Professional Documents
Culture Documents
ORIGINAL Project 8th Sem
ORIGINAL Project 8th Sem
ORIGINAL Project 8th Sem
S.B.M.P., MUMBAI
SUBMISSION CERTIFICATE
I certify that I have not copied the report or its any appreciable part from any
other literature in contravention of academic year.
ROLL NO : Y720059
Date: ____________
S.B.M.P., MUMBAI
Signature:
____________
S.B.M.P., MUMBAI
NO OBJECTION CERTIFICATE
student of SHRI
S.B.M.P., MUMBAI
ANKUSH R JADHAV
( Asst. Manager,QC FPEX )
M.S.RAJU
( Sr. DGM, QC-FPEX )
ACKNOWLEDGEMENT
The success of my training at LARSEN & TOUBRO LTD., POWAI
CAMPUS is not only due to my work alone, but also due to interest, help & guidance
offered to me by employees of the company.
I would like to express my deepest sense of gratitude to Mr. M.S.Raju
(Sr.DGM - QC-FPEX),
QC-FPEX), Mr.Ankush Jadhav & Mr. Pankaj Sachdeva for their valuable
guidance, their helping hand & fruitful advice during my projects, which gave me
immense confidence and widened my knowledge.
I cant forget, Mr Abhishek Waravadekar , Mr Kiran Pagar, Mr SAGAR
BOGWAD for guiding and encouraging me throughout my work. Last but not the least; I
would like to appreciate the kindness & co-operation extended by all the employees &
the trainees in the department that helped in making my training a grand success.
S.B.M.P., MUMBAI
S.B.M.P., MUMBAI
INDEX
S.B.M.P., MUMBAI
Sr No
Page
No.
Topic
INTRODUCTION TO HEAVY
ENGINEERING DIVISION.
INTRODUCTION TO INSPECTION
DEPARTMENT.
MY ROLL IN MY DEPARTMENT
5
6
CONCLUSION.
BIBLIOGRAPHY.
CHAPTER 1
INTRODUCTION TO L&T
Larsen & Toubro Limited (L&T) is a technology-driven engineering and
construction organization, and one of the largest companies in Indias private sector. It
has additional interests in manufacturing, services and Information Technology.
S.B.M.P., MUMBAI
9
Two Danish engineers, Henning Holck-Larsen
and Soren Kristian Toubro
founded L&T, in 1938. Beginning with the import of machinery from Europe, L&T rapidly
took on engineering and construction assignments of increasing sophistication. It now
has a major presence in key sectors of the economy.
A strong, customer-focussed approach and the constant quest for top-class quality
have enabled the Company to attain and sustain leadership in its major lines of
business across seven decades.
With factories and offices located around the country, further supplemented by a
comprehensive marketing and distribution network, L&T enjoys an image and equity in
virtually every district of India.
The Company has an international presence, with a global spread of offices and
joint ventures with world leaders. L&Ts large technology base and pool of experienced
personnel enable it to offer integrated services in world markets.
L&T is Indias largest builder of world-class, custom-made engineering equipment
with logistics capabilities of supplying it to a tight delivery schedule worldwide. It has
globallyBenchmarked workshops at Powai in Mumbai, Hazira and Baroda in Gujarat,
and Kansbahal in Orissa.
L&T are consistently expanding the magnitude, scope and range of its operations
to offer value-addition to client and shareholder alike. With its unique strengths
technological sophistication, quality consciousness, top-class manpower L&T strides
into the future, confident of conquering the challenges ahead.
The Beginning: L&Ts record of outstanding achievements coupled with its European name lead
many to believe that it is the Indian arm of foreign corporation. The truth is that genesis
S.B.M.P., MUMBAI
Holck Larsen & Mr. Soren Kristian Toubro in 1935 to asses the value of various cement
manufacturing groups on behalf of F.L.Smith & Co. After having completed their task
they stayed in India to open F.L.Smiths local office. During course of their work they
came to know about India and there people & decided to build their own business.
They started a partnership concern on 1
St.
L&T at Present: Within span of four decades L&T has achieved leadership position in designing,
manufacturing & installing plants & equipment for vital industries.
Today it projects many-sided image of an organization involved in over thirty
distinct fields of engineering. It has gradually expanded over the years with its branch
offices at Madras, Ahmadabad, Lucknow, Bhopal, Chandigarh, Durgapur, Rurkela etc. It
employees about 25000 personnel. At present L&Ts turnover ranks third largest
companies in India (Rs.7423 crores for the year ended 1999). In 1994, the ISO 9001
certificate was awarded to group three of L&T. Over the years of its existence, the
company has established a reputation of having a strong customer orientation,
technological sophistication displayed by its products and projects, and an impression
record of achievements.
