A CKNOWLEDGEMENT

A ll praise is to Almighty Allah, the Beneficent, and the Merciful. He showered

His great blessings upon us in the form of Holy Prophet, Hazrat Muhammad
(P.B.U.H).

With much effort and time spent, we thank God for being able to complete the
internship in HMC.

We wish to take this space and opportunity to express our thanks to all workers
for providing us with helpful information and exchanging thoughts, family
members for their financial support and HMC for supporting us in doing our
project.

Thank you.

Page 1 of 40
 Table of Contents
Sr. no Workshops & Labs Page no.

1. Introduction to HMC ………… 3

2. Organization and Function of PPC ……….. 5

3. Basic Machine Shop ………… 8

4. TTC & Heat Treatment ………… 24

5. Fabrication Shop ………… 27

6. NDT Lab ………… 33

7. Material Testing Lab ………… 34

8. Pattern Shop ………… 36

9. Forge shop-I&II ………… 38

10. Inspection ………… 39

11. Recommendations ………… 40

Page 2 of 40
 INTRODUCTION TO HMC
Heavy Mechanical Complex (Pvt) Limited is a leading engineering goods manufacturing
enterprise in Pakistan located at Taxila about 32 Kilometers north of capital Islamabad. It is a
professionally managed progressive organization with over 160,000 sq. meters covered
facilities and 1,100 employees.

Heavy Mechanical Complex Ltd. (HMC), Taxila is a major heavy engineering subsidiary of the
State Engineering Corporation (SEC) under the Ministry of Industries & Production, Government
of Pakistan.

In 1969, General YAHYA KHAN laid the basis of HMC. Then in 1971, HMC started its
production. In 1975, Prime minister of Pakistan ZULFIQAR ALI BHUTTO inaugurated the HFF. For
some years, these two industries worked separately. But after some years, both were combined
because for many works they had need of one another

HMC defines itself as “A technical institute in which all types of machines including Sugar
plants, Cement Plants, Road rollers, Over Head Cranes ranging from 0.5 to 50 tons Heat
Exchanger boilers, Special Defense parts (i.e., NDC works), Special Vibratory Rollers (which can
bear statistically 10 to 12 tons vibratory load) and Pakistan steel works. Some other processes
that are also done by HMC are Designing and manufacturing and assembling and installation
with the certification of ISO – 9001 and ASME Standards.

The Heavy Mechanical Complex (HMC), the biggest undertaking of its type in Pakistan,
was established in 1976 with Chinese assistance. The Heavy Forge Factory (HFF) at this complex
has proved crucial for Pakistan's defense production needs. HMC has the capability for
designing, engineering and manufacturing of industrial plants and machinery. HMC has the
largest fabrication and machining facilities in the country equipped with Computer Aided
Designing (CAD) and can undertake a variety of fabrication / machining jobs on sub-contracting
basis.

HMC manufactures equipment for hydro-electric power plants, thermal power plants, Sulphuric
acid plants, industrial alcohol plants, oil & gas processing plants, and chemical & petro-chemical
plants, etc. Boilers, cranes, construction machinery, material handling equipment, steel
structure, railway equipment, etc. are some of the other products which are produced on
regular basis. The company's capabilities include engineering and manufacturing of Sugar Mills
ranging between 1,500 - 12,000 TCD (tons of cane crushing capacity per day), Portland Cement
Plants of 700- 5,500 TPD (tons per day) module and White Cement Plant of 50 - 1,000 TPD.

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HMC have the resources to handle large projects with demanding delivery schedules. Being the
largest and most extensive fabrication and machining facility equipped with state of the art
technology. HMC provide manufacturing services both on our own or customers design. .

 PRODUCTS
HMC is one of the leading industries of Pakistan especially in the field of Steel.

Heavy machineries are being produced here like:

Road rollers
Overhead cranes
Mobile crane
Sugar plants
Cement plants
Oil refineries
Power plants
Pressure vessels
Boilers 40 to 80 Ton
Heavy duty machinery
Hydral power plants
Turbines
Rod construction machinery
Asphalt mixing plant etc.
First Boiler With Capacity of 140 Tons

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 Organization and Function of PPC (Production, Planning and Control)
Objective of PPC: - PPC is organized for improving the performance of company. PPC
department is headed by Dy. General Manager. It has following sections.

