heat obtained from a concentrated coherent light beam and impinging upon the
surface to be joined. This process uses the energy in an extremely concentrated beam of
coherent, mono-chromatic light to melt the weld metal. This process is illustrated in Figure
M6.1.4.

Figure M6.1.4: Laser-beam welding.

TESTING PROCESS

Destructive Testing (DT)

As the name suggests, destructive testing (DT) includes methods where your
material is broken down in order to determine mechanical properties, such as
strength, toughness and hardness. In practice it means, for example, finding out if
 the quality of a weld is good enough to withstand extreme pressure or to verify
the properties of a material.

These properties can’t be examined with non-destructive methods, as specimens of the material must be
extracted. Destructive testing is generally most suitable and economic for mass produced objects, as the cost of
destroying a small number of pieces is negligible. The samples are put under different loads and stress.

Benefits of Destructive Testing (DT)

 Verifies properties of a material

 Determines quality of welds
 Helps you to reduce failures, accidents and costs
 Ensures compliance with regulations
 Destructive testing

 Bend test
 Break test
 Tensile test
 Hardness test
 Impact test
 Macro examination
 Micro examination

Non-Destructive Testing
Non-destructive testing is used as part of a manufacturing or installation
inspection to check if quality demands are being met. As an example, welded steel
joints are x-rayed to check the quality of the welding. The radiographic test
reveals if the joint is fully welded or contains unacceptable faults.

Non-destructive testing is also used as part of in-service inspections or preventive

maintenance to quantify the status of critical components and equipment. As an example,
the steel plate floor of a storage tank can be inspected with a special floor scanner.

NON DESRTRUCTIVE TESTING

 Visual Testing (VT)

 Magnetic Particle Testing (MT)
 Penetrating Testing (PT)
 Radiography Testing (RT)
 Ultrasonic Testing (UT)
 Eddy Current Testing (ET)
 Leak Testing (LT)
 Material Identification (PMI)

Benefits of using NDT

 High quality
 Verifies requirements
 Prevents failure or break down of critical equipment