S.B.M.P., MUMBAI
11
Company
:Public limited
Founded
No. Employees
:25,000
Turnover
:USS 10 Billion
:USS 20 Million
Overseen By
:Board of directors
Head office
&
S.B.M.P., MUMBAI
12
Factories
Malaysia
location
CHAPTER 2
S.B.M.P., MUMBAI
13
INTRODUCTION: Heavy Engineering deals with the marketing, designing, engineering and
manufacturing of one off equipment and machinerys required for basic industries
in the core sector, such as Fertilizer, Chemical, Petrol Chemical Power, Cement,
Nuclear, Aerospace, Defense, Oil, etc. The unit is headed by a Vice President and
has manpower of over 3000 personnel, including 1000 at Hazira works near Surat.
L&T's Heavy Engineering Division activities are organized under self-reliant
Strategic Business Units (SBUs) catering to the needs of core sector industries
through supply of equipment to Process Plant Industries and Defense, Nuclear
Power & Aerospace Sectors. The Division operates at the upper end of the
technology spectrum and has been at the forefront of introducing new processes,
products and materials into manufacturing sector, for over six decades. Heavy
Engineering Division has the state of the art manufacturing facilities, which are
capable of meeting the challenges of technology, quality conformance & delivery,
while ensuring cost competitiveness.
HED Fabrication shops have a built-up area of 46,000 sq.m & equipped with
sophisticated facilities for fabrication, machining, handling and quality control. The
Division's advanced technology and high standard of specialization facilitate the
manufacture of high quality heavy equipment of thick nesses up to 250mm in monoblock construction with individual sections weighing over 300t.
Specialized fabrication facilities include:
S.B.M.P., MUMBAI
Heavy-duty plate bending rolls of capacity 90mm thickness in cold and 180mm
thickness
in hot condition.
Facing and turning lathe of 6000mm dia & 100t weight between centers
Welding machines for a variety of processes (SAW, TIG, MIG, automatic pulse
TIG
tube-to-tube sheet welding, strip cladding, FCAW over-lay, internal bore welding,
etc.
STRATEGIC BUSINESS UNITS: Business activities of Heavy Engineering are overseen by three self reliant
Strategic Business Units (SBUs). These three SBUs are formed on the basis of
following sub-divisions:
Apart from marketing teams, SBUs comprise of design and engineering teams
who work on state of art software packages developed in-house on account of our
being member of HTRI, USA & HTFS, UK. The design teams are supported by
specialized thermal engineering teams for carrying out thermal sizing of different
Heat Transfer processes for the customers basic process data, check rating of
already thermally sized designs, flow induced vibration analysis etc. A specialized
design team is available to carry out stress analysis using Finite Element method.
SBU CODE
S.B.M.P., MUMBAI
SBU DESCRIPTION
FPEX
15 Transfer Equipment
Fertilizers, petroleum & Heat
Business
CGPP
RCOG
TECP
PRCP
SPLP
AERO
MARI
NUCL
Nuclear Business
WSAS
ARMY
Army Business
TECS
IBCU
PRODUCTS
L&T fabricate ultra high pressure - high temperature equipment using a wide
variety of materials of thickness ranging from 2 mm to 250 mm for various
applications. The equipment can be manufactured and supplied in monowall or
multiwall construction depending upon design requirements. Our Workshops have
been approved by Snamprogetti, Stamicarbon, Lloyds, TUV, UHDE, Kellogg, TEC,
EIL, BV, ISO, IBR ...
The products manufactured by us is in accordance with major international codes
like ASME, AD Merckblatter, AS, BS, JIS, ISO, IBR ... More than 4000 welding
procedures have been qualified.
S.B.M.P., MUMBAI
Non-ferrous metals such as Ni, Ti, Cu-Ni, Zr, Inconel, Monel, Ta, and Hastelloy...
S.B.M.P., MUMBAI
17
CHAPTER 3
INTRODUCTION TO MY (INSPECTION)
DEPARTMENT
INTRODUCTION
Quality control is one of the most important aspects of engineering today.
Because of the requirement of higher quality standards & fierce competition in the
engineering field, the importance of inspection department has been very much
emphasized. The quality requirements of a particular job are mentioned in the
specifications & the inspection has to work according to those specifications to maintain
the quality. For this, individual member of the department, who is called as inspector,
may be required to carry out different tests & inspection activities.