A. Sales order numbering system:-

The sales order numbering system allocates a unique identification system to each order
acquired by the sales and marketing department. This sales order consists of six digits. The
first two of these numbers designate the product group number of the products to be
manufactured or services to be provided by the organization. The next two digits specify the
fiscal year in which the order is received and the last two digits give the number of similar
orders already received in the same fiscal year.
For example, a job order given as11-11-04 is read as follows
11_______ product group no for sugar spares
13_______represents 2013 as the fiscal year
04_______specifies the fourth order for the current year
That is fourth order of sugar spares in 2013.

B. Core Planning:-
Core planning section has following works.

 Master schedule planning.

 Order Activity plans.
 Monitoring of all the schedules.
 Preparation of various periodic reports for MIS.
 Maintaining of balance order position.
 Maintaining sale and production report.
 Sale/production budget.
 Project review meeting and follow up.
 Data entry for DP list and updating of all files.
 Processing of all data and generation of reports.

C. Project planning:-
 To ensure receipt of all drawings and documentation from design.
 To issue the material purchase requirement.

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  To prepare the requirements of materials to be issued.
 To coordinate the production technology for preparation of necessary production
documents for manufacture.
 To prepare and issue job orders and prepare the follow up.
 To suggest the alternate materials for use from available stock to design.
 To compile standard material requirements for all products and projects.
 To draw the standard items /equipments from stores for dispatch to costumer sites.
 To prepare data for ICR (Income tax Cost and Revenue) for the survey by CBR
(Central Board of Revenue).

D. Material Management (MMG):-

C-1:- MMG Section:-
 Material requirement planning.
 Intending and follow up of indent.
 To keep updated purchase status of all project documents.
 Establish stock levels for general consumable items and raw materials.
 Coding of store items.
 Insurance of material to appropriate job.
 To keep and maintain updated stock status of all store items.
 To look after stores and related functions.
C-2:- General Stores:-
 To receive and issue all the materials and equipments in stores as per laid down
procedure.
 Maintain detailed record of stock movement.
 Maintain stock location system.
 Ensure daily submission of issue and receipt statement to concerned department.
 Ensure that all the storage areas (open/covered) are kept properly secured and organized.

E. Production Technology:-
D-1:- Feasibility/Quantitative Detail:-
 Feasibility study and quantitative details of client´s enquiries for cost estimates.
D-2:-Process Planning:-
Preparation of following documents.
 Detail parts list.
 Route card (machining and fabrication) if required.
 Cutting plans.
 Time sheets.
D-3:- Tool designing:-
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 Designing of all types of press tools, dies, templates, jigs and fixtures.
 To produce drawings for machinery components for maintenance.
 Cutting plans, cutting/marketing templates for shop.

F. Dispatch Cell/Material Handling:-

E-1:- Material handling:-
 To keep all the material handling equipment operation worthy.
 Provide material handling services to stores and dispatch cells and shops as and when
required.
 Keep the open yard tidy and organized.
 Receive materials from shops for surface preparation.
 Arrange sand blasting/paint as per contractual requirement.
 Receive raw materials from general stores for onward issuance to shops against job
orders.
E-2:- Dispatch Cell:-
 To receive finish goods from shops/material handling sections.
 To draw the standard items/equipments from stores for dispatch to costumer/sites.
 To organize preservation/packing.
 Maintain detailed dispatch records of finished goods, equipments, standard items against
each contract.
 Organize transportation.
 Ensure complete and accurate documentation along with each dispatch.
 To prepare the dispatch plans and ensure compliance.
G. I.C.R (Income tax Cost and Revenue):-
 To defend in litigation/adjudication and contravention.
 To organize industrial survey.
 To obtain the consumption certificates and release of guarantee.
 To obtain extension/coordination from CBR (Central Board of Revenue) and custom
collectrate.
 To deal with matter pertaining to custom duty and sale tax.
 To clear consignments for dry port and Islamabad airport.
 To keep close contact with collectorates of custom, sales tax, Central Excise
Islamabad/Rawalpindi and Central Board of Revenue (CBR) for all matters to HMC´s
imports.

To follow up for the settlement of all customs and sales tax matters with concerned agencies

Page 7 of 40
 Basic Machine Shop
In the development of every nation industries are very important and for industries
machinery is key factor. To check the development of any industry check it’s machinery.

In the machine shop of Heavy mechanical Complex there are nearly 500 machines of different
sizes and capacities. The machine shop of HMC contains various types of machines.

