Internship Reort Par

8th SEMESTER INTERNSHIPN AT
PAR TECHNO HEAT PVT. LTD.
A PROJECT REPORT
Submitted by
DHAMELIYA JAYDIP ATULBHAI
ENROLLMENT NO: - 200160119516
In partial fulfillment for the award of the degree of
BACHELOR OF ENGINEERING
In
MECHANICAL
Government Engineering College, Modasa
Gujarat Technological University, Ahmedabad
April , 2023
Gujarat Technological University, Ahmedabad.
Feb, 2023
Feb, 2023
GOVERNMENT ENGINEERING COLLEGE, MODASA
Shamlaji road,Aravalli District, Modasa, Gujarat-383315.
CERTIFICATE
This is to certify that the internship report submitted along with the project
entitled 8th Semester Internship(3181901) has been carried out by
DHAMELIYA JAYDIP ATULBHAI(200160119516) under my guidance
in partial fulfilment for the degree of Bachelor of Engineering in Mechanical
Engineering, 8th semester of Gujarat Technological University, Ahmedabad
during the academic year 2022-23.
Dr. J.C. GAMIT Dr. J.A. VADHER
Internal Guide Head of the Department

GOVERNMENT ENGINEERING COLLEGE, MODASA
Shamlaji road, Aravalli District, Modasa, Gujarat-383315.
DECLARATION
We hereby declare that the Internship report submitted along with the
Internship entitled To study about manufacturing of water and fire tube
boilers, TFH and HAG submitted in partial fulfilment for the degree of
Bechelor of Engineering in Mechanical engineering to Gujarat
Technological University, Ahmedabad, is a bonafide record of original
work carried out by me at Par Techno Heat pvt ltd under the supervision of
Mr. Jignesh Bhavsar and that no part of this report has been directly copied
from any students reports or taken from any other source, without providing
due reference.
Name of the Student Sign of Student

Dhameliya Jaydip Atulbhai
I
Acknowledgement
I wish to express our sincere gratitude to our External guide Mr. Jignesh Bhavsar for
continuously guiding me at the company and answering all my doubts with patience. I
would also like to thank our Internal guide Prof. J.C.Gamit for helping us through our
internship by giving us the necessary suggestions and advices along with their valuable
coordination in completing this internship.
We also thank our parents, friends and all the members of the family for their precious
support and encouragement which they had provided in completion of our work. In
addition to that, we would also like to mention the company personals who gave us the
permission to use and experience the valuable resources required for the internship.
Thus, In conclusion to the above said, we once again thank the staff members of Par
Techno Heat Pvt Ltd for their valuable support in completion of the internship.
Thank you
Dhameliya Jaydip Atulbhai 200160119516
II
Abstract
My project title is “To study about manufacturing of water tube as well as fired
tube boilers, Thermic fluid heaters and Hot air generation systems.” First of all
according to client requirements, we receives a plant layout of ac tual site area
of that company to make a suitable design of boilers assembly and then
according to requirements we decide actual boiler parts size with their loading
condition as well as thermal capacity by IBR calculations and then make P&ID
and GA drawing of boiler assembly and then fix into that plant layout. Then we
make a detail drawing of all components of boiler and then manufacturing is
done by different fabricationtechniques and welding processes. In between this
hole project is done, all departments are working on their respective work
behind project. The main objectives of internship are: (1) Explore career
alternatives prior to graduation. (2) Integrate theory and practice. (3) Assess
interests and abilities in their field of study. (4) Learn to appreciate work and its
function in the economy.
III
List of Figures
Figure 1.1 Industry layout 1