First of all, all the inspector should be a qualified quality control engineer in order
to carry out those tests & inspection activities, which also should be as per the customer
and the job requirements. Inspection is the department, which releases the job for
S.B.M.P., MUMBAI
further work; thus it is the last department in18the sequence of manufacturing process. So
the role of inspection department is to find out or point out or detect the flaws in the job
at any stage in the manufacturing cycle & get it rectified from them. Thus a major chunk
of the quality standard requirements rests on the inspection department.
Depending upon the stages of inspection department is divided into few groups
such as:
S.B.M.P., MUMBAI
19
In-process inspection.
Size
Shape
Quality
Quantity.
IN PROCESS INSPECTION
S.B.M.P., MUMBAI
FINAL INSPECTION
Inspection department inspects the product prier to the time of dispatch.
Inspection department has to inspect:
In-process inspection
Final inspection
IMPLEMENTATION OF IDEAS
S.B.M.P., MUMBAI
DOCUMENTATION
This department prepares all the documents related to:
Final product.
INSPECTION REQUIREMENTS
Material identification.
S.B.M.P., MUMBAI
Material cutting.
22
S.B.M.P., MUMBAI
23O N I A C O N V E R T E R
STUDY PROJECT ON AMM
GENERAL
1.1 INTRODUCTION
S.B.M.P., MUMBAI
24
In both the processes, the reaction is in the basket, and the converter shell is
the vessel for holding the pressure. The special advantage of the radial converter is
to allow the use of the catalyst small particles without a prohibited pressure drop.
The average lifetime of the catalyst is around 10 years but at high temperature the
reaction is fast and hence the deterioration of catalyst too. Lower temperature
decreases catalyst activity & hence provide high lifetime. Ammonia concentration
at the converter inlet should be minimum as it gives high reaction rate & thus a
high production capacity. Inert gas (Ar) dissolved in the liquid ammonia product is
flashed off in the let down vessel where the pressure is decreased to 25 kg/cm 2 g.
S.B.M.P., MUMBAI
25
Process condensate used like CO2, Methanol,
ammonia separated at different
pressure with the help of steam.
Before the material comes to shop floor for fabrication process, it has to
go through following cycle:
S.B.M.P., MUMBAI
26
S.B.M.P., MUMBAI
27
Inspection Planning
In-Process Inspection
Final Inspection
S.B.M.P., MUMBAI
1.
2.
3.
4.
28
CALIBERATION:
S.B.M.P., MUMBAI
29
S.B.M.P., MUMBAI
30
FASTENERS
S.B.M.P., MUMBAI
31
MATERIAL INSPECTION
1. Material Identification & Marking
2. Dimensional Check :
L x W x thickness
3. Visual Inspection :
Pitting , Damage, Lamination
PLATES
FORGINGS
S.B.M.P., MUMBAI
PIPES
32
FORGINGS
TRANSFER OFTUBESHEET
MARKING:
Transfer of marking is basically done for identification of the same material
whenever it will be come in use again in future.
e.g. suppose if the one long plate is taken then it must be having its own
identification as heat no., supplier punching, third party punching etc. now if this
plate is to be cut in two different parts then this all information is transferred to the
other part as it is so that both the part is having their own identification marks
which will be useful to identify the parts.
70
Gr 0004
6
76
67
51
SA t no. 4000
.
a
He e no
t
Pla
v
S.B.M.P., MUMBAI
33
70
G r 0004
6
76
67
51
SA t no. 4000
.
a
He e no
t
Pla
TRANSFER OF MARKING
S.B.M.P., MUMBAI
34
S.B.M.P., MUMBAI
35
L
ROLLING DIR.
No Hard Punching on
SHELL PLATE
1) FM Below 6 mm thick
2) NFM Below 12 mm thick
S.B.M.P., MUMBAI
36 innermost point.
Mark a reference line 100mm from
EDGE BREAKING :
S.B.M.P., MUMBAI
37
S.B.M.P., MUMBAI
ROLLING OF SHELL:
38
ROLLING OF SHELL
After shot blasting & edge breaking rolling is done at room temperature.
No. Of rolling passes as per thickness of plate & pressure applied
S.B.M.P., MUMBAI
39
D/4 TAMPLET
PEAK OUT
PEAK IN
ACTUAL THK.
S.B.M.P., MUMBAI
40
S.B.M.P., MUMBAI
41
D/4 Template
D/4 Template
S.B.M.P., MUMBAI
42
Peak Out
S.B.M.P., MUMBAI
43
S.B.M.P., MUMBAI
required.
Check longitudinal as well as circumferential edges for lamination etc.
S.B.M.P., MUMBAI
45
WHY PREHEATING:
It slows the cooling rate in the weld metal & base metal, producing a more
ductile metallurgical structure with greater resistance to cracking.