Available machines:
 Lathe machine (three jaws and four jaws chucks, turret).
 Planer.
 Milling machine.
 Drilling machine.
 HDL (heavy duty lathe).
 BVT (boring vertical turret lathe machine).
 Gear hobbing machine.
 Gear shaper machine.
 Straight bevel machine.
 Horizontal lathe machine.
 Radial drilling machine.
 Slotting machine.
 Double housing planner.
 Face plate machine.
 Column drilling machine.

MACHINING OPERATIONS AND MACHINE TOOLS:-

• Turning and Related Operations

• Drilling and Related Operations

• Milling

• Machining Centers and Turning Centers

• Other Machining Operations

• High Speed Machining

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 Machining
• A material removal process in which a sharp cutting tool is used to mechanically cut
away material so that the desired part geometry remains

• Most common application: to shape metal parts

• Machining is the most versatile and accurate of all manufacturing processes in its
capability to produce a diversity of part geometries and geometric features (e.g. screw
threads, gear teeth, flat surfaces)

Classification of Machined Parts

1. Rotational - cylindrical or disk-like shape. Achieved by rotation motion of the workpart.

Ex. turning and boring

2. Nonrotational (also called prismatic) - block-like or plate-like. Achieved by linear

motion of the workpart. Ex. Milling, shaping, planing and sawing

Rotational Non-Rotational

Turning
• A single point cutting tool removes material from a rotating workpiece to generate a
cylindrical shape

• The tool is fed linearly in a direction parallel to the axis of rotation

• Performed on a machine tool called a lathe

• Variations of turning that are performed on a lathe:

 Facing

 Contour turning

 Chamfering

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  Cutoff

 Threading

Figure 1.2 - Turning operation

Facing
Tool is fed radially inward to create a flat surface.

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Chamfering
Cutting edge cuts an angle on the corner of the cylinder, forming a "chamfer".

Threading
Pointed form tool is fed linearly across surface of rotating work part parallel to axis of rotation at
a large feed rate, thus creating threads.

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Lathe Machines
• Most lathe machines are horizontal but vertical lathe machines are also used for jobs with
large diameter relative to the length and for heavy work

• The size of the lathe is designated by swing and maximum distance between centers

• Swing is the maximum workpart diameter that can be rotated in the spindle

• Maximum distance between centers indicate the maximum length of a workpiece that
can be mounted between headstock and tailstock centers

• 350 mm x 1.2 m lathe means a swing of 350 mm and maximum distance between centers
of 1.2 m

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Methods of Holding the Work in a Lathe

There are four common methods used to hold workparts in turning-to grasp the work, center and
support it in position along the spindle axis, and rotate it:

• Holding the work between centers

• Chuck

• Collet

• Face plate

Holding the Work

Between Centers

3 jaw self centered Chuck

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 Collet

Face Plate

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Boring
• Boring is similar to turning. It uses a single-point tool against a rotating workpart

• Difference between boring and turning:

 Boring is performed on the inside diameter of an existing hole

 Turning is performed on the outside diameter of an existing cylinder

• In effect, boring is an internal turning operation

• Machine tools used to perform boring operations are called boring machines

• Boring machines

 Horizontal or vertical - refers to the orientation of the axis of rotation of machine

spindle

Boring bar on tool post Boring bar between

centres

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Vertical Boring Mill

• Figure - A vertical boring mill –for large, heavy workparts

• Usually the workpart diameter is greater than its length

• Typical boring machine can position and feed several cutting tools

simultaneously

Drilling
• Machining operation used to create a round hole in a workpart

• Contrasts with boring which can only enlarge an existing hole

• Cutting tool called a drill or drill bit-a rotating cylindrical tool which has two cutting
edges on its working end

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 • Customarily performed on a drill
press

Radial Drill
• Large drill press designed for large parts

• Head can be positioned at significant distance from the column to accommodate large
work

Page 17 of 40
Milling
• A machining operation in which work is fed past a rotating tool with multiple cutting
edges

• Axis of tool rotation is perpendicular to feed direction

• Creates a planar surface; other geometries possible either by cutter path or shape

• Owing to the variety of shapes possible and its high production rates, milling is one of the
most versatile and widely used machining operations

• Other factors and terms:

 Milling is an interrupted cutting operation-the teeth of the milling cutter enter

and exit work during each revolution

 Cutting tool called a milling cutter, cutting edges called "teeth"

 Machine tool called a milling machine

Basic Types of Milling Operations

(a) Peripheral milling (b) Face milling

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Peripheral Milling vs. Face Milling
• Peripheral milling or plain milling:

