An Industrial Interaction report on

In-plant training at

UMASONS STEEL FAB. PRIVATE LIMITED

Submitted by

SUBODH NITIN DANAO

(BE19F02F012)

Submitted in partial fulfillment of the requirement for

Degree of
Bachelor of Technology (Mechanical Engineering Major)
Of
Autonomous Institute Affiliated To
Dr. Babasaheb Ambedkar Marathwada University,
Aurangabad.

Department of Mechanical Engineering,

Government College of Engineering, Aurangabad.
Maharashtra State – India
2021-2022
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 CERTIFICATE

This is to certify that report on industrial interaction at UMASONS STEEL FAB.

PVT. LTD. submitted by Mr. Subodh Nitin Danao is a bona fide work completed under
my supervision and guidance in partial fulfillment for the award degree of Bachelor in
Engineering (Mechanical Engineering) of GOVERNMENT COLLEGE OF
ENGINEERING, AURANGABAD.

Place: Aurangabad

Date:

Dr. A.M. Nikalje Dr. U. V. Hambire

(H.O.D. - Mechanical) (Project Guide)

Dr. A. S. Bhalchandra

(Principal)

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3
 CONTENTS

ACKNOWLEDGEMENT 2
ABSTRACT 8
1 INTRODUCTION 9
1.1 Objectives of In Plant Training 9
1.2 Company Profile 9
1.3 Company Infrastructure 10
1.4 Company officials 11
1.5 Customers of company 11
1.6 Material Vendors 12

2 DETAILS OF ORGANISATION 13
2.1 Plant Layout 13
2.2 Details of equipment 14
2.2.1 Bending and Press Working Section 14
2.2.2 Welding Section 14
2.2.3 Plasma Arc Cutting Section 16
2.3 Products of the Company 16
2.3.1 SS Storage Tanks (SS 316 L) 17
2.3.2 SS Storage Tanks (SS 304) 17
2.3.3 SS Pressure Vessels 17

3 DETAILS OF TRAINING 17
3.1 Welding Shop 17
3.1.1 MIG Welding 18
3.1.2 TIG welding 23
3.1.3 Weld purging 25
3.2 Plasma Arc Cutting Shop 27
3.3 Buffing Shop 30
3.3.1 Sisals 31
3.3.2 Loose Full Disc Buffs 31

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 3.4 Product Design 32
3.4.1 Pressure Vessels 32
3.5 Material Selection 34
3.5.1 Stainless-Steel 304 35
3.5.2 Stainless-Steel 316 37

4 OUTCOMES 38

REFERENCES 39

LIST OF FIGURES

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Figure 1 Infrastructure at Umasons Steel Fab. 11
Figure 2 Plant Layout of M/S Umasons Steel Fab. Pvt. Ltd. 14
Figure 3 GMAW torch nozzle cutaway 16
Figure 4 Stainless-Steel Storage Tanks 17
Figure 5 Stainless-Steel Storage Tanks (SS 304) 18
Figure 6 Stainless-Steel Pressure Vessels 18
Figure 7 MIG welding machine 20
Figure 8 Shield for MIG welding 23
Figure 9 TIG welding 24
Figure 10 Back Purging 27
Figure 11 Plasma Arc Cutting 28
Figure 12 Buffing operation on SS Cylinder 30
Figure 13 Different geometries of end caps 32

LIST OF TABLES

Table 1 Equipment Details (Sheet Metal Shop) 13

Table 2 Equipment Details (Welding Shop) 14
Table 3 Plasma Arc Cutting Shop 15
Table 4 Shade levels for Plasma Arc Cutting 29
Table 5 Current Ratings for SS Plasma Arc Cutting 29
Table 6 Type Analysis of Stainless Type 304 37
Table 7 Type Analysis of Stainless Type 316 38

I. ABSTRACT

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 In-plant training is an essential and integral part of B.E Degree curriculum of
various universities and educational institutions in almost all parts of India. In-plant
training and project work is carried out in various R&D / Industrial / Operational
Organizations.
Technical training in industry is an integral part of engineering education &
development. The training program is a unique experience in learning and witnessing
first-hand, many manufacturing and production processes. It aims at providing the
technical knowledge & skills required for industrial operations and management. Other
organizational techniques like Total Quality Management are also familiarized by
students during the training period. This also is instrumental in aiding students to ascertain
their fields of interest.
In today’s world, there is a strong demand from industry for engineers who have
specific training in new technologies. To bridge the gap between the Industry
requirements and engineers’ skills, In-Plant Training Program offers practical approach to
bridge this deficit.

