Aidan Singh Report
Aidan Singh Report
Aidan Singh Report
PRACTICAL TRAINING
REPORT
ON
BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
GUIDED BY:
SUBMITTED BY:
CERTIFICATE
This is to certify that the Practical Training Seminar report for Practical
Training taken at JINDAL SAW LTD.(IPU) , MUNDRA (GUJRAT)
from 11th June 2014 to 10th July 2014 is submitted by Mr. AIDAN
SINGH (11EJJME002) in partial fulfillment for the award of degree of
Bachelor of Technology in Mech. Engineering has been found
satisfactory and is approved for submission.
JIT/DOCE/2014-15/PS 02
ACKNOWLEDGEMENT
JIT/DOCE/2014-15/PS 03
PREFACE
are
INDUCTION
FURNACE,
CENTRIFUGAL
CASTING
JIT/DOCE/2014-15/PS 04
Introduction to company:
INDEX
INDUCTION FURNACE
Mg CONVERTER
CCM
ANNEALING
Zn COATING
TRI-GRINDING
HPTM
CEMENT LINING
CULTIVATION FURNACE
BUFFING
PRE-HEATING FURNACE
BITUMEN COATING
POST HEATING FURNACE
DISPATCH AND INSPECTION
BOILER OPERATION
RMHS
CPP
JIT/DOCE/2014-15/PS 07
JIT/DOCE/2014-15/PS 08
1 INDUCTION FURNACE
WHAT IS INDUTION FURNACE?
OPERATING PRINCIPAL
Induction furnace works on the principal of induction
Induction furnace is a furnace in which heating is initiated
by electricity.
Hollow copper coils are provided around furnace in which
demineralised water run for cooling, as current generates
heat. When current is passed through coils magnetic field
is set up due to which eddy currents are generated in
molten metal. These eddy currents heats up the molten
metal. Direct heating by coils is not possible here as the
molten metal will melt the coils.
WORKING AND CONSTRUCTION
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CONSTRUCTION
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PARTS OF CCM
1.Hooper
2.Fallchute
3.Runner (a) spout inclined at 55 degree
(b) runner tube
(c) ms pipe (for mould spray
(d) nozzle (for mould powder)
(e)rubbing pad
(f) roller blade (to support runner)
(g) runner bogie
4. CCM- sleeve(2 roller bearing ), mould, DC motor, core loader, MTC,
runner rollers , water cooling(indirect )
JIT/DOCE/2014-15/PS 012
5. Diabola trolley
6. water jet
7.extractor
8.arms
9. graphite powder
WORKING
CCM works on the principle of centrifugal force, which is provided
by a DC motor and 6-V belt drive. The molten metal splashes to
periphery of the mould such that it does not drop down again. The
molten metal at temperature 1400 C is poured in hoppers capacities
0.8-1 ton.
Hopper is lifted hydraulically, the molten metal passes through fall
chute in runner. Meanwhile innocoolant powder is sprinkled at the
beginning of runner. The runner is line with graphite powder before
the molten metal is poured so that it must no stick to the runner.
A nozzle is provided at CCM end to sprinkle mould powder in
mould so that pipe can be extracted easily. Meanwhile on the other
side he operator the worker loades the core through core loader .
The core gives shape to socket and company designation is given on the
core and the year of manufacture. Now the ccm is made to move forward
. Its forward motion is due to the main travell cylinder which works on
hydraulic. As it move forward the hopper pours the molten metal into the
runner from runner it enter the mould . the runner travels fully inside the
mould .The mould is rotating at the rpm of 1200. After 12 second of
pouring the runner is automatically shifted by dia bola trolley
The pipe is cooled rapidly by water after cooling pipe is extracted
through pneumatic extractor. The motion of extractor is due to the roller
fixed at rear end. The roller rotates with the help of gear box. From
extractor the pipe is shifted to pt trolley and then carried out for
annealing
NOTE whole process in ccm is controlled by plc and is completely
interlocked
(3) ANNEALING FURNACE
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MAX. TEMP.(
C)
HEATING ZONE
880
920
960
HOLDING ZONE
920
940
960
740
820
The pipe from ccm are bought to annealing furnace. Before the pipes are
introduced into the furnace the naming on pipe is don with chalk after
that sand is removed through high pressure air and the socket is grinded.
After that it is introduced in furnace the pipe are carried inside the
furnace through chain which is rotating at 500 mm/min. the chain takes
the pipes through various heating zones .