 Cutter axis is parallel to surface being machined

 Cutting edges on outside periphery of cutter

• Face milling

 Cutter axis is perpendicular to surface being milled

 Cutting edges on both the end and outside periphery of the cutter

Types of Milling
• Peripheral Milling

 Slab milling

 Slotting

 Side milling

 Straddle milling

• Face milling

 Conventional face milling

 Partial face milling

 End milling

 Profile milling

 Pocket milling

 Surface contouring

Milling Machines
• Milling machines must provide a rotating spindle for the cutter and a table for fastening,
positioning and feeding the workpart

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• Types:

 Knee-and-column milling machine

 Universal milling machine

 Ram mill

 Bed type milling machine

 Planer type

 Tracer mills

 Tracer mills

 CNC milling machines

Horizontal knee-and-column milling

machine Suitable for peripheral
milling

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 Vertical knee-and-column milling machine

Suitable for face milling

Ram type knee-and-column machine; ram can

be adjusted in and out, and toolhead can be swiveled

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 Universal milling machine

Simplex bed-type milling machine: rigid construction for mass production

Page 22 of 40
Hobbing

Hobbing is a machining process for making gears, splines, and sprockets on a hobbing machine,
which is a special type of milling machine. The teeth or splines are progressively cut into the
workpiece by a series of cuts made by a cutting tool called a hob. Compared to other gear
forming processes it is relatively inexpensive but still quite accurate, thus it is used for a broad
range of parts and quantities

It is the most widely used gear cutting process for creating spur and helical gears and more gears
are cut by hobbing than any other process since it is relatively quick and inexpensive.

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 Heat treatment Shop
Heat treatment is a method used to alter the physical and sometimes chemical properties of a
material. The most common application is metallurgical. Heat treatments are also used in the
manufacture of many other materials, such as glass. Heat treatment involves the use of heating
or chilling, normally to extreme temperatures, to achieve a desired result such as hardening or
softening of a material.. It is noteworthy that while the term heat treatment applies only to
processes where the heating and cooling are done for the specific purpose of altering
properties intentionally, heating and cooling often occur incidentally during other
manufacturing processes such as hot forming or welding.

Heat treatment techniques include

Full hardening
 Annealing.
 Hardening Surface hardening
 Tempering
 Normalizing
 Stress releasing Cause hardening
 Carburizing
 Phosphating (phosphate coating is used to protect the surface from corrosion)

HMC has following Types of Furnace and facilities which are use in heat treatment section

 HTS-1 Electric carbon furnace

 Electric box type furnace
 Flame hardening machine for surface hardening
 Chamber type Cleaner
 Electric tempering oil bath
 High temperature salt bath
 Low temperature salt bath
 Medium temperature salt bath
 High frequency induction heat treatment lab

Heat treatment of metals and alloys

Metallic materials consist of a microstructure of small crystals called "grains" or crystallites. The
nature of the grains (i.e. grain size and composition) is one of the most effective factors that
can determine the overall mechanical behavior of the metal. Heat

Treatment provides an efficient way to manipulate the properties of the metal by controlling
rate of diffusion, and the rate of cooling within the microstructure.

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Annealing

Annealing is a technique used to recover cold work and relax stresses within a metal. Annealing
typically results in a soft, ductile metal. When an annealed part is allowed to cool in the
furnace, it is called a "full anneal" heat treatment. During annealing, small grains recrystalliz to
form larger grains.

Normalizing

When an annealed part is removed from the furnace and allowed to cool in air, it is called a
"normalizing" heat treatment. Normalizing: Carbon steel is heated to approximately 55 °C
above Ac3 or Acm for 1 hour; this assures the steel completely transforms to austenite. The
steel is then air-cooled, which is a cooling rate of approximately 38 °C (100 °F) per minute. This
results in a fine pearlitic structure, and a more-uniform structure. Normalized steel has a higher
strength than annealed steel; it has a relatively high strength and ductility .Typical annealing
processes include, "normalizing", "stress relief" annealing to recover cold work, and full
annealing.

Hardening and tempering (quenching and tempering)

To harden by quenching, a metal (usually steel or cast iron) must be heated into the austenitic
crystal phase and then quickly cooled. Depending on the alloy and other considerations (such as
concern for maximum hardness vs. cracking and distortion), cooling may be done with forced
air or other gas (such as nitrogen), oil, polymer dissolved in water, or brine. The quenched
hardness of a metal depends upon its chemical composition and quenching method. Cooling
speeds, from fastest to slowest, go from polymer (silicon), brine, fresh water, oil, and forced air.

