Smeclabs pvtltd

Internship Report

Submitted By:
JAGADEV(3PD15ME024)
Student of MECHANICAL ENGINEERING
PDA COLLEGE OF ENGINEERING
Table ofContents

1. Introduction……………………………………………….

2. Introduction to the Company………………......................

3. What I
learned???...............................................................

4. Main Body…………………………………………………

3.1QA/QC…………………………………………………
3.2 PurposeofQA/QCdepartment………………………..
3.2IDM…………………………………………………….
3.3Testingmethodsandtypesofwelding………………..
3.4Productsmanufactured……………………..

5. Conclusion………………………………………………….
1. Introduction

“This report is about my four weeks internship program which describes

the things which I learned in the Quality Control / Quality Assurance
department.Ithasthebasicconcepts,onhowaninspectionisdoneandof
whichmechanicalproducts.Thisreportalsotellsthedocumentationofan
inspectionreport,howtheproceduresarefollowedandsoon.”

2. Introduction totheCompany
SMEClabs is the research, development and training wing of
SMECAutomation,anISO9001:2008globalsolutionproviderand
theAuthorizedSystemIntegratorofSchneiderElectric,Franc
TheengineersatSMEClabs,formingtheCoreResourceGroup
(C.R.G.), constantly strive to keep the company ahead of its
competitionintermsoftechnologicaledge.
The C. R. G. also forms the faculty of SMEClabs, imparting world-
class Industrial automation training and process control training
to the students of the training facility, which is anAuthorized
System Integrator of Schneider Electric,France.
SMEClabs is proud to host an array of engineers and industry
experts who put in their ideas and instincts to develop new
technology, which is crucial for any player to stay on top of the
game.Wearefocusedondevelopingandconstantlyre-innovating
indigenous technology which is more adaptable to the Indian
customer needs and which is also more economically viable.
SMEClabsaimsatdevelopingandprovidingservicesandtoolsto
addresstheaspectsofearlyprocessdesign,processengineering
andimplementationfromapurelyengineeringperspective.The
economicalaspectsofcontrolsystemshavehighfocus,asdoes the
provisioning of the customer with improved knowledge and
decision supporttools.
With its combination of control architecture, logistics and
optimization,aswellasastronglogicdevelopmentcapacityand
training,SMEClabsformsanaturalextensiontoSMEC'sdiverse
activitiesonthecontrolengineeringarena.Tobeabletoprovide
clients with state-of-the-art services and tools, the unit
collaboratesclosewithalltheregionalbasesofSMEC,drawing
fromtheextensivecompetencyinthoseunits.
Weareabletoprovideassistanceindevelopingaprojectfroman
earlystage,baseduponcustomerneeds,throughtoaconceptual
design including an outline specification. We use our unique
conceptdevelopmentprocessdevelopedbySMEClabs,together
withexpertisefromotherunitsofSMEC,tofacilitatetheprocess
design development through pre-defined stages involving
analysesonbotheconomicalandtechnicallevel.Overtheyears
team SMEC has succesfully completed work onboard over 300
vessels. Work scope has mainly included complete electrical
system installations during the ship building process, complete
electricaloverhaulandmodernizationofvariousvesselsincluding
thoseoftheIndianNavy,SCI,Univanetc.
Industrial projects completed include various national level
projectsforcompanieslikeAdityaBirla,Reliance,TATAamongst
others. Govt. enterprises that have benefited from the SMEC
scientificofferingincludeISRO,VSSC,NPOL,ONGCandBARC
amongstothers.Oneoftherecentnoteworthyaccomplishments of
team SMEC in association with Schneider Electric was the
installation of the 'fully automated fuel supply system' for the
PSLVlaunchingChandrayaan-Iintospace.FYIthecontrollerused
forthisoperationwastheModiconM340trainingProgrammable
AutomationController(DCSlevel),AllenBardlyPLCtrainingthe
practical sessions of which are included in the SMEClabs
curriculum.

WhatIlearned???

Firstweek:
 Reading of isometricdiagrams.

 Got knowledge of different terms use in drawing i.e inlet deflector, ID,
EL,WL,liftinglugs,CS,LSjoint,Manway,Materials,Groovesign,fillet
sign.

 HaveintroductionofdifferentNDTtechniques.
1. Ultrasonictesting

2. Radiographytesting

3. Magnetic particletesting

4. Die penetratingtesting

 HaveintroductionofHeatexchanger,Boiler.

 Have introduction of coolant,vessels.

  Have introduction of weldingtechniques.