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1 INTRODUCTION

1.1 Objectives of In Plant Training

For any engineering student, a learning combination of theory and practice is an
invaluable asset, as it helps in understanding the core principles of business by way of
first hand experiences, this in – plant training is a stepping stone which will groom me for
my future in the corporate world. Following are the objectives of In – plant training:

a. To acquire knowledge about raw materials and their manufactures.

b. To acquire knowledge about machinery.
c. To execute work and delegate work
d. To have human interaction.
e. To behave with colleagues and co – workers.
f. To become familiar with modern test equipment.
g. To understand the commercial world.
h. To get an Industrial exposure.
i. To learn functioning and operations of different department in an
organization.
j. To get knowledge about the working culture of the organization.
k. To have knowledge about the huge management practices and get the
practical knowledge of what we have studied.

1.2 Company Profile

I have successfully completed in plant training at M/S. Umasons Steel Fab. Pvt.
Ltd. It is a Maharashtra based ISO 9001:2008 certified company established in the year
1962. It is one of the leading manufacturers and suppliers of Stainless-Steel Products,
Bulk Storage Tank, Charging Vessels, Mixing Vessels, High Pressure Reactors, Mobile
Hand Wash Sink, Skid Mounted System and PTFE Coating Products. The annual turnover
of the company in the market is about ₹ 5 crores.

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 Name of Director: Mr. Ravindra K. Padhye
Year of Establishment: 1962
Nature of Business: Manufacturer & Supplier
Market Covered: Domestic

1.3 Company Infrastructure

Umasons Steel Fab. Pvt. Ltd. Has a state of art infrastructure facility to run the
business smoothly with accelerating growth. The company is spread over an area of Total
16000 square feet with 5000 square feet covered area. The company is equipped with
latest technology and sophisticated machines such as:
• Electric
• TIG and MIG Welding M/C
• Plasma Cutting
• Hydraulic Shearing and Bending M/C
• Buffing Machinery
• Hot Cranes

Figure 1 Infrastructure at Umasons Steel Fab.

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 The production capacity of the unit is to handle and fabricate from 1mm to 16mm
thick sheet material.

1.4 Company officials

II. Managing Director - Mr. Ravindra K. Padhye.
III. General Manager - Mr. Ravindra K. Padhye
IV. Quality Manager - Mr. L. M. Thorat
V. Production Supervisor-Mr. Pramod Nirwal

1.5 Customers of company

I. Fresenius Kabi (I) Ltd.

Fifth Floor,A-wing, Ashoka Plaza, Pune-Nagar Road, Survey No.
32/2, Vadgaon Sheri,Viman Nagar, Pune, Maharashtra 411014
II. Lakshmi Agni auto Component Ltd.
B 15/1, MIDC Waluj, CIDCO, Aurangabad, Maharashtra
431003
III. Orchid Pharmaceutical and Chemicals Ltd
'Orchid Towers', #313, Valluvar Kottam High Road,
Nungambakkam, Chennai - 600 034
Tamil Nadu, India
IV. Wockhardt Ltd.
Prozone Mall, L1, M.I.D.C., Chikalthana, Aurangabad,
Maharashtra,
431005
V. Emcure Biotech Ltd.
Emcure House, T184, M.I.D.C., Bhosri Industrial Area,
Pune 411026.
VI. Serium Institute of India Ltd.
212/2, Hadapsar, Off Soli Poonawalla Road, Pune 411028.
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 VII. Concept Pharmaceuticals
A-28, Main Road, Near BSNL Office, Chikalthana, M I D C,
Aurangabad, Maharashtra.
431210
VIII. Micro Lab Ltd
CTS No. 73, Saki Estate Off, Chandivali Farm Rd, Chandivali,
Andheri East, Mumbai, Maharashtra.
400072
IX. Midas Care Pharmaceuticals P. Ltd
B-16, M I D C Road, Waluj, Aurangabad, Maharashtra
431136
X. Matrix Lab Ltd
1-1-151/1, 4th Floor, Sairam Tower, Alexander Road, Alexander
Road, Secunderabad, Telangana 500003

1.6 Material Vendors

I. Ganpati Alloys & steels
Plot No P-124, M I D C Industrial Area, Waluj, Near BPL Tower,
Waluj, Aurangabad, Maharashtra 431133

II. Paras Industrial Corporation

X-150, Opp. Akar Tools, MIDC, Waluj, Aurangabad, Maharashtra
431136

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2 DETAILS OF ORGANISATION

2.1 Plant Layout

Figure 2 Plant Layout of M/S Umasons Steel Fab. Pvt. Ltd.