Slower cooling rate provides an opportunity for hydrogen that may be
present to diffuse out harmlessly reducing the potential of cracking.
It reduces the shrinkage stress in the weld and adjacent base metal , which is
especially important in higher restrained joints.
It raises same steel above the temperature above the temperature at which
brittle fracture would occur in fabrication.
INTERPASS:
The interpass temperature is the base metal temperature at the time of
welding is to be performed between the first & last welding process,
cannot be permitted to fall below the preheat temperature.
S.B.M.P., MUMBAI
46
S.B.M.P., MUMBAI
S.B.M.P., MUMBAI
Put glasswool blanket from inside over the seam & complete the postheating of shell long seam.
Gas cut the run-in & run-out plates, ensure min. 200C while gas cutting.
S.B.M.P., MUMBAI
S.B.M.P., MUMBAI
50
Check the dressing of weld from
inside / outside for adequacy for
S.B.M.P., MUMBAI
The ammonia converter required shell of thickness around 235 mm. so as per
the drawing five different sub shell of concentric diameter are rolled and then
after finishing of all the five sub shell, they are put in to one other one by one
to form a shell of required thickness. This is done by the process of SHRINK
FITTING the diameter of the final shell is maintained.
SHRINK FITTING
S.B.M.P., MUMBAI
52
S.B.M.P., MUMBAI
53
There should be no dust particles
or burrs (observed during gap check)
in the interlayer gaps. Insist of cleaning the same before start of gap checking
Check and note the orientation of seams. (This is required at every gap check
stage subsequent to shrink fitting) Confirm the top / bottom side or left / right
side of shell and note the same.
Each of the sub shell is with its own identification, so before gap check first
the identification punching of the shell near the long seam of the shell &
long seam no. (LW115, LW110 etc.) is checked.
The gap check is done with calibrated feeler gauge.
Gap check is done after every shrink fitting and after final machining. At
every stage (after every shrink fitting or final machining) of gap check,
carry out gap check in between all the layers.
Gap between the layers is noted & if the gap is within acceptable range then
the shell is released for machining.
MACHINING OF SHELL:
After receiving the operation card from the designer the shell is then
released for machining where the W.E.P. (Weld Edge Preparation) on both
the side of the shell is done according to operation card or drawing. After
S.B.M.P., MUMBAI
S.B.M.P., MUMBAI
contact sensor.
Final weld run should overlap only up to the specified limit on either side of
the shell & then weld temper beads.
S.B.M.P., MUMBAI
56
fabrication the two most common procedures
used are post heating and stress
relieving.
STRESS RELIEVING:
Stress relief heat treatment is used to reduce the stresses that remain
locked in a structure as a consequence of manufacturing processes. There are many
sources of residual stresses, and & those due to welding are of a magnitude roughly
equal to the yield strength of the base material. Uniformly heating a structure to a
sufficiently high temperature, but below the lower transformation temperature
range, & then uniformly cooling it, can relax these residual stresses. Carbon steels
are typically held at 1,100 to 1250F (600 to 675C) for 1 hour per inch (25mm) of
thickness
After all the process, These all long seams & circ seams are subjected to
NDT (Non-Destructive Test) to ensure that the seams are free from any defect
& with the assembly of externals like SUPPORT BRACKET, CLEAT etc. the
shell assembly of the equipment is completed.
S.B.M.P., MUMBAI
57
Hemispherical
Ellipsoidal
Torispherical
The D Ends which are used in the ammonia converter equipment are of
hemispherical type. This D Ends are in the form of raw material & which are
being subcontracted to vendor.
IDENTIFICATION OF MARKING:
D/E No.
Project No.
Material Specification
Heat No. & Plate No
S.B.M.P., MUMBAI
58
D/E BLANK
MARKING
CENTRE
S.B.M.P., MUMBAI
59
STUDY OF DRAWING:
Nozzle Mark
Nozzle Size, pipe Schedule, Pipe Thickness
Elevation From Bottom Tan / Ref Line
Height from Centre Line
Orientation of Nozzle
Tolerance Sheet
Details of Pair Nozzle if any
Released or under Hold
HYDROTEST OF EQUIPMENT:
S.B.M.P., MUMBAI
60
ENSURE PRIOR TO WATER FILLING:
S.B.M.P., MUMBAI
61outlet connection.
Square bar arrangements on inlet &
S.B.M.P., MUMBAI
S.B.M.P., MUMBAI
pressure line and hold for 30 min (as specified in spec) and observe the
vessel from distance.
Reduce the test pressure to above design pressure and inspect all
connections for leakage
If any leakage is observed through gasket connection, repeat the test after
depressurize the vessel & tighten the studs / nuts.