Second week:
 Came aware of different parts of vessels i.e Skirt, saddle lifting
lugs, man way, demister, internalrugs

 Gotknowledgeofdifferentweldingpositionsi.e1g,2g,3g…….etc.

 Learninspectionofpressurevesselhead.

 Learn sheet development measurement for shell ofvessel.

 Learninspectionofshelltag/fitup.

 Type offlanges

 Cameawareofdifferenttypesofflangesandtheirratings

1. WNRF

2. LWNRF

3. Blindflange

4. Socketflange

5. Threadedflange

6. Slip onflange

Third week:
 Witnessed different ASME codes used incompany

1. ASME section 8 div1

2. ASME section9
 3. ASMEB31.3

4. ASMEB31.3

5. ASMEB16.5

6. ASME section5

7. ASME section2

 Witnessedhydrotestandlearnimportantparameterofhydrotesting

 Havebriefexplanationofradiographytestingiert1,rt2,rt3,rt4

 Came ware of different parts of Heat exchanger and their

manufacturingiebaffleplates,mainshell,channelhead…….etc

 Learn different welding types and joint types ie but joint,

filler, groove….etc

 HavebriefexplanationofNDTtechniquesieRT,UT,MPIandDPT.

 Learnabouttubeexpansion,cuttersuseforCSandSS

 Witnessed sand blastingtechnique

 LearnaboutdifferentdocumentsformedinQA/QCdeptieWPS,PQR,
QIP,MTC,NCR,NDEmapandIDM

 Havebriefexplanationofdifferentweldingtechniques

1. SMAW

2. GTAW

3. FCAW

4. GMAW

5. SAW
  Learnaboutimportanceofpolesinwelding.

 Learn importance of Impacttest

Fourth week
 Learn inspection done forthickness.

 Cameawareofdifferenttypesofelectrodesuseforweldingieok
7018…etc

 LearnaboutPWHTandPREHEATINGofjob.

 Haveknowledgeofdifferentmaterialusedinmanufacturing.

 LearnaboutdocumentsuseinstoreieIRandWIN.

 Learnaboutdifferentcolorcodingusedinstoreforstorage.

 Learnimportanceofhotandcoldrollingprocess.

 Witnessing sheetdimensions.

 Have knowledge of storeinspection.

 Learn what electrode codingshow.

 Have knowledge of holiday detectortechnique.

3. MainBody
3.1 Quality:
Qualitymeanstoassurethattherespectivethingisaccordingtothe
prescribed standards andcodes.
 Quality Control:
Qualitycontrol(QC)isaprocedureorsetofproceduresintendedtoensure
thatamanufacturedproductorperformedserviceadherestoadefinedset
ofqualitycriteriaormeetstherequirementsoftheclientorcustomer.

Quality Assurance:
Quality Assurance(QA) is defined as a procedure or set of procedures
intended to ensure that a product or service under development (before
work is complete, as opposed to afterwards) meets specified requirements.
QA is sometimes expressed together with QC as a single expression,
quality assurance and control (QA/QC).

Departments under QA/QC:

IndescontherearefourdepartmentswhichcomeunderQA/QC,theseareas
mentioned below:

 Inspectors

 Weldingdepartment

 NDT( Non Destructive Testing)

 Materialcheck

3.2 What’s the purpose and job of QA/QCdepartment?

 ThepreparationofthecompaniesQAmanualcontrolandsupervisionofall
amendments andrevisions
 Controlandthedistributionofallthecompaniesqualitydocumentation
 Monitorallqualityrelatedactivitiesontheproject
 Perform all internal and external audits on behalf of the company’s
management
 Verifycontractorqualityrequirementsarespecifiedtovendorsand
contractor documentationsubmittals.
 Attendallpre-bidmeetingsandcoordinateallprojectrequirementswiththe
projectbidders.
 Attend client quality managementmeetings
 Thepreparationandcontrolofprojectqualitysystemmanagement
documentationpriortoprojectcommencement.
 Review quality inspection personnel qualifications and training
requirements
 Monitorthedispositionofallissuednonconformancereports.
 Monitortheprogressandeffectivenessoftheprojectqualitymanagement
system.Recommendandimplementimprovementswhenrequired.
 CoordinateallQA/QCactivitieswiththesiteQCmanager
 CoordinateallQA/QCactivitieswiththesiteQA/QCprocurementmanager
 Coordinateallqualityrelatedcorrespondencewiththecustomers
representatives.
 Monitor statistical methodreporting.
 Actionandcloseallcustomercomplaints
 Controlallachievesdocumentationuponthecompletionoftheproject.