2.2 Details of equipment

2.2.1 Bending and Press Working Section

Sr. No. Machines Qty.

1 Shearing Machine 1

2 Bending Machine 1
3 Hydraulic press 2

4 Squeezing machine 1

Table 1 Equipment Details (Sheet Metal Shop)

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 2.2.2 Welding Section

Sr. No. Machines Qty.

1 MIG Welding Machine 4

2 TIG Welding Machine 2

Table 2 Equipment Details (Welding Shop)

Welding gun and wire feed unit

The typical GMAW welding gun has a number of key parts—a control switch, a
contact tip, a power cable, a gas nozzle, an electrode conduit and liner, and a gas hose.
The control switch, or trigger, when pressed by the operator, initiates the wire feed,
electric power, and the shielding gas flow, causing an electric arc to be struck.

The contact tip, normally made of copper and sometimes chemically treated to

reduce spatter, is connected to the welding power source through the power cable and
transmits the electrical energy to the electrode while directing it to the weld area. It must
be firmly secured and properly sized, since it must allow the electrode to pass while
maintaining electrical contact. On the way to the contact tip, the wire is protected and
guided by the electrode conduit and liner, which help prevent buckling and maintain an
uninterrupted wire feed.

The gas nozzle directs the shielding gas evenly into the welding zone. Inconsistent
flow may not adequately protect the weld area. Larger nozzles provide greater shielding
gas flow, which is useful for high current welding operations that develop a larger molten
weld pool. A gas hose from the tanks of shielding gas supplies the gas to the nozzle.
Sometimes, a water hose is also built into the welding gun, cooling the gun in high heat
operations.

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 Figure 3 GMAW torch nozzle cutaway image. (1) Torch handle, (2) Molded phenolic dielectric (shown in white) and
threaded metal nut insert (yellow), (3) Shielding gas diffuser, (4) Contact tip, (5) Nozzle output face.

The wire feed unit supplies the electrode to the work, driving it through the
conduit and on to the contact tip. Most models provide the wire at a constant feed rate, but
more advanced machines can vary the feed rate in response to the arc length and voltage.
Some wire feeders can reach feed rates as high as 30.5 m/min (1200 in/min), but feed
rates for semiautomatic GMAW typically range from 2 to 10 m/min (75 – 400 in/min)

2.2.3 Plasma Arc Cutting Section

Sr. No. Machines Qty.

1 Plasma Arc Cutting Machine 2

Table 3 Plasma Arc Cutting Shop

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 2.3 Products of the Company

2.3.1 SS Storage Tanks (SS 316 L)

The company is a manufacturer and supplier of Stainless-Steel Storage Tank (SS
316 L/ Ss304). These Stainless-Steel Storage Tanks have various capacity (up to
25000Liters.). The Tank is especially manufactured for pharmaceutical Industry. Vessel
can be designed for Pressure and full vacuum having heating/ cooling etc. The internal
mirror has excellent finishing.

Figure 4 Stainless-Steel Storage Tanks

2.3.2 SS Storage Tanks (SS 304)

The company is engaged in manufacturing and supplying Stainless-Steel Storage
Tank. The Stainless-Steel Storage Tank are of SS 304, 316 as per requirement. The
capacity offered is from 50 Ltrs to 25000 Ltrs, having various configuration of pressure
and vacuum use.

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 Figure 5 Stainless-Steel Storage Tanks (SS 304)

2.3.3 SS Pressure Vessels

The company is among well-known manufacturers and suppliers of Stainless-Steel
Pressure Vessels. It designs and fabricate Stainless-Steel Pressure Vessels as per process
requirement. The working thickness of Stainless-Steel sheets is from 1.6 mm to 16 mm SS
316/ 304.

Figure 6 Stainless-Steel Pressure Vessels

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3 DETAILS OF TRAINING

3.1 Welding Shop

Definition: -  “Welding is the process of joining together two pieces of metal so that

bonding takes place at their original boundary surfaces” When two parts to be joined are
melted together, heat or pressure or both is applied and with or without added metal for
formation of metallic bond.

Type

● Arc welding
● MIG welding
● TIG welding

3.1.1 MIG Welding

Gas metal arc welding (GMAW), sometimes referred to by its subtypes metal inert
gas (MIG) welding or metal active gas welding, is a welding process in which an electric
arc forms between a consumable wire electrode and the workpiece metal(s), which heats
the workpiece metal, causing them to melt and join.