Figure 2.1 Multi-Fuel 4 Pass single drum 100% water tube boiler 3
Figure 2.2 Multi-Fuel single drum corner tube type WTB. 4
Figure 2.3 Multi-Fuel BI-Drum W.T.B. Boiler 5
Figure 2.4 D type mobile Bi-drum water tube boiler 6
Figure 2.5 Mobile Steam generator 7
Figure 2.6 4 Pass vertical Thermic fluid heater(TFH) 8
Figure 2.7 5 Pass vertical TFH 9
Figure 2.8 3 Pass horizontal TFH 10
Figure 2.9 Multi-Fuel Direct Hot Air Generator(DHAG) 11
Figure 2.10 Multi-Fuel Indirect HAG 12
Figure 2.11 Electrostatic precipitator 13
Figure 2.12 Pulse jet Bag filter 14
Figure 2.13 Wet venture scrubber 15
Figure 2.14 Mechanical dust collector 16
Figure 3.1 Project management 18
Figure 3.2 Production Department 19
Figure 3.3 Quality control Department 20
Figure 3.4 ASME Water quality guidelines 21
Figure 3.5 Design Department 22
Figure 3.6 Marketing Department 24
IV
List of Symbols, Abbreviations and Nomenclature
TFH Thermic Fluid Heater
HAG Hot Air Generator
DHAG Direct Hot Air Generator
IHAG In Direct Hot Air Generator
APCEs Air Pollution Control Equipments
FBC Fludized Bed Combustion Boiler
Pvt. Ltd. Private Limited
MDC Mechanical Dust Collector
ESP Electrostatic Precipitator
WTB Water Tube Boiler
V
Table of Contents
Declaration............................................................................................................................I
Acknowledgement...............................................................................................................II
Abstract..............................................................................................................................III
List of Figures....................................................................................................................IV
List of Abbreviations and Symbols...................................................................................VI
Table of Contents..............................................................................................................VII
Chapter 1 Introduction.....................................................................................................1
1.1 Introduction about Industry...........................................................................................1
Chapter 2 Company Products...........................................................................................2
2.1 Steam Boilers.................................................................................................................2
2.1.1 Multi-Fuel 4 Pass Single drum 100% water tube boiler...................................3
2.1.2 Multi-Fuel single drum in corner tube type boiler...........................................4
2.1.3 Multi-Fuel BI Drum water tube boiler..............................................................5
2.1.4 D-type mobile BI Drum water tube boiler........................................................6
2.1.5 Mobile Steam Generator..................................................................................7
2.2 Thermic Fluid Heater....................................................................................................8
2.2.1 4 Pass Vertical Thermic Fluid Heater..............................................................8
2.2.25 Pass Vertical TFH...........................................................................................9
2.2.3 3 Pass Horizontal TFH UPS...........................................................................10
2.3 Hot Air Generator.......................................................................................................11
2.3.1..................................................Multiple Direct type hot air generator (DHAG)

..........................................................................................................................11
VI
2.3.2 Multiple In-Direct type hot air generator (IHAG)..........................................12
2.4 Air pollution control Equipment................................................................................13
2.4.1 Electrostatic Precipitator................................................................................13
2.4.2 Pulse jet bag filter..........................................................................................14
2.4.3 Wet venturi Scrubber.......................................................................................15
2.4.4 Mechanical dust collector................................................................................16
Chapter 3 Introduction About Department...................................................................17
3.1 Project Management................................................................................................18
3.2 Production Department............................................................................................19
3.3 Quality Department................................................................................................20
3.4 Design Department..................................................................................................22
3.5 Purchase Department..............................................................................................23
3.6 Marketing Department............................................................................................24
3.7 Human Resources Department................................................................................25
References.........................................................................................................................26
VI
INTRODUCTION
CHAPTER 1: INTRODUCTION
1.1 INTRODUCTION ABOUT INDUSTRY
Figure 1.1 Industry Layout
The The design, develop and manufectureFludized Bed Combustion (FBC) Boilers, Cogeneration
Power Plants, FBC Thermic Fluid Heating systems, FBC Hot Air generators and Pollution
control equipments. It also fabricate various types of fans, ductings, dampers, pressure vessels and
carry out heavy fabrication jobs according to IBR standars.
The foundation of our organization rests on the shoulders of our skilled design and production
department. They have access to not only the latest engineering and quality assurance procedures
under various codes but are also exposed and trained to handle robust design software and latest
heavy machineries. They are also trained to execute complex design calculations under strict
accordance with the relevant design codes such IBR 1950(and its latest amendments), ASME
Section I, ASME Section VIII and PED under CE.
Par, company have developed a computerized package for design & cost estimation for our
products. It also generates a built of materials and estimates costs of customized products.
industry Name is ― Par Techno Heat Pvt Ltd‖. This company initiated our enterprise in 1996.
GUJARAT TECHNOLOGICAL UNIVERSITY 1 GEC MODASA

CHAPTER 2: COMPANY PRODUCTS
(1) STEAM BOILERS
 Multi-Fuel 4 Pass Single Drum 100% water Tube Boiler

 Multi-fuel BI drum water tube boiler
 Multi-fuel 5 pass smoke cum water tube package boiler
 D-type mobile BI-drum water tube boiler
 Horizontal smoke tube wet back boiler
 Small industrial boiler
 Mobile steam generator
 Waste heat recovery steam generator
 Multi- fuel single drum in Corner tube type boiler
(2) THERMIC FLUID HEATER
 4 Pass vertical thermic fluid heater

 5 Pass vertical thermic fluid heater
 3 Pass horizontal thermic fluid heater
(3) HOT AIR GENERATOR
 Multi fuel direct type hot air generator

 Multi fuel indirect type hot air generator
(4) AIR POLLUTION CONTROL EQUIPMENT
 Electro static Precipitator

 Pulse jet bag filter
 Wet venturi Scrubber
 Mechanical dust collector
(5) CORRUGATED FURNACES
(6) WASTE TO ENERGY PLANT
(7) HOT WATER GENERATOR
(8) MULTI SOLID FUEL FIRED FBCINCINERATOR