Flowchart:
ThefollowingFlowchartwilltellushowaprojectisacquiredandafter
passingitthroughdifferentphasesitisfinallydispatched
3.3 IDM:
IDM(InstructionDataManual)isacomprehensivedocumentationinthe
formofacompletefilewhichisrequiredinqualityinspection.Itconsistsof every
single document of the inspection done of different parts of any
mechanical design orstructure.

ThetableofcontentsofanIDMandtheirdescriptionisasfollow: Table

ofcontents:

 As-BuiltDrawings

 DesignCalculations

 Quality inspectionplan

 Weld matrix/Weld Map/WPS/PQR

 Welder’s continuitylist
  MTR SummarySheet

 Dimensional inspectionreport

 NDE procedures and NDEpersonnel

 NDEreports

 Hydrostatic/Pneumatictestreportsandgaugescalibration
certificates/procedures

 Surface preparation/Paintingreport

 Copy of nameplate

 Manufacturer datareport

 NCR(ifany)

Description of IDM:
Brief description is asfollow:

 As-built drawingsare those drawings which are made after the

completionoftheproject,itincorporatesthechangeswhicharedone
during fabrication in fabricationdrawing.

 Qualityinspectionplanconsistsofthestepsandtheprocedureof
inspectionandeverystepofinspectionisrecordedinit.
  Weldmatrixshowswhichprocessofweldingisusedinwhichportion of
the project. WPS(welding procedure specification) shows how a
particular welding isdone.

3.4TestingmethodsandthemethodsofweldingusedinDescon:
NDT methods:
Nondestructive testing or Non-destructive testing (NDT) is a wide
group of analysis techniques used in science and industry to
evaluate the properties of a material, component or system
without causing damage.

Because NDT does not permanently alter the article being

inspected, it is a highly valuable technique that can save both
money and time in product evaluation, troubleshooting, and
research.

Types of NDT methods used in Descon:

 Ultrasonictesting

 Magnetic-particleInspection

 Radiographictesting

 Die penetrating

inspection Ultrasonic Testing(UT)

Ultrasonic Examination uses high-frequency sound waves which are
transmittedintoamaterialtodetectdiscontinuitiesorlocatechangesin material
characteristics. Sound is introduced into the object being
examinedandreflectionsfrominternalimperfections,areasofacoustic
impedance,orvaryinggeometricalsurfacesarereturnedtoareceiver.
Magnetic Particle Testing (MT)
Magnetic Particle Examination is accomplished by inducing a magnetic
fieldintoaferromagneticmaterialandapplyingironparticlestothesurface
oftheitembeingexamined.Surfaceandnear-surfacediscontinuitiesaffect
theflowofthemagneticfieldwithinthepartcausingtheappliedparticles
togatheratlocationsoffluxleakage,thusproducingavisibleindicationof
theirregularityonthesurfaceofthematerial.

Radiography (RT)
Radiographic Examination involves using radioactive isotopes (gamma
rays)orX-raysinmaterialstopeerqualitativelyforindicationsthesame
wayadoctorlooksforfracturesorotherconditionswithinthebody.
Radiation is directed through a part and projected onto film or a digital
detection device leaving an image which can be examined by the qualified
Radiographer.
Die Penetrant Testing (PT)
Penetrant Examination is performed with a dye solution. Once applied to
the surface, the dye will effectively penetrate any surface-breaking cavity.
Excess solution is removed from the object. A developer is then applied
to draw out any penetrant that remains unseen. With fluorescent dyes,
ultraviolet light is used to make the “bleed-out” fluoresce brightly, allowing
imperfections to be readily seen. With visible dyes, a color contrast
between the penetrant and developer makes the “bleed-out” easy to see.

TypesofweldingusedinDescon:
 SMAW

 GTAW

 GMAW

 FCAW
  SAW

Arc Welding or SMAW

Generallyknownasstickorarcwelding.Arcweldingisthemostbasicof
allweldingtypes,iseasytomasterinahomeweldingsituation.
Stick welding can be used for manufacturing, construction and repairs,
very much well suited for heavy metal size 4 millimetres upwards. Thinner
sheet metals and alloys are usually more suited to the mig welding types.

GTAW or Tungsten Inert Gas

TIG welding is comparable to oxy acetylene gas welding and needs a lot
more expertise from the operator. Employed for carrying out high-quality
work when a superior standard of finish is needed without making use of
excessive clean up by sanding orgrinding.