If any leakage is observed from weld or parent metal, drain the water, repair
the leak and repeat the test
Time, temperature & pressure chart wherever specified shall be obtained
RECORDER
PRESSURE GAUGE
S.B.M.P., MUMBAI
SURFACE PREPARATION:
What is surface preparation?
Surface preparation is the process in which the surface of the work-piece is
been cleaned for next process like painting, coating etc.
Why it required?
With proper surface preparation we can make the work-piece corrosion free.
With this process we can provide more efficiency for the next process.
TYPES OF SURFACE PREPARATION:
S.B.M.P., MUMBAI
65
Types of BLASTING:
I)
Wheelabrators
II)
Air Blasting
DISPATCH:
After completion of whole assembly. & documentation & getting released note
from third party the job is ready for dispatch.
S.B.M.P., MUMBAI
66
S.B.M.P., MUMBAI
67
CHAPTER
7
WORK IN DEPARTMENT
My role in the Department
S.B.M.P., MUMBAI
68
CHAPTER
8
S.B.M.P., MUMBAI
69
Features
The metal hardness tester Equotip 3 converts directly to all common hardness
scales (HV, HB, HRC, HRB, HRA, HS, Rm); creates and uses another up to 20
customer-specific conversions for uncommon alloys
Highly accurate 4 HL (0.5% at 800 HL) with automatic correction for impact
direction
The metal hardness tester Equotip 3 offers user profiles for a quick change of
test setup (with password protection)
S.B.M.P., MUMBAI
Ferrite meter:-
70
The rugged FERITSCOPE with plug-in type smart probe is suited for fast, nondestructive and accurate measurement of ferrite content on-site or in the lab according
to the magnetic inductive method.
S.B.M.P., MUMBAI
71
duplex steel.
S.B.M.P., MUMBAI
72
CALIBRATION
Recheck calibration using a mock-up block with known Base Metal to Liner gap.
The reading observed should be near to known gap. (Fig -1)
S.B.M.P., MUMBAI
73
CHAPTER 9
CONCLUSION
DURING THE LAST 46 WEEKS OF MY TRAINING IN LARSEN
AND TOUBRO I ACHIEVED A LOT OF PRACTICAL EXPERIENCE IN
THE FIELD OF QUALITY CONTROL.
AT FIRST 46 WEEKS OF MY TRAINING TERM WHICH I REFER
TO AS MOST EXCITING, ENRICHING AND CHALLENGING
EXPERIENCE EVER IN MY ENGINEERING
CURRICULUM.I HAVE LEARNED THE IMPORTANCE OF WORK
CULTURE AND TEAMWORK. DURING THIS, I HAVE LEANED VERY
IMPORTANT ASPECT OF PLANNING AND CO-ORDINATITION.THIS
TRAINING HELPED ME TO BRIDGE GAP BETWEEN THEORY AND
PRACTICAL KNOWLEDGE.IT HAS MADE ME AWARE THAT
VALIDATING A PROJECT IS VERY IMPORTANT AND CRITICAL JOB
FOR THE COMPANY AND ITS OFFICIALS. I HAVE ALSO LEARNT
THAT CUSTOMER SATISFACTION, SAFETY AND QUALITY ARE OF
MOST IMPORTANCE.
LOOKING AT THE TRAINING FROM A BROADER VIEW, I HAVE
FOUND THAT APART FROM THE TECHNICAL KNOWLEDGE
IMPARTED TO US, IT HAS ALSO TAUGHT US TO BUILD AND
MAINTAIN BETTER HUMAN INTERACTIONS, TO UNDERSTAND
HUMAN NATURE AT WORK AND EXECUTE AN ASSIGNED TASK
EFFECTIVELY.
THE CREDIT TO WHAT WE HAVE LEARNT DURING THE
TRAINING PERIOD GOES TO THE COMPANY PERSONNEL AND OUR
COLLEGE AUTHORITIES. AT LAST I
CONCLUDE MY REPORT WITH MOST SATISFACTION AND BY TAKING
A LOT OF MEMORIES AND EXPERIENCES WITH ME, WHICH WILL
LAST FOREVER.
S.B.M.P., MUMBAI
74
CHAPTER
10
BIBLIOGRAPHY
I had visited the following websites for completion of my
Inplant Training report during my Training period.
1) http:// gr2ueintra [L&T Intranet site]
2) www.ltindia.com
3) www.larsentoubo.com
4) www.google.com
Along with this I also referred books on heat exchanger&
pressure vessel. But mainly guidance provided by the shop
supervisors made an invaluable enhancement of my knowledge
at L&T.
S.B.M.P., MUMBAI