The firing in annealing furnace is initiated by mixture of BF gas
and air. This mixture Moves through holes of 16mm dia. in
ceramic blocks of 6X4 inches present in burners. The gas burn due
to high temperature in furnace. There are valve provided at the top of
furnace which allow exhaust and inlet .The position changes after
every 40 seconds.In this way temperature of the furnace is
maintained. Aligners are provide to ensure pipe.Are not shifted from
the path. 12Aligners are provided 6 on both sides which are
JIT/DOCE/2014-15/PS 014
Hydraulically operated.
130
800-900
200
750-850
JIT/DOCE/2014-15/PS 015
400
300-400
Zylos
Mixing tank.
Slurry tank.
Slurry trolley.
Reciprocating pump for cement supply.
Feed pipes.
Gas seals.
Thrust rollers.and Hydro motor
The pipes from after cement lining are carried to the cultivation
chamber . the cultivation chamber is 100 m long chamber. In this
chamber the cement lining is cured by provided required humitidy and
temp. The humitdy and the temp inside the furnace is provided by the
steam which is coming from the boiler . The pipes are made to travel the
100 m distance in approxx 2 hrs. This tym period is known as curing
period .in this period the cement lining of pipes is cured completely.
Temperature regulating units 6 Actuator valves 12 Chain speed
1.5m/min
The process of curing is followed asTwo steam lines are provided, one is for maintaining humidity
and other is to maintain temperature.
a) Actuator or butterfly valves are present on both lines to
ensure optimum humidity.
b) Around 85% humidity is set on the panel, above it the
valve closes.
c) One of the steam line is directly utilized in the furnace
for steam supply, other line is passed through a unit
comprising blower, radiator, and supply pipes.
d) In temperature regulating unit, blower sucks the air from
furnace. This air when strikes the steam tubes, takes up
the heat and again it enters the furnace. This cycle repeats
again and again. The outlet of steam pipe from radiator
goes to a auto condensate pump which takes up the
moisture from steam at pressure 3.5 bar and send it to
boiler unit at 11 bar.
e) Blowers are provided at the entry and exit of furnace to
prevent exit of steam.
(10 ) BUFFING
Buffing is a finishing operation. It finishes the cement lining and
makes it smooth. Pipes are hold on PU rubber rollers and
supported by push rollers. A barrel buffing tool enters the pipe and
it is rotated by 4 V belt drive. Buffing tool is made up of emry
paper. Pipes are washed by water to remove cement dust after
buffing. If any cracks are seen they are filled manually after
buffing.
(11) PRE-HEATING FURNACE
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Length 15m
Temperature - 50C
Pipes are pre-heated so that bitumen could stick to the outer
surface and also to remove moisture after buffing. Temperature is
set up by same process as in cultivation furnace.
(12) BITUMEN COATING Now before external coating the inner end
of the pipe is coated manually for this a small motor is used to rotate the
pipes. After that by the help of trolley the pipes are transfer to the
external coating machine.
Coating is done to prevent corrosion .As per the customer requirement
the coating type is selected.
There are many types of bitumen coating,some of them are black
bitumen, blue epoxy, red epoxy which is selected as per the customer
requirement.
CHARACTERISTICS:
Coating shall not be applied to any pipe unless its surfaces are
clean, dry and free from rust.
Unless otherwise agreed between the purchaser and the
manufacturer all pipes shall be coatedexternally and internally
with the same material.
the coating material has a bitumen base,it shall be smooth and
tenacious and hard enough notto flow when exposed to a
temperature of 65C butnot so brittle at a temperature of 0C.
Pipes with or without sockets and flanges whichare imperfectly
coated or where the coating does notset or conform to the required
quality, the coating shallbe removed and the pipes/flanges
recoated.
Pipes thickness should be 70-75 microns , Dia-100mm pipes required
400 gm bituminous and dia-150 mm required 600 gm.
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(15)BOILER OPERATION
Type fire tube cylindrical.
Capacity 12000 kg/hr
Working pressure 10.55 kg/cm^2
Heating surface area 305.89 m^2
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WATER PARAMETERS
PH
TDS
TH
MAKE-UP
WATER
7.5-8.5
<200
<100 PPM
SOFT WATER
8.5-9.5
<200
<5 PPM
FEED WATER
8.5-9.5
<200
<5 PPM
BLOW DOWN
WATER
11.0-12.0
<3500
<5 PPM
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wherever required.
(17)CPP ( Captive power plant)
Captive power plant is installed with diesel generators. It is a
standby power plant. In case there is a shut down in
switchyard or monsoon conditions are not preferable, then DG
are used. There are total 8 DG in CPP. Total power produced
is around 25 MW. DG is simply a diesel engine connected
with alternator. Fuel used is either furnace oil or diesel.
Governors are also provided to maintain the mean speed.
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JIT/DOCE/2014-15/PS 024
REFRENCES :1
2
3
4
JIT/DOCE/2014-15/PS 025