GMAW or Gas Metal Arc Welding

MorecommonlycalledMIGweldingthisweldingtypeisthemostwidely
usedandperhapsthemosteasilymasteredtypeofweldingforindustry and
home use. The GMAW process is suitable for fusing mild steel,
stainless-steel as well asaluminium.
FCAW

Flux-coredweldingwascreatedandputintouseintheearlyyearsofthe
1950’s.Itspurposewastogiveanotheroptiontothepopularuseof‘stick
welding’.TheFlux-Coredprocessismostlyusedforprojectsthatrequire
fastspeedasitisanautomaticformofwelding.

SAW

The Submerged Arc Welding process can only be used properly on

materialscontaininghighironcontents,suchasstainlesssteel.Thedevice
usedinthisprocesscanbeautomaticorsemi-automaticmakingitafairly fast
welding process. While it is a fast process, the electrical arc must
constantly be covered by ‘flux’ in order to protect the metal from the
atmosphere during the welding process. This cover also prevents any
welding spatter which makes it safer for welders than some of the other
formsofwelding.Theprocessisnamedafterthisneedtobe‘submerged’ in a
fluxcover.
5.4 Detail of Products Manufactured by SMEC:
The major products which SMEC is manufacturing are as follows:

 HeatExchangers

 Pressurevessels

 Boilers

 Fin FanCooler

Heat exchanger:

Aheatexchangerisadevicethatallowsheatfromafluid(aliquidoragas) to pass
to a second fluid (another liquid or gas) without the two fluids
havingtomixtogetherorcomeintodirectcontact.Ifthat'snotcompletely
clear,considerthis.Intheory,wecouldgettheheatfromthegasjetsjust
bythrowingcoldwaterontothem,butthentheflameswouldgoout!The
essentialprincipleofaheatexchangeristhatittransferstheheatwithout
transferringthefluidthatcarriestheheat.
Pressure Vessels:

A pressure vessel is a closed container designed to hold gases or liquids

at a pressure substantially different from the ambient pressure.The
pressure differential is dangerous, and fatal accidents have occurred in the
history of
pressurevesseldevelopmentandoperation.Consequently,pressurevessel
design, manufacture, and operation are regulated by engineering
authorities backed bylegislation.

Boiler:
Aboilerisaclosedvesselinwhichwaterorotherfluidisheated.Thefluid
doesnotnecessarilyboil.(InNorthAmericatheterm"furnace"isnormally
usedifthepurposeisnotactuallytoboilthefluid.)Theheatedorvaporized fluid
exits the boiler for use in various processes or heating
applications,including water heating, central heating,boiler-based power
generation, cooking, and sanitation.

Fin Fan Cooler:

An air cooled heat exchanger, or ACHE or Fin tubes heat exchanger, is
simplyapressurevesselwhichcoolsacirculatingfluidwithinfinnedtubes
byforcingambientairovertheexteriorofthetubes.Acommonexampleof
anaircoolerisacar’sradiator.

Air cooled heat exchangers are used for two primary reasons:

 They increase plantefficiency

 They are a “green” solution as compared to cooling towers andshell
and tube heat exchangers because they do not require an auxiliary
water supply (water lost due to drift and evaporation, plus nowater
 treatment chemicals are required).

SKILLS AND TECNIQUES LEARNED DURING INTERRNSHIP

An internship assits with career development by providing real
work experiences that provide us with opportunities to explore
our intrest and develop professional skills and competencies.
During internship ,we are provided with opportunities to apply
what we learned in classes to actual practice.It is expected that
wewillalsobechallengedtoexaminehowourattitude,beliefs
,and values influence the process.
It was valuable time in M.S.Industries and we learn unlimited here
are few point I have summarized:
1. About the leadership and term work to do an effective
work.
2. About the tactics to maintain disciplines and how to deal
withworkers.
3. How to control quality problems,defects in
material,labrotary testing of hardness of as material and
howtomeetthedemandsofcoustomers.
4. About the designing and important software like CATIA
etc.
5. How to make a powerfull team to achive target and to
solve theirproblem.
6. About the CNC machining process in CNC cell and some
heat treatmentprocess.
7. Howtofaceproblemsinindustrialsectors.
8. Obsereved some models of the machines along
with
advancemachiningcenterandsmallholedrillingmachine.
CONCLUSION
Internship helped me to enhance to my problems,solving
ability by seeing mangers using various methods, ideas and
plans to come out of the problems in different situation.Every
organisation before carrying out any task has to perform
managerial functions such as planning, organizing, directing,
controlling etc. besides usual functions such as
administation andmanufacturing.