2.1 STEAM BOILERS
The steam boilers are used in pharmaceutical, solvex, biotech, textiles, agriculture etc
industries in very heavy usage. In this company this all types of boilers are made. The
company makes a highly precise boilers according to customer requirements. The highly
skilled engineers are design the boilers to works with high quality steam generation with
fully electrically controlled components of boilers.
The use of steam boilers in every systems include water heating, sanitation, cooking,
waste heat energy utilization or recovery systems, and central heating. This company
makes a 100% water tube boilers and other components sizes and shapes are changes
according to clients requirements, like drum position, tonnage capacity of steam required
etc. The main product of company is 100% water tube boilers. Fired tube boilers are used
to warm the air which is transferred to the rooms of a house or warehouse.
2.1.1 MULTI-FUEL 4 PASS SINGLE DRUM 100% WATER TUBE BOILER
Figure 2.1 Multi- fuel 4 pass single drum 100% water tube Boiler
This boiler is the main product of company and according to name the 4 pass means to
create a path of flue gas in 4 passes to increase the heat transfer area and get maximum
steam from that. The 4 passes are made by using the hollow bricks which are set on the
column of supporting structure and to make 4 pasSSE in GBT PANEL. The GBT stands
for GENERATING BANKS TUBES.

2.1.2 MULTI-FUEL SINGLE DRUM CORNER TUBE TYPE BOILER
Figure 2.2 Multi- fuel single drum corner tube type Boiler
A corner tube boiler is a natural type of circulation water tube which differentiates itself
from other water tube boilers by its characteristic water steam cycle and a pre- separation
of heated steam from the steam- water mixture occurs outside the drum and the unheated
downcomers.

2.1.3 MULTI-FUEL BI-DRUM WATER TUBE BOILER
Figure 2.3 Multi fuel BI-Drum water tube Boiler
SPECIFICATION:
Fuel: - Oil / Gas fired
Steam Generation capacity:- 3TPH to 60 TPH
Working pressure:- Upto 21 bar
Super heater steam temperature:- Upto 490 degree C
This boiler have versatile two drum, water tube design, solid fuel fired boiler generally
used to generate high steam pressure required for incidental power generation or
cogeneration. It is also used for saturated steam application.

2.1.4 D TYPE MOBILE BI-DRUM WATER TUBE BOILER
Figure 2.4 D Type mobile BI- Drum water tube boiler
 Steam generating capacity of 25 Ton/ Hr. at a pressure of 44 Kg/cm2, with super

heating of 440 oC.
 This type of boilers is most common type of small to medium sized boilers,
similar to the one shown in diagram. It is used in both stationary and marine
application. Itconsist of a large steam drum vertically connected to a smaller water
drum or can say that Mud drum via multiple steam generating tubes.
 This boilers are ranges available from 6 TPH to 80 TPH.
 Pressure Range is upto 87 kg/cm2(g).
 Temperature is upto520 degree C.
 Highly efficient drum, eliminate internal fouling of super heater.
 Multifuel firing option.
 Easy to maintain.

2.1.5 MOBILE STEAM GENERATOR
Figure 2.5 Mobile Steam Generator
Steam generating capacity from 0.5 Ton/hr. to 15 Ton/hr. at pressure up to 160 Kg/cm 2.
These are truck mounted boilers with their own power generating source (diesel
generator), pumps, and control system and burner furnace. These types of boilers are used
mainly in oil, gas and mineral exploration at remote sites with scares or no facility of
steam generation is available.

2.2 THERMIC FLUID HEATER
A Thermic fluid heater is industrial heating equipment, used where only heat transfers are
desired instead of pressure. In this equipment, a thermic fluid is circulated in the entire
system for heat transfers to the desired processes.
2.2.1. 4 PASS VERTICAL THERMIC FLUID HEATER
Figure 2.6 4 Pass vertical TFH
SPECIFICATIONS:-
 Design: 4 pass
 Fuel: Wood, Lignite, Coal, etc.
Where the Thermic Fluid Travelled through the pump in to the convective h.e.and than
radiative h.e. to final process.

2.2.2. 5 PASS VERTICAL TFH
Figure 2.7 5 Pass vertical TFH
SALIENT FEATURES:
 4-5 Pass vertical design

 Minimum space required.
 Multi fuel compatibility
 Fully automatic system
 Less cleaning required compare to horizontal design.
 Capacity: 400000 Kcals/hr to 8000000 Kcals/hr and temp upto300-350 degree C.
 Fuel: Coal, lignite, husk, Rice husk, wood, sawdust etc.

2.2.3. 3 PASS HORIZONTAL TFH
Figure 2.8 3 Pass horizontal tfh
SALIENT FEATURES:
 3 Pass vertical design

 Minimum space required
 Multi fuel compatibility
 Less cleaning is required
 Capacity is 200000 kcals/hr to 800000kcals/hr
 Fuel are Coal, lignite, wood, and all type of agro waste.