Along with the wire electrode, a shielding gas feeds through the welding gun,
which shields the process from contaminants in the air. The process can be semi-
automatic or automatic. A constant voltage, direct current power source is most
commonly used with GMAW, but constant current systems, as well as alternating current,
can be used. There are four primary methods of metal transfer in GMAW, called globular,
short-circuiting, spray, and pulsed-spray, each of which has distinct properties and
corresponding advantages and limitations.

Originally developed for welding aluminum and other non-ferrous materials in the

1940s, GMAW was soon applied to steels because it provided faster welding time
compared to other welding processes.

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 The cost of inert gas limited its use in steels until several years later, when the use
of semi-inert gases such as carbon dioxide became common. Further developments during
the 1950s and 1960s gave the process more versatility and as a result, it became a highly
used industrial process.

Today, GMAW is the most common industrial welding process, preferred for its
versatility, speed and the relative ease of adapting the process to robotic automation.

Figure 7 MIG welding machine

Advantages

● Higher Productivity

Many welders will enjoy higher productivity due to time saved by not having to
constantly change rods or chip away slag, as well as not having to brush the weld
repeatedly. They’re able to work faster and cleaner.

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● Simple to Learn
One of the top advantages of MIG welding is its simplicity. Welders can learn how to
MIG weld in a few hours, and some instructors claim they can provide basic training
in twenty minutes—with the majority of the time being spent on cleaning the weld.
TIG welding takes a long time to learn, and most welders working on home projects
won’t want to invest the time into it. One instructor described MIG welding as a
“point and shoot” process.

● Simple and Great Welds

MIG provides better weld pool visibility. Add this to the simplicity of the process and
better control offered by the auto-feed wire, and MIG makes it simple to produce a
great looking weld.

● Clean and Efficient

Since MIG uses a shielding gas to protect the arc, there is very little loss of alloying
elements as the metal transfers across the arc. There is no slag to remove, which is
typical for stick welding, and only minor weld spatter is produced. After a brief clean
up, MIG welders will be back on the job in a fraction of the time thanks to the
minimal cleanup it requires.

● Versatile
MIG welding is extremely versatile and can weld a wide variety of metals and alloys,
while operating at a variety of ways, such as semi and fully automatic. While MIG
welding is useful for many home welding projects, it is also used by a large number of
industries.
MIG is used for the following metals: aluminum, copper, Stainless-Steel, mild steel,
magnesium, nickel, and many of their alloys, as well as iron and most of its alloys.

● Faster Welding Speed

The continuously fed wire keeps both hands free for MIG welding, which improves
the welding speed, quality of the weld, and overall control.

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 Disadvantages

● Cost
Welders will notice right away that MIG welding equipment is more complex and
costly, while also sacrificing portability. In addition, shielding gas, electrodes, and
replacement tips and nozzles for MIG welding can add up.

● Limited Positions
The fluidity of the welding puddle and the high heat input of a MIG welder rules it out
for vertical or overhead welding. While some welders would never even think of
welding in one of these positions, take this factor into consideration when deciding
whether or not to purchase a MIG welder to make sure it can accomplish all of the
jobs planned for it.

● Unsuitable for Outdoor Welding

Besides not being portable, MIG welders are also unsuitable for working outside since
they use a shielding gas to protect the purity of the weld. Wind will play havoc with
the shielding gas and impact the quality of the weld. A MIG welder also can’t be
hauled out into a field to repair a tractor, but works great in the garage for automotive
work.

● Fast Cooling Rates

The welded metal will cool at rates that are higher since they aren’t covered by slag
when the weld is completed.

● Unsuitable for Thick Metals

While MIG welding is suitable for thin metals, it does not deliver proper penetration
for thicker steel that delivers a solid weld.

● Shielding Gas

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 The bottle of shielding gas can take time to replace and can get in the way while
welding.
● Metal Preparation Time
Before welding with a MIG welder, the material has to be free of rust or dirt in order
to get a good weld and for safety’s sake.

Figure 8 Shield for MIG welding

3.1.2 TIG welding

Gas tungsten arc welding (GTAW), also known as tungsten inert
gas (TIG) welding, is an arc welding process that uses a non-
consumable tungsten electrode to produce the weld. The weld area is protected from
atmospheric contamination by an inert shielding gas (argon or helium), and a filler
metal is normally used, though some welds, known as autogenous welds, do not require it.

A constant-current welding power supply produces electrical 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 non-

ferrous metals such as aluminum, magnesium, and copper alloys. The process grants the

21
operator greater control over the weld than competing processes such as shielded metal
arc welding and gas metal arc welding, allowing for stronger, higher quality welds.