Tempering is a heat treatment technique for metals, alloys and glass. In steels, tempering is
done to "toughen" the metal by transforming brittle martensite into bainite or a combination of
ferrite and cementite.

Untempered martensite, while very hard and strong, is too brittle to be useful for most
applications. A method for alleviating this problem is called tempering. Most applications
require that quenched parts be tempered (heat treated at a low temperature, often three
hundred degree Fahrenheit or one hundred fifty degrees Celsius) to impart some toughness.
Higher tempering temperatures (may be up to thirteen hundred degrees Fahrenheit or seven
hundred degrees Celsius, depending on alloy and application) are sometimes used to impart
further ductility, although some yield strength is lost.

Precipitation hardening

Some metals are classified as precipitation hardening metals. When a precipitation hardening
alloy is quenched, its alloying elements will be trapped in solution, resulting in a soft metal.
Aging a "solutionized" metal will allow the alloying elements to diffuse through the

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microstructure and form intermetallic particles. These intermetallic particles will nucl eate and
fall out of solution and act as a reinforcing phase, thereby increasing the strength of the alloy.
Alloys may age "naturally" meaning that the precipitates form at room temperature, or they
may age "artificially" when precipitates only form at elevated temperatures. In some
applications, naturally aging alloys may be stored in a freezer to prevent hardening until after
further operations - assembly of rivets, for example, may be easier with a softer part.

Induction heating

Induction heating is the process of heating an electrically conducting object (usually a metal) by
electromagnetic induction, where eddy currents are generated within the metal and resistance
leads to Joule heating of the metal. An induction heater (for any
process) consists of an electromagnet, through which a high-
frequency alternating current (AC) is passed. Heat may also be
generated by magnetic hysteresis losses in materials that
have significant relative permeability. The frequency of AC
used depends on the object size, material type, coupling
(between the work coil and the object to be heated) and the
penetration depth.

Induction heating allows the targeted heating of an applicable item for applications including
surface hardening, melting, brazing and soldering and heating to fit. Iron and its alloys respond
best to induction heating, due to their ferromagnetic nature. Eddy currents can, however, be
generated in any conductor, and magnetic hysteresis can occur in any magnetic material.
Induction heating has been used to heat liquid conductors (such as molten metals) and also
gaseous conductors (such as gas plasma). Induction heating is often used to heat graphite
crucibles (containing other materials) and is used extensively in the semiconductor industry for
the heating of silicon and other semiconductors

Induction furnace

An induction furnace uses induction to heat metal

to its melting point. Once molten, the high-
frequency magnetic field can also be used to stir
the hot metal, which is useful in ensuring that
alloying additions are fully mixed into the melt.
Most induction furnaces consist of a tube of water-cooled copper rings surrounding a container
of refractory material. Induction furnaces are used in most modern foundries as a cleaner
method of melting metals than a reverberatory. Metals melted include iron and steel, copper,
aluminum, and precious metals. Because it is a clean and non-contact process it can be used in

Page 26 of 40
a vacuum or inert atmosphere. Vacuum furnaces make use of induction heating for the
production of specialty steels and other alloys that would oxidize if heated in the presence of
air.

FABRICATION SHOP

Customer

Fabrication shop

Sale and
Material
marketing issue to
fab shop Check
the
work
Design deppt Fabrication CTC
Job planning
for fab shop

PPC
Deliver to
dispatch
cell

HMC fabrication shop has full capacity to fabricate every part which is used in boiler, gas tanks,
teem boiler, roar roller parts etc; HMC has following machine in fabrication shop.

 Parallel cutting machine.

 Trennjaeger circular saw.
 CNC cutting Machine
 Angle cutting machine
 Boom Column sub march welding machine
 Photo cell cutting machine
 Semi automated machine
 Non ferrous steel cutting machine

Page 27 of 40
  Circular saw small size and large size.
 Straight rolling machine
 Rerolling machine
 Plasma cutting machine
 100ton press machine
 160ton brack press machine
 3000ton press machine
 Membrane water wall welding machine etc

Fabrication is the process of forming, casting, machining and welding of metals.

Fabrication, when used as an industrial term, applies to the building of machine, structures and
other equipment, by cutting, shaping and assembling components made from raw materials.
Small businesses that specialize in metal are called fabrication shop. Steel fabrication shops and
machine shops have overlapping capabilities, but fabrication shops generally concentrate on
the metal preparation, welding and assembly aspect while the machine shop is more concerned
with the machining of parts.