2.3 HOT AIR GENERATOR
Hot air generator are equipments intended for heating any type of premises where a fast
and efficient heating system is required. Its operation is based on the carrying out
combustion in a home and the gases produced pass through a heat exchanger where heat
transfer is carried out with the air driven by a fan.
2.3.1. MULTI FUEL DIRECT TYPE HOT AIR GENERATOR (DHAG)
Figure 2.9 Multi fuel DHAG
SALIENT FEATURES:
 Fuel: Multi solid fuels, oil/gas fired

 Steam generation capacity:4 million k-cal/ Hr to 50 million k- cal/hr
 Super heater steam temp: upto 650 degree C
There are mainly three types of different types of air heat generators. Direct combustion
HAG and Indirect combustion HAG and electric HAG.

2.3.2 MULTI FUEL IN-DIRECT TYPE HOT AIR GENERATOR (IHAG)
Figure 2.10 Multi fuel IHAG
This is most manufectured product in HAG in this company.
In this type of HAG, Fresh air passes onto surface of combustion chamber with the help
of a blower, shape of the passage is such that maximum heat transfer is possible,
generating hot air in just few minutes of its start.
Indirect HAG can supply the fresh air and Clean air upto 450 degree C.
Now in our company, one IHAG project is running and that parts are primary,secondary,
tertiary, final air pre heater, cyclone, furnace etc parts are complete.

2.4 AIR POLLUTION CONTROL EQUIPMENTS
The air pollution control equipments collect particulate emissions work on the principle
of (i) Gravity separation, (ii) Cyclonic separation, (iii) Filtration, (iv)Electro static
precipitation, and (v) wet scrubbing.
The APCEs are a series of devices that work to prevent a variety of different pollutants,
both gaseous and solid, from entering the atmosphere primarily out of industrial
smokestacks.
2.4.1 ELECTRO STATIC PRECIPITATOR
Figure 2.11 Electro static precipitator
This APCE is removes particles from a gas stream by using the electrical energy to
charge the particles either positively or negatively.
The charged particles are then attracted to collector plates carrying yhe opposite charge.
An ESP is also called is Electrostatic air cleaner, a device that uses an electric charge to
remove certain impurities.
An ESP is very complicated to manufacture. One ESP is to take a time to manufacture

that is 4 to 5 months.

2.4.2 PULSE JET BAG FILTER
Figure 2.12 Pulse jet bag filter
A pulse jet bag filter, also called a pulse jet baghouse or pulse jet dust collector, is a self
cleaning dry filtration system.
The pulse jet dust collector cleaning system removes particulate matter and dust from the
surface of internal filter media with bursts of compressed air.

2.4.3. WET VENTURI SCRUBBER
Figure 2.13 Wet venturi Scrubber
A venture scrubber accelerates the waste gas stream to atomise the scrubbing liquid and
to improve gas liquid contact.
In a venture scrubber, a ―throat‖ section is built into the duct that force the gas stream to
accelerate as the duct narrows and then expands.
In this process, liquid or soild particles are removed from gas stream by transferring them
to a liquid.
The liquid most commonly used is water.
A wet scrubber particulate collection efficiently is directly related to the amount of

energy off expanded in contacting the gas stream with the scrubber liquid.

2.4.4. MECHANICAL DUST COLLECTOR
Figure 2.14 Mechanical dust collector
This is known as MDC in short name. Mechanical dust collector, often called cyclones or
multiclones have been used extensively to separate large particles from a flue gas stream.
Mechanical collectors are particulate control devices that are use centrifugal force, gravity
settling and inertia to collect pollutants.
This is mainly used for removes dirt, dust, debris, gases, and chemicals from the air,
providing your factory with cleaner air, which can provide numerous benefits.
IMPORTANCE OF MDC:
 They improve health and safety

 They increase productivity
 They lead to better product quality
 They help you meet compliance regulations
 They help to ensure happier employees.