Figure 9 TIG welding

Advantages: -

● Non-consumable electrodes - It helps to provide flawless joints because it is not

needed to stop for replacing the electrode as in consumable electrode welding.
That also contributes to reducing downtime in production.
● No flux is required because inert gas shields molten metal. So no slag and slag
inclusion problems.
● High quality and strong welding achieved by TIG.
● Cleaner and more appealing joints. Sometimes they don’t need finishing process.
● They are suitable for welding of very thin sections.

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Disadvantages: -
● TIG is a time-consuming process - They are slower than any other welding
process. Lower filler deposition rate.
● More complicated - Highly skilled and professional workers are needed to perform
TIG welding.
● Safety issue - Welders, are exposed to high intensity of light which can cause eye
damage.
● High initial cost.
● It cannot use in thicker sheets of metal.

3.1.3 Weld purging

It is the act of removing, from the vicinity of the joint, oxygen, water vapour and
any other gases or vapours that might be harmful to a welding joint as it is being welded
and immediately after welding.

Necessity of purging
When you are welding Stainless-Steel pipe for the food service, industrial or
automotive industries back purging is done to prevent the formation of oxides inside of
the pipe, which are caused by the presence of oxygen.

In weld speak, this is known as "sugaring" and these oxides will result in a poor
weld characterized by a black, crusty appearance of the weld metal on the inside (root) of
the pipe and an irregular root cross-section. Weld defects include lack of fusion to the
base metal, root-pass cracking and incomplete penetration.

When heated to welding temperatures, alloys such as Stainless-Steel and Inconel

are prone to the formation of oxides if not shielded from oxygen present in the air.
Technically known as "sugaring" or "noogies," these oxides will result in a poor
weldment, characterized by a black, crusty appearance of the weld metal on the inside
(root) of the pipe and an irregular root cross-section. Weld defects include lack of fusion
to the base metal, root-pass cracking and incomplete penetration.

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 Stainless-Steels, duplex steels, titanium-, nickel- and zirconium- alloys are
sensitive to the presence of air, oxygen, hydrogen, water vapors and other vapors and
gases that may combine with the hot metal as it is being joined. Such gases may combine
with the metal to form undesirable compounds that may reduce corrosion resistance or
may be instrumental in creating cracks or other structural defects in metals.

Weld Purging is generally necessary for the first weld run when joining to separate
parts. This sealing weld will be called a “root run” when it takes more than one run or
(pass) to fully seal the root area from above.

Once the root run has been completed, it is possible to stop the purging process
unless the welding engineer has specified that purging should be continued for the second
and third passes for example in case the root weld becomes hot enough to oxidise in the
air that will have replaced the purge gas.

Back Purging:

In all but very large diameter pipes, welding should be done from the outside only
and the root passes are normally done by the GTA process. Gas backing is most
frequently employed in conjunction with GTA welding. Backing gas protects the
underside of the weld and the adjacent base metal surfaces from atmospheric
contamination which may result in weld porosity or poor surface appearance. The
requirement is for a small gas flow to maintain the purge. Where necessary to minimize
oxidation on the inside surface of the pipe, the back purging should be maintained during
several subsequent layers of welding regardless of welding process used. The volume of
gas required is therefore considerable.

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 Figure 10 Back Purging

3.2 Plasma Arc Cutting Shop

Plasma cutting is a process that cuts through electrically conductive materials by

means of an accelerated jet of hot plasma. Typical materials cut with a plasma
torch include steel, Stainless-Steel, aluminum, brass and copper, although other
conductive metals may be cut as well. Plasma cutting is often used
in fabrication shops, automotive repair and restoration, industrial construction,
and salvage and scrapping operations. Due to the high speed and precision cuts combined
with low cost, plasma cutting sees widespread use from large-scale
industrial CNC applications down to small hobbyist shops.

The basic plasma cutting process involves creating an electrical channel of

superheated, electrically ionized gas i.e. plasma from the plasma cutter itself, through the
work piece to be cut, thus forming a completed electric circuit back to the plasma cutter
via a grounding clamp. This is accomplished by a compressed gas (oxygen, air, inert and
others depending on material being cut) which is blown through a focused nozzle at high
speed toward the work piece. An electrical arc is then formed within the gas, between an

25
electrode near or integrated into the gas nozzle and the work piece itself. The electrical arc
ionizes some of the gas, thereby creating an electrically conductive channel of plasma.

As electricity from the cutter torch travels down this plasma it delivers sufficient
heat to melt through the work piece. At the same time, much of the high velocity plasma
and compressed gas blow the hot molten metal away, thereby separating i.e. cutting
through the work piece.