Metal fabrication

Metal fabrication is a value added process that involves the construction of machines and
structures from various raw materials. A fabrication shop will bid on a job, usually based on the
engineering drawings.

Raw materials

Standard raw materials used by metal fabricators are

 plate metal
 welding wire
 co gas
 argon gas
 Cutting torches
 silica etc

The raw material has to be cut to size. This is done with a variety of tools.

Cutting

The raw material has to be cut to size. This is done with a variety of tools. The most common
way to cut material is by Shearing (metalworking); Special band saws designed for cutting metal
have hardened blades and a feed mechanism for even cutting. Abrasive cut-off saws, also
known as chop saws, are similar to miter saws but with a steel cutting abrasive dis k. Cutting
torches can cut very large sections of steel with little effort.

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Forming

Hydraulic brake presses with v-dies are the most common method of forming metal. The cut
plate is placed in the press and a v-shaped die is pressed a predetermined distance to bend the
plate to the desired angle. Tube bending machines have specially shaped dies and mandrels to
bend tubular sections without kinking them. Rolling machines are used to form plate steel into
a round section.

Machining

Fabrication shops will generally have a limited machining capability including; metal lathes,
mills, magnetic based drills along with other portable metal working tools.

Welding

Welding is the main focus of steel fabrication. The formed and machined parts will be
assembled and tack welded into place then re-checked for accuracy. A fixture may be

Used to locate parts for welding if multiple weldments have been ordered. The welder then
completes welding per the engineering drawings, if welding is detailed or per his own judgment
if no welding details are provided.

Special precautions may be needed to prevent warping of the weldments due to heat. These
may include re-designing the weldments to use less weld, welding in a staggered fashion, using
a stout fixture, covering the weldments in sand during cooling, and straightening operations
after welding.

Straightening of warped steel weldments is done with an Oxy-acetylene torch and is somewhat
of an art. Heat is selectively applied to the steel in a slow, linear sweep. The steel will ha ve a net
contraction, upon cooling, in the direction of the sweep. A highly skilled welder can remove
significant war page using this technique.

Final assembly

After the weldments have cooled it is generally sand blasted, primed and painted. Any
additional manufacturing specified by the customer is then completed. The finished product is
then inspected and shipped.

TYPE OF WELDINGS

 Stick welding
 Tig welding

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  Mig welding etc

Shielded Metal Arc Welding (SMAW) is frequently

referred to as stick or covered electrode welding. Stick
welding is among the most widely used welding
processes. The flux covering the electrode melts
during welding. This forms the gas and slag to shield
the arc and molten weld pool. The slag must be
chipped off the weld bead after welding. The flux also
provides a method of adding scavengers, deoxidizers,
and alloying elements to the weld metal.

Tungsten inert gas (TIG) welding,

Gas tungsten arc welding (GTAW), also known as tungsten inert gas (TIG) welding, is an arc
welding process that uses a no consumable tungsten electrode to produce the weld. The weld
area is protected from atmospheric contamination by a shielding gas (usually an inert gas such
as argon), and a filler metal is normally used, though some welds, known as autogenously
welds, do not require it. A constant-current welding power supply produces energy which is
conducted across the arc through a column of highly ionized gas and metal vapors known as a
plasma .GTAW is most

Commonly used to weld thin sections of stainless steel and light metals such as aluminum,
magnesium, and copper alloys. The process grants the operator greater control over the weld
than competing procedures such as shielded metal arc welding and gas metal arc welding,
allowing for stronger, higher quality welds. However, GTAW is comparatively more complex
and difficult to master, and furthermore, it is significantly slower than most other welding
techniques. A related process, plasma arc welding, uses a slightly different welding torch to
create a more focused welding arc and as a result is often automated.

BOILER FABRICATION

In the energy sector HMC has supplied over 30,000 tons of fabricated equipment and parts to
different power plants. Major strength is HMC's capabilities for manufacturing utility boilers
pressure parts. For this purpose some of the major machines are:

 3 roller bending machines for making drums

 Booster pipe bending machine for making super heater

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  Reheated and economizer coils
 Specialized machine for machining and welding of headers and complete train of
machines for manufacture of membrane walls in panel and bent form

HMC has the capability to manufacture following type of boilers:

 Natural circulation steam generators

 Heat recovery steam generators
 Fluidized bed combustion boilers

Besides Boiler Island, HMC have also capabilities and expertise for manufacture of balance of
plant equipment / parts such as:

 Condensers
 L.P. heater
 H.P. heater parts
 Water treatment plant
 Deaerator and feed water tank
 Pressure vessels
 Oil storage tanks
 Cooling water system
 Heat exchangers
 Steel structure
 Elevator hoist and cranes
 Piping
 Other misc. items

With a team of well experienced engineers and technicians, HMC is well prepared to carry out
all site construction work which includes:

 Site fabrication
 Erection / installation and commissioning
 Civil works (if part of complete construction work, package)

HMC is also providing services for repair / maintenance and BMR of existing power plant for its
boilers, turbines, condensers, heaters and other equipment.