CHAPTER 3: INTRODUCTION ABOUT DEPARTMENTS
3.1 DESIGN DEPARTMENT
Figure 3.5 Design Department
The design department is a team within a company or organization that is responsible for
creating visual concepts, designs, and layouts for various projects, such as advertising
campaigns, product packaging, websites, and other forms of media. The department may consist
of graphic designers, art directors, web designers, UX/UI designers, and other creative
professionals who work together to bring the client's vision to life.
The design department typically collaborates closely with other departments, such as marketing,
product development, and engineering, to ensure that the final product meets the client's needs
and objectives. The team may also be responsible for managing brand identity, creating style
guides, and ensuring that all visual materials are consistent with the company's overall design
aesthetic.
The design department plays a crucial role in shaping the company's image and communicating
its message to the public. As such, it requires individuals with strong creative skills, an eye for
detail, and the ability to work effectively under pressure and tight deadlines
Design engineering :
A design engineer is an engineer focused on the engineering design process in any of the
various engineering disciplines
(including civil, mechanical, electrical, chemical, textiles, aerospace, nuclear, manufacturing, sys
tems, and structural /building/architectural) and design disciplines like Human-Computer
Interaction. Design engineers tend to work on products and systems that involve adapting and
using complex scientific and mathematical techniques. The emphasis tends to be on
utilizing engineering physics and other applied sciences to develop solutions for society.
A design engineer usually works with a team of other engineers and other types of designers
(e.g. industrial designers), to develop conceptual and detailed designs that ensure a product
functions, performs, and is fit for its purpose. They may also work with marketers to develop the
product concept and specifications to meet customer needs, and may direct the design effort. In
many engineering areas, a distinction is made between the "design engineer" and other
engineering roles (e.g. planning engineer, project engineer, test engineer). Analysis tends to play
a larger role for the latter areas, while synthesis is more paramount for the former; nevertheless,
all such roles are technically part of the overall engineering design process.
When an engineering project involves public safety, design engineers involved are often
required to be licensed - for example, as a Professional Engineer (in the U.S and Canada). There
is often an "industrial exemption" for engineers working on project only internally to their
organization, although the scope and conditions of such exemptions vary widely across
jurisdictions.
There are two software are used to design the boilers: (1) AutoCAD and (2) Solid works.
Solid Works is a solid modeler, and utilizes a parametric feature-based approach which was
initially developed by PTC (Creo/Pro-Engineer) to create models and assemblies. The software
uses the Parasolid modelling kernel.
Parameters refer to constraints whose values determine the shape or geometry of the model or
assembly. Parameters can be either numeric parameters, such as line lengths or circle diameters,
or geometric parameters, such as tangent, parallel, concentric, horizontal or vertical, etc.
Numeric parameters can be associated with each other through the use of relations, which allows
them to capture design intent.
Design intent is how the creator of the part wants it to respond to changes and updates. For
example, you would want the hole at the top of a beverage can to stay at the top surface,
regardless of the height or size of the can. SolidWorks allows the user to specify that the hole is
a feature on the top surface, and will then honor their design intent no matter what height they
later assign to the can.
Features refer to the building blocks of the part. They are the shapes and operations that
construct the part. Shape-based features typically begin with a 2D or 3D sketch of shapes such as
bosses, holes, slots, etc. This shape is then extruded to add or cut to remove material from the
part. Operation-based features are not sketch-based, and include features such as fillets,
chamfers, shells, applying draft to the faces of a part, etc.
Building a model in SolidWorks usually starts with a 2D sketch (although 3D sketches are
available for power users). The sketch consists of geometry such as points, lines, arcs, conics
(except the hyperbola), and splines. Dimensions are added to the sketch to define the size and
location of the geometry. Relations are used to define attributes such as tangency, parallelism,
perpendicularity, and concentricity. The parametric nature of SolidWorks means that the
dimensions and relations drive the geometry, not the other way around. The dimensions in the
sketch can be controlled independently, or by relationships to other parameters inside or outside
the sketch.
In an assembly, the analog to sketch relations are mates. Just as sketch relations define
conditions such as tangency, parallelism, and concentricity with respect to sketch
geometry, assembly mates define equivalent relations with respect to the individual parts or
components, allowing the easy construction of assemblies. SolidWorks also includes additional
advanced mating features such as gear and cam follower mates, which allow modeled gear
assemblies to accurately reproduce the rotational movement of an actual gear train.
Finally, drawings can be created either from parts or assemblies. Views are automatically
generated from the solid model, and notes, dimensions and tolerances can then be easily added

to the drawing as needed. The drawing module includes most paper sizes and standards
(ANSI, ISO, DIN, GOST, JIS, BSI and SAC)
AutoCAD is a computer-aided design (CAD) software program used by architects, engineers,

designers, and other professionals to create 2D and 3D designs for various industries such as
architecture, engineering, construction, and product design.
AutoCAD is developed and marketed by Autodesk, Inc. and was first released in 1982. It is
available on Windows and macOS operating systems and is widely used in many industries for
drafting, modeling, and design purposes.
AutoCAD provides a wide range of features and tools that allow users to create precise and
accurate designs, including:
2D drafting and documentation tools, such as lines, arcs, circles, and text.
3D modeling and visualization tools, including surface modeling, solid modeling, and mesh
modeling.
Collaboration and sharing tools, such as cloud storage integration and real-time collaboration.
Customization options, allowing users to customize menus, toolbars, and shortcuts according to
their specific needs.
Automation and scripting tools, allowing users to automate repetitive tasks and customize their
workflow.
AutoCAD is widely used by professionals in the architectural, engineering, and construction

industries to create detailed and accurate designs, including floor plans, elevations, and
construction documents. It is also used by product designers and manufacturers to create 3D
models and prototypes..
AutoCAD is majorly used to understand the 2d view of all boiler components.
For production workers the 2d view is easy to understand, because in this organization
whole boiler is made by fabrication work, so 2d view of drawing is most easiest.
 Designing manufacturing processes and products

 Assessing product usability and safety
 Writing reports and presenting results to managers and customers
 Design new engineering products and processes
 Craft models and drawings of products using CAD
 Analyze prototype data and retest if needed
 Research new product ideas and methods
 Improve existing products and processes

 Ensure compliance with the industry’s safety standards
 Maintain accurate records
 Ensure products are user- and environment-friendly
 Write detailed reports
 Find creative design solutions to problems
 Present prototypes and designs to customers and project managers