Plasma cutting is an effective means of cutting thin and thick materials alike.
Hand-held torches can usually cut up to 38 mm (1.5 in) thick steel plate, and stronger
computer-controlled torches can cut steel up to 150 mm (6 in) thick. Since plasma cutters
produce a very hot and much localized "cone" to cut with, they are extremely useful for
cutting sheet metal in curved or angled shapes.

Figure 11 Plasma Arc Cutting

Safety

Proper eye protection and face shields are needed to prevent eye damage called arc eye as
well as damage from debris. It is recommended to use green lens shade #5. OSHA recommends a
shade 8 for arc current less than 300. Longevity Global, Inc., another manufacturer, offers this
more specific table for Eye Protection for Plasma Arc Cutting at lower amperages.

26
 Current Level in Minimum Shade
Amps Number

Below 20 #4

20-40 #5

40-60 #6

60-80 #8

Table 4 Shade levels for Plasma Arc Cutting

Leather gloves, apron and jacket are also recommended to prevent burns from
sparks and debris.

Table 5 Current Ratings for SS Plasma Arc Cutting

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 3.3 Buffing Shop

"Buffing" is the process used to shine metal, wood, or composites using a cloth
wheel impregnated with cutting compounds or rouges. The cloth buff "holds" or "carries"
the compound, while the compound does the cutting. The industry refers to "polishing" as
the process, which uses abrasive belt finishing. Buffing generally requires two operations,
a cut buff and a finish buff. Even the cut buff, which is the coarsest buffing operation, is
too fine for removal of pits, course abrasive polishing lines, or deep scratches. This is why
surface preparation prior to buffing is critical to a high luster, final finish.

Figure 12 Buffing operation on SS Cylinder

Excellent pre-buff surface preparation starts with using the finest abrasive belt that
production will allow. It is from this point that removal of the original scratch line needs
to be accomplished to achieve the final buff finish. The original "scratch" or polish is

28
followed by one or two additional polishing steps. Cross polishing the abrasive lines if
possible and buff off of approximately 400 grit or finer abrasive on metals. The cut buff
will remove the final polishing lines, but may not be as bright as required. The finishing
buff will produce the luster.

3.3.1 Sisals
These buffs are made of a hard, cellular fiber material with high strength. It is
formed into a slender cord that constructs the buff. The Sisal material has natural cutting
properties. There are various stiffening treatments that will vary in color and hardness, as
well as untreated sisal and cloth combinations. Sisal buffs will remove orange peel and
grit lines from abrasive belts or Set-up wheels. They are used for finishing Drawn, Roll
Formed, and Stamped metals. When a sisal is combined with cloth, they can cut and finish
stampings in one operation prior to pre- plating. Spiral Sewn Sisals: Spiral sewn buffs are
constructed with sewing from the arbor hole spiraling outward toward the outside of the
buff. The standard distance between sewing’s are available in 1/16, 1/8, 3/8 and most
common, 1/4". The buff will stiffen and cut faster as the sewing’s tighten. The Spiral
Sewn Sisal is a very aggressive cut

Buff used on all metals. Bias Spiral Sewn Sisals: This is the same construction as
the previous spiral sewn buff, with the difference being that the fabric is cut on a bias to
minimize raveling. This helps the buff to last longer as well as providing better cut and
color. They are cooler running, thus more burn resistant. The buff is constructed with a
steel center and is mainly used on automated buffing equipment.

3.3.2 Loose Full Disc Buffs

This buff is constructed of individual cloth sheets, sewn once around the arbor
hole. Each cloth sheet is considered one ply. Sixteen to twenty ply is fairly standard. It
may be necessary to stack buffs together when additional width is required. The buff cloth
comes in two standard mill weaves of 6060 & 8080. The 8080 with a higher thread count

29
produces a better finish. The loose buff lacks firmness, but is a good standard finishing
buff on all metals and plastic.

3.4 Product Design

3.4.1 Pressure Vessels

A pressure vessel is a 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 pressure vessel development and operation. Consequently, pressure vessel
design, manufacture, and operation are regulated by engineering authorities backed by
legislation. For these reasons, the definition of a pressure vessel varies from country to
country, but involves parameters such as maximum safe operating pressure and
temperature, and are engineered with a safety factor, corrosion allowance, minimum
design temperature (for brittle fracture), and involve nondestructive testing, such
as ultrasonic testing, radiography, and pressure tests, usually involving water, also known
as a hydro test, but could be pneumatically tested involving air or another gas. The
preferred test is hydrostatic testing because it's a much safer method of testing as it
releases much less energy if fracture were to occur (water does not rapidly increase its
volume while rapid depressurization occurs, unlike gases like air, i.e. gasses
fail explosively).