BOILER COMPONENTS Super Heaters One of the most important

accessories of a boiler is a superheated. It affects improvement and
economy in the following ways.

 The superheated increases the capacity of the plant.

 Eliminates corrosion of the steam turbine.

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Reduces steam consumption of the steam turbine.

ECONOMISERS

This is feed-water heaters in which the heat from waste gases is

recovered to raise the temperature of feed-water supplied to the
boiler. They offer the following advantages:

 Fuel economy
 Longer life of the boiler
 Increase in steaming capacity
 Finned Tube Economizers
 C.I. Gilled Tube Economizers
 Plain Tube Coil Economizers

Steam Generating Tubes

These are tubes in the Boiler where water is evaporated to steam and
are also called Steam Generating Tubes. These Tubes also form the Walls
of the Boiler and are hence called Water Walls or Water Wall Panels.
These Tubes have very complicated shapes to allow Inspection openings
and burner throats and fabrication require bending Machines.

Boiler Fabrication Techniques. HMC has 3.5 meter rolling capacity. And
it can manufacture 2 ton to 80 ton boiler.
Radiography
Material purchase Stress releasing

Re rolling Hydraulic testing

Third party verify material

Welding
Third party test
Marking & cutting
layout
Third party verify material
Pre bending

Rolling LW fit up

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 NON DESTRUCTIVEVE TESTING(NDT)
IT INCLUDE DIFFERENT OPEREATIONS

 INDICATION

 INTERPRETATION

 FALSE

 RELEVENT

 NON RELEVENT

 EVALUATION

 ACCEPT

 REJECT

NON DESTRUCTIVE EVALUATION FACILITIES:

1- X-ray radiography

2- Gamma rays radiography

3- Ultrasonic

4- Magnetic particle inspection

5- Liquid penetrant method

6- Eddy current spectroscopy

RADIOGRAPHY TESTING METHOD:

Radiography testing is most universally used NDT method for the detection of gas porosity in
weldments. The radiographic image of a round porosity will appear as oval shaped spots with
smooth edges, while elongated porosity will appear as oval shaped spots with the major axis
sometimes several times longer than the minor axis. Foreign material such as loose scale flux or
splatter will affect validity of test results.

ULTSONIC TESTING:

Ultrasonic testing equipment is highly sensitive, capable of detecting micro separations.

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 Surface finish and grain size will affect the validity of test results.

EDDY CURRENT TESTING METHOD:

Normally confined to thin wall welded pipe and tube

Penetration restricts testing to a depth of more than one quarter inch

LIQUID PENETRANT TESTING METHOD:

Normally confined to in process control of ferrous and non ferrous welds

Liquid penetrant testing like magnetic particle is restricted to surface evaluation

Extreme caution must be exercised to prevent any cleaning material and liquid
penetrant materials from becoming entrapped and contaminating the rewelding
operation

MAGNETIC PARTICLE TESTING METHOD:

Not normally used to detect gas porosity. Only surface porosity would be evident. Near surface
porosity would not be clearly defined since indications are neither strong nor pronounced.

MATERIAL TESTING LAB

There are three sections of the lab;

1- Chemical section

2- Metallographic

3- Mechanical

CHEMICAL SECTION:

The chemical section lies in the steel foundry. So, it mainly concerns with the determination of
the chemical composition of steel. However, samples from cast iron foundry are also brought
here to determine the chemical composition.

EMISSION SPECTROMETER:

In emission spectrometer, a 2”*2” sample is used. Arc is produced by using a tungsten

electrode. Argon gas is used for shielding. The atoms got excited. When they return to their

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ground state, they emit radiations. Each element emits radiations of some specific wavelength.
So, from the wavelength element and its percentage can be calculated.

WET ANALYSIS:

The chemical composition can also be determined by wet analysis. Different chemicals are used
in different proportions. The color achieved at the end is a measure of element and its
percentage.

Other facilities include;

1. Spectrophotometer 2. Carbon apparatus

MECHANICAL SECTION

HMC has a capability to test for metal mechanical properties like hardness, strength, shearing,
crushing, impact bend test etc.

HMC mechanical testing lab has following facilities…

FACILITIES:

 30 ton universal testing machine (UTM)

 60 ton UTM

 10 ton UTM

 100 ton UTM

 Charpy impact testing machine

 Brinell hardness tester 2 pieces

 Rockwell hardness tester 2 pieces

 Vicker hardness tester TESTS:

 Tensile

 Bend

 Shear

 Compression/crushing

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METALLOGRAPHY:

Here, the macrostructure and microstructure is determined. A number of microscopes are

placed here in lab having different

magnifications such as;

 100 X

 450 X

 1000 X

 2000 X

 A hardness tester with 450 X

PATTERN SHOP
The purpose of pattern shop is to make wooden or metallic components for casting
process.

TYPES OF PATTERN:-

 One piece or solid pattern

 Two piece or split pattern

 Three piece pattern

 Loose piece pattern.

 Self core pattern.

 Sweep pattern.

 Skeleton pattern.

 Match plate pattern.

 Connecting pattern.

 Master pattern

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TYPES OF CORE PRINTS:-

 Top print.

 Bottom print.

 Side print.

 Tail print.

 Hang print.

 Balancing print.

TYPES OF CORE BOX :-

 Box type core box.

 Shake out type core box.

 Gang type core box

MACHINES IN PATTERN SHOP:-

 Band saw.

 Joint planner.

 Thickness planner.

 Disc and spindle sander.

 Wooden lathe machine.

 Wooden milling machine.

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 Forging Shop

In HMC there are two forging shop that differs in capacity and type of job.

They are also facilitated with heat treatment processes.

Forging shop I:
In this shop die forging is done.

Die forging:
In this type of forging method specific dies are used to produce the specific job
for this allowance is very low.

Requirements:
For die forging we need:

 Furnace
 Hammers
 In HMC forging shop 1 has following facilities:
 150kg hammering machine
 300kg hammering machine
 750kg hammering machine
 800 ton hydraulic press with 3 ton manipulator
 25 to counter blow
 Trimming press
 Crew presser
 63 ton power press
 400 ton press
 1250 ton press
 Swelling crane of 1 ton capacity

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 Forging shop II

In this shop free forging is done. Free forging is method of producing jobs without using
dies. In free forging large allowance is present.
HMC have following facilities in this shop:
 1 ton hammer
 2 ton hammer
 3 ton hammer

Forge:
It is the ability of the material to undergo deformation under compression without rapture.
Any material or alloy which can be brought to plastic stage through heating can be forged the
extent to which the material can be forged is governed by its compositions as well as
temperature of the forging. Selection of the forging material depend upon certain mechanical
prosperities inherent in the material like strength, malleability, resistance to fatigue ,
durability, shock or bending machinability . Some forgeable materials are listed below:
 Pure aluminum
 Pure magnesium
 Pure copper
 Aluminum alloys
 Magnesium alloys
 Copper alloys
 Carbon and low alloy steels
 Stainless steel
 Nickel alloys

INSPECTION
QUALITY INSPECTION

It is one of the most responsible and sensible department of the complex. If some part fails
outside in the field, it is not the mistake of the production department but of quality inspector
who passed it. So, the repute of any industry depends to a great extent on this department.
This department checks each and every material which comes in or goes out of the factory, i.e.
from the raw material to the final product. There is at least one quality inspector always
present in a shop for the stage inspection and the final inspection. If something exceeds the
tolerance, they have the right to reject it. They have different tools with them for the
measurements. Some of them are;

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  Inside micrometer

 Outside micrometer

 Mercer gage

 Vernier caliper

 Bevel protector etc.

Recommendations

We would like to give some recommendations to improve the quality of work and save time
along the health of the workers because during our visit we observed that the workers are not
playing with their own lives which are a great loss of man power. To eradicate it we recommend
following things:

Safety should be made necessary for each and every one especially for the fabrication shop
Their should be check and balance of these safety steps
Trained labor must have junior or fresh labor because in the future they can take their seats.
Environment should be made clean and healthy by planting plants and keeping the surface clean
To increase the rate of work the repeated jobs should be given to that person who had worked on it
but this should be made necessary for that person that he will convey his knowledge to his sub-
ordinates.

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