3.2 MARKETING DEPARTMENT
Figure 3.6 Marketing
 A marketing team plan is a visual representation of your marketing strategy, goals,

and initiatives. It helps you see the connections between your different activities
and the impact they’re expected to have on your target audience.
 By creating a marketing team plan, you can ensure that everyone on your team is
working toward the same goals and that all your efforts are aligned.
 This marketing team plan template is designed for product-focused marketing
teams. It can be used by teams of any size and in any industry. Here are a few use
cases for this template:
 Product launches: Use this template to plan and coordinate your product launch
efforts.
 Content marketing: Use this template to map out your content marketing strategy
and ensure all your efforts are aligned with your goals.
 Go-to-market strategy: Use this template to visualize your go-to-market strategy
and make sure all your efforts are working together effectively.
 This template is perfect for marketing teams who want to take a more strategic
approach to their work and ensure everyone is working toward the same goals.

3.3 Tasks of the Mechanical Engineers:
The tasks of mechanical enginees can not be define in just one line they work in almost
every fields. Mechanical engineers research, design, develops, build, and test mechanical
and thermal devices, including tools, engines, and machines.
Mechanical engineers typically do the following:
 Analyze problems to see how mechanical and thermal devices might

help solve the problem.
 Design or redesign mechanical and thermal devices using analysis
and computer-aided design.
 Develop and test prototypes of devices they design.
 Analyze the test results and change the design as needed.
 Oversee the manufacturing process for the device.
 Manage a team of professionals in specialized fields like mechanical drafting
and designing, prototyping, 3D printing or/and CNC Machines specialists.
Mechanical engineers design and oversee the manufacturing of many products ranging
from medical devices to new batteries. They also design power-producing machines such
as electric generators, internal combustion engines, and steam and gas turbines as well as
power-using machines, such as refrigeration and air-conditioning systems.
Like other engineers, mechanical engineers use computers to help create and analyze
designs, run simulations and test how a machine is likely to work.
All Departments are works together and make a successful every product and all
department are integrated by Software which name is STERP. This software is used to
help to the complete one product from material selection to final instalment of boiler to
the respective client company.

3.4 PROJECT MANAGEMENT
Figure 3.1 Project management
 In the broadest sense, project managers (PMs) are responsible for planning,
organizing, and directing the completion of specific projects for an organization
while ensuring these projects are on time, on budget, and within scope.
 By overseeing complex projects from inception to completion, project managers
have the potential to shape an organization’s trajectory, helping to reduce costs,
maximize company efficiencies, and increase revenue.
 The exact duties of a project manager will depend on their industry, organization,
and the types of projects that a PM is tasked with overseeing. But across the
board, all project managers share responsibilities across what’s commonly
referred to as the ―project life cycle,‖ which consists of five phases (or processes):
 Initiating
 Planning
 Executing
 Monitoring and Controlling
 Closing
 While it may be tempting to think of these as ―steps,‖ they aren’t. Rather,
these are processes project managers continually return to throughout the life of a
project.
 Below, we take a closer look at each phase of the project life cycle, as well as the
different responsibilities a project manager might have in each.

3.5 PRODUCTION DEPARTMENT
Figure 3.3 Production Department
The production department is responsible for overseeing the manufacturing process of a

company's products. Its primary role is to ensure that the products are produced efficiently, cost-
effectively, and with the required level of quality.
Some of the specific responsibilities of the production department include:
1) Planning and scheduling production: The production department is responsible for

creating a production schedule that maximizes efficiency and meets customer demand.
2) Managing resources: The production department is responsible for managing the

resources needed to produce the products, including raw materials, labor, and equipment.
3) Quality control: The production department is responsible for ensuring that the products
meet the required level of quality by implementing quality control procedures and
conducting regular inspections.
4) Safety and compliance: The production department is responsible for ensuring that the
manufacturing process complies with all relevant safety and environmental regulations.
5) Cost control: The production department is responsible for managing production costs
and implementing cost-saving measures to improve profitability.
6) Continuous improvement: The production department is responsible for identifying areas

for improvement in the manufacturing process and implementing changes to increase
efficiency and productivity.
7) Coordination with other departments: The production department must work closely with
other departments such as sales, marketing, and logistics to ensure that the manufacturing
process meets the overall goals of the company.
Overall, the production department plays a critical role in ensuring the success of a company by
managing the manufacturing process and ensuring that the products are produced efficiently,
cost-effectively, and with the required level of quality.

3.6 Role and Responsibilities Production Department:
In welding industries, the production department is responsible for the manufacturing
process of welded components and products. The department is responsible for
designing, planning, organizing, and controlling the production process to ensure that
the final product is of high quality and meets the required specifications.
The production department typically includes the following functions:
 Production Planning: This function involves creating a plan for the manufacturing
process, including selecting the appropriate welding techniques, determining the
required materials and welding consumables, and scheduling production
activities.
 Welding Engineering: This function is responsible for designing and developing

the welding process, including selecting the appropriate welding equipment,
designing the welding fixtures and jigs, and developing welding procedures.
 Quality Control: This function is responsible for ensuring that the final welded
product meets the required quality standards. This involves performing inspections
and tests at various stages of the welding process, identifying any defects or
issues, and implementing corrective actions.
 Welding Inspection: This function involves performing visual inspections, dye

penetrant inspections, magnetic particle inspections, radiographic inspections,
and ultrasonic inspections to ensure that the welded joints meet the required
quality standards.
 Welding Supervision: This function involves supervising the welders, ensuring

that they are following the welding procedures, and implementing any necessary
corrective actions.
Overall, the production department in welding industries is critical in ensuring that

the welding process runs smoothly and efficiently and that the final welded product is
of high quality and meets the required specifications.

3.7 Welding Processes in Production Department:
 Submerged Arc Welding (SAW):
SAW is normally operated in the automatic or mechanized mode, however, semi-

automatic (hand-held) SAW guns with pressurized or gravity flux feed delivery are
available. The process is normally limited to the flat or horizontal-fillet welding
positions (although horizontal groove position welds have been done with a special
arrangement to support the flux). Deposition rates approaching 45 kg/h (100 lb/h) have
been reported — this compares to ~5 kg/h (10 lb/h) (max) for shielded metal arc
welding. Although currents ranging from 300 to 2000 A are commonly utilized,
currents of up to 5000 A have also been used (multiple arcs).
Single or multiple (2 to 5) electrode wire variations of the process exist. SAW strip-
cladding utilizes a flat strip electrode (e.g. 60 mm wide x 0.5 mm thick). DC or AC
power can be used, and combinations of DC and AC are common on multiple
electrode systems. Constant voltage welding power supplies are most commonly used;
however, constant current systems in combination with a voltage sensing wire-feeder
are available.
 Features of SAW Welding:
 Welding Head:
It stores the flux and controls the rate of flux deposition on the welding
joint.

 Flux:
The granulated flux shields and thus protects molten weld from
atmospheric contamination.[2] The flux cleans weld metal and can also
modify its chemical composition. The flux is granulated to a definite size.
It may be of fused, bonded or mechanically mixed type. The flux may
consist of fluorides of calcium and oxides of calcium, magnesium, silicon,
aluminium and manganese comounds.[citation needed] Alloying elements
may be added as per requirements. Substances evolving large amount of
gases during welding are never mixed with the flux. Flux with fine and
coarse particle sizes are recommended for welding heavier and smaller
thickness respectively.
 Electrode:
SAW filler material usually is a standard wire as well as other special
forms. This wire normally has a thickness of 1.6 mm to 6 mm (1/16 in. to
1/4 in.). In certain circumstances, twisted wire can be used to give the arc
an oscillating movement. This helps fuse the toe of the weld to the base
metal.[4] The electrode composition depends upon the material being
welded. Alloying elements may be added in the electrodes. Electrodes are
available to weld mild steels, high carbon steels, low and special alloy
steels, stainless steel and some of the nonferrous of copper and nickel.
Electrodes are generally copper coated to prevent rusting and to increase
their electrical conductivity. Electrodes are available in straight lengths
and coils. Their diameters may be 1.6, 2.0, 2.4, 3, 4.0, 4.8, and 6.4 mm.
The approximate value of currents to weld with 1.6, 3.2 and 6.4 mm
diameter electrodes are 150–350, 250–800 and 650–1350 Amps
respectively.

 Principle :
The flux starts depositing on the joint to be welded. Since the flux is not
electrically conductive when cold, the arc may be struck either by
touching the electrode with the work piece or by placing steel wool
between electrode and job before switching on the welding current or by
using a high frequency unit. In all cases the arc is struck under a cover of
flux. Flux otherwise is an insulator but once it melts due to heat of the arc,
it becomes highly conductive and hence the current flow is maintained
between the electrode and the workpiece through the molten flux. The
upper portion of the flux, in contact with atmosphere, which is visible
remains granular (unchanged) and can be reused. The lower, melted flux
becomes slag, which is waste material and must be removed after
welding.
The electrode is continuously fed to the joint to be welded at a

predetermined speed. In semi-automatic welding sets the welding head is
moved manually along the joint. In automatic welding a separate drive
moves either the welding head over the stationary job or the job
moves/rotates under the stationary welding head.

The arc length is kept constant by using the principle of a self-adjusting
arc. If the arc length decreases, arc voltage will increase, arc current and
therefore burn-off rate will increase thereby causing the arc to lengthen.
The reverse occurs if the arc length increases more than the normal.[5]
A backing plate of steel or copper may be used to control penetration and

to support large amounts of molten metal associated with the process.
 Submerged Arc Welding (SAW):
Shielded metal arc welding (SMAW), also known as manual metal arc
welding (MMA or MMAW), flux shielded arc welding[1] or informally as
stick welding, is a manual arc welding process that uses a consumable
electrode covered with a flux to lay the weld.
An electric current, in the form of either alternating current or direct

current from a welding power supply, is used to form an electric arc
between the electrode and the metals to be joined. The workpiece and the
electrode melts forming a pool of molten metal (weld pool) that cools to
form a joint. As the weld is laid, the flux coating of the electrode
disintegrates, giving off vapors that serve as a shielding gas and providing
a layer of slag, both of which protect the weld area from atmospheric
contamination.

Because of the versatility of the process and the simplicity of its
equipment and operation, shielded metal arc welding is one of the world's
first and most popular welding processes. It dominates other welding
processes in the maintenance and repair industry, and though flux-cored
arc welding is growing in popularity, SMAW continues to be used
extensively in the construction of heavy steel structures and in industrial
fabrication. The process is used primarily to weld iron and steels
(including stainless steel) but aluminium, nickel and copper alloys can
also be welded with this method.
Submerged arc welding (SAW) is a common arc welding process. The

first SAW patent was taken out in 1935. The process requires a
continuously fed consumable solid or tubular (metal cored) electrode.The
molten weld and the arc zone are protected from atmospheric
contamination by being "submerged" under a blanket of granular fusible
flux consisting of lime, silica, manganese oxide, calcium fluoride, and
other compounds. When molten, the flux becomes conductive, and
provides a current path between the electrode and the work. This thick
layer of flux completely covers the molten metal thus preventing spatter
and sparks as well as suppressing the intense ultraviolet radiation and
fumes that are a part of the shielded metal arc welding (SMAW) process.

3.3 QUALITY DEPARTMENT
Figure 3.3 QC
 At Par, they follow the IBR 1950 (and its latest amendments) , ASME Section I
and ASME Section VIII design codes to design and manufacture our Boilers,
Thermal Oil Heater & other heating systems under the TPI of TUV, BVQi, IBR-
2015 as well as per ASME Section I and ASME Section VIII, PED under CE.
 We have also initiated the process, for ―S‖ Stamps and ―U‖ Stamps certification,
under ASME Code and very soon we shall have S & U stamp accreditation.
 For the mechanical design of our boilers, pressure vessels, chimney we make use
of the latest computer software like ANSYS and PVelite. For the process design
and thermal calculationsthey make use of HTRI.
 It is a standard practice at Par to commence production after getting the QAP
(Quality Assurance Plan) approval from the End user and we STRICTLY follow
the approved QAP ,during design and manufacturing. In the absence of client
approved QAP , we follow our own QAP of our own Quality Assurance
department.
 Eliminating Pass or Fail - Another important aspect to ensure that you are
producing items of high quality is to turn away from simple pass/fail indicators.
This indicator provides little to no information about cases where one or more
technical parameters of the item is just within the allowed tolerance. Instead,
manufacturers should record actual values so that they can make data-driven
decisions and work toward improving the production process and reduce the
number of low-quality items.

3.3.3 Role of Quality Department:
The quality department is a specialized team or group within an organization that is responsible
for ensuring that products or services meet the established quality standards and customer
expectations. This department plays a crucial role in ensuring that the organization's products or
services are consistent, reliable, and of high quality.
The primary goal of the quality department is to ensure that the products or services produced by
the organization meet the established quality standards and comply with any applicable
regulations and laws. This involves developing and implementing quality control processes,
conducting inspections and audits, identifying and addressing quality issues, and continuously
improving the quality of the organization's products or services.
Some specific tasks that the quality department may be responsible for include creating quality
standards and procedures, training employees on quality control processes, conducting quality
audits and inspections, and implementing corrective actions to address quality issues. The
quality department may also be responsible for conducting customer surveys and feedback to
identify areas for improvement.
In summary, the quality department is a critical component of many organizations that ensures
that the products or services produced meet the established quality standards and customer
expectations. It plays a vital role in identifying and addressing quality issues , implementing
quality control processes, and continuously improving the quality of the organization's products
or services.
The main task of quality department is management of the quality of raw materials, assemblies,
products and components, services related to production, and management, production and
inspection processes comes under the aegis of Quality Department.

 Role of Quality Department:
 At Shop :
1) Make QAP (Quality Assurance plane) as per the Purchase Order items and requirements.
2) Take QAP approval from clients.
3) Check the drawings and boiler calculations as per the IBR Regulations.
4) Take drawing approval from inspecting authorities.
5) Check the inward material and it’s dimensions as per the specifications.
6) Receive the material TC (Test Certificates) from venders & review it.
7) Prepare the material inspection report inspection of material, tc & report by
inspecting authority.
8) Prepare the Material Inspection reports.
9) Inspection of dimensions in various stages of production in workshop.
10) Inspection of materials, TC & reports by inspecting authorities.
11) Prepare the inspection document for various stages of inspection.
12) Prepare the welder logsheet.
13) Stage inspection by clients as per the QAP requirements.
14) Welding & finishing quality checking.
15) Take Radiography & Stress reliving process.
16) Take Hydraulic / Air Test of parts & prepare the report of test.
17) Inspection of Hydraulic Test & report