In many countries, it is the law that vessels over a certain size and pressure (15
PSI) be built to Code, in the United States that Code is the ASME Boiler and Pressure
Vessel Code (BPVC), these vessels also require an Authorized Inspector to sign off on
every new vessel constructed and each vessel has a nameplate with pertinent information
about the vessel such as maximum allowable working pressure, maximum temperature,
minimum design metal temperature, what company manufactured it, the date, its
registration number, and ASME's official stamp for pressure vessels, making the vessel
traceable and officially an ASME Code vessel.

30
3.4.1.1 Construction

Most pressure vessels are cylindrical (swaged vessels are an exception) and have
integer length: diameter ratios (2:1, 3:1, and 4:1). Vertical vessels are more commonly
used than horizontal ones. This is because it is easier to have uniform distribution across
the cross section, and they take up less space. However, there may be cases in which
horizontal vessels may be preferable. They can be used to promote phase separation (in
decanters, settling tanks, separators, and flash vessels), and to allow easy access to clean
the inside (in heat exchangers).

3.4.1.2 Fabrication

In general, vessel shells are made by rolling and welding. It is easier for thin walls,
however there may still be difficulty for small diameters. Vessels with thicker walls may
need to be drum forged. The end closures are usually forged, and auxiliary components
such as nozzles and support rings are welded on. Post weld heat treating (PWHT) is used
to relieve residual stresses caused by forming and joining.

3.4.1.2.1 End Closures

The heads on the ends of the vessels can be hemispherical, ellipsoidal, or tori
spherical. Hemispherical heads have greater internal volumes than ellipsoidal heads,
which have greater internal volumes than tori spherical heads. The internal volumes are
correlated with the cost of each type of head. Tangent and weld lines usually are not the
same. Tangent lines are where the curvature ends. Weld lines are where the closures are
attached. Different kinds of welds can be used. ASME BPV Code has guidelines
concerning weld types and inspection.

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 Figure 13 Different geometries of end caps: a) hemispherical b) ellipsoidal c) tori spherical

Casketed joints can be used then vessels need to be frequently opened, and for instrument
connections. However, they are not used at high temperature or pressures because they
may fail, and welds are stronger. They are also more prone to leaks than welded joints.

3.4.1.2.2 Supports

Different saddles will be used depending on a variety of factors. These factors include
vessel dimensions and weight, temperature and pressure, arrangement, and fittings and
attachments. Saddles are usually used for horizontal vessels; skirt supports – vertical
columns & brackets – all types of vessels.

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3.4.1.2.3 Welded Joints

The ASME defines four kinds of welds and criteria for their evaluation.

A. Longitudinal or spiral welds in the main shell, necks, or nozzles, or circumferential

welds connecting hemispherical head the main shell, necks or nozzles

B. Circumferential welds in the main shell, necks, or nozzles or connecting a formed head
other than hemispherical

C. Welds connecting flanges, tube sheets, or flat heads to the main shell, a formed head,
neck or nozzle

D. Welds connecting communicating

3.4.1.2.4 Autofrettage

The internal surface of the vessel is subject to enormous pressures to pre stress it. When
released, the inside will be under compression by the outside. The vessel can be used up
to the “autofrettage” pressure without further deformation.

3.5 Material Selection

Stainless-Steel is used as the only material used for fabrication at Umasons Steel Fab. Pvt.
Ltd. Various grades of Stainless-Steels used are as follows:

3.5.1 Stainless-Steel 304

The basic alloy Type 304 (18-8) is an austenitic steel possessing a minimum of
18% chromium and 8% nickel, combined with a maximum of 0.08% carbon. It is a
nonmagnetic steel which cannot be hardened by heat treatment, but instead must be cold-
worked to obtain higher tensile strengths.

The 18% minimum chromium content provides corrosion and oxidation resistance.
The alloy's metallurgical characteristics are established primarily by the nickel content
(8% mm.), which also extends resistance to corrosion caused by reducing chemicals.

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Carbon, a necessity of mixed benefit, is held at a level (0.08% max.) that is satisfactory
for most service applications.

The stainless alloy resists most oxidizing acids and can withstand all ordinary
rusting, however it will tarnish. It is immune to foodstuffs, sterilizing solutions, most of
the organic chemicals and dyestuffs, and a wide variety of inorganic chemicals. Type 304,
or one of its modifications, is the material specified more than 50% of the time whenever
a Stainless-Steel is used.

Because of its ability to withstand the corrosive action of various acids found in
fruits, meats, milk, and vegetables, Type 304 is used for sinks, table tops, coffee urns,
stoves, refrigerators, milk and cream dispensers, and steam tables. It is also used in
numerous other utensils such as cooking appliances, pots, pans, and flatware.
Type 304 is especially suited for all types of dairy equipment - milking machines,
containers, homogenizers, sterilizers, and storage and hauling tanks, including piping,
valves, milk trucks and railroad cars. This 18-8 alloy is equally serviceable in the brewing
industry where it is used in pipelines, yeast pans, fermentation vats, storage and railway
cars, etc. The citrus and fruit juice industry also uses Type 304 for all their handling,
crushing, preparation, storage and hauling equipment.

In those food processing applications such as in mills, bakeries, and slaughter and
packing houses, all metal equipment exposed to animal and vegetable oils, fats, and acids
is manufactured from Type 304. Type 304 is also used for the dye tanks, pipelines
buckets, dippers, etc. that come in contact with the formic, acetic, and other organic acids
used in the dyeing industry. In the marine environment, because of it slightly higher
strength and wear resistance than type 316 it is also used for nuts, bolts, screws, and other
fasteners. It is also used for springs, cogs, and other components where both wear and
corrosion resistance is needed.

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 0.08
1.00%
Carbon % Silicon
max.
max.
2.00 18.00-
Manganes Chromiu
% 20.00
e m
max. %
0.045 8.00-
Phosphor
% Nickel 10.50
us
max. %
0.030
Sulphur %    
max.

Table 6 Type Analysis of Stainless Type 304

3.5.2 Stainless-Steel 316

For severe environments. Of course, there are many industrial processes that
require a higher level of resistance to corrosion than Type 304 can offer. For these
applications, Type 316 is the most used grade.

Type 316 is also austenitic, non-magnetic, and thermally non-hardenable

Stainless-Steel like Type 304. The carbon content is held to 0.08% maximum, while the
nickel content is increased slightly. What distinguishes Type 316 from Type 304 is the
addition of molybdenum up to a maximum of 3%.

Molybdenum increases the corrosion resistance of this chromium-nickel alloy to

withstand attack by many industrial chemicals and solvents, and, in particular, inhibits
pitting caused by chlorides. As such, molybdenum is one of the single most useful
alloying additives in the fight against corrosion.
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 By virtue of the molybdenum addition, Type 316 can withstand corrosive attack
by sodium and calcium brines, hypochlorite solutions, phosphoric acid; and the sulphite
liquors and sulphurous acids used in the paper pulp industry. This alloy, therefore, is
specified for industrial equipment that handles the corrosive process chemicals used to
produce inks, crayons, photographic chemicals, paper, textiles, bleaches, and rubber. Type
316 is also used extensively for surgical implants within the hostile environment of the
body.

Type 316 is the main stainless used in the marine environment, with the exception
of fasteners and other items where strength and wear resistance are needed, then Type 304
is typically used.

0.08
1.00%
Carbon % Silicon
max.
max.
2.00 16.00-
Manganes
% Chromium 18.00
e
max. %
0.045 10.00-
Phosphor
% Nickel 14.00
us
max. %
0.030
Molybdenu 2.00-
Sulphur %
m 3.00%
max.
Table 7 Type Analysis of Stainless Type 316

4 OUTCOMES

36
 1. After complete my industrial training, I have been exposed to a mechanical
engineers’ working life. Throughout my internship, I could understand more about
the actual work of a Mechanical Engineer.

2. It is better to sub-divide the goals to a few achievable tasks, so that we will be

gaining more confidence by accomplishing those tasks.

3. In working environment, teamwork is vital in contributing to a strong

organization. Teamwork is also essential in reaching the goals of the organization
as an entity.

4. It gave me the complete exposure of sheet metal working and various welding
processes of Stainless-Steel.

5. I got idea of implementation of theoretical knowledge in practical condition.

6. While going through the entire industrial training, the cooperation is found to be
very well organized, developed.

References:

37
1. University of Florida- Department of Mechanical Engineering- Welding Processes
http://www2.mae.ufl.edu/designlab/Lab%20Assignments/EML2322L-Welding.pdf

2. Umasons Steel Fab.–Products (http://www.umasonsSteel

Fab..com/&grqid=PrjlYjOX&hl=en=IN&geid=1010 )

3. NPTEL Lectures- TIG Welding ( http://nptel.ac.in/courses/112107144/34 )

4. Plasma cutting primer ( http://www.thefabricator.com/article/plasmacutting/plasma-

cutting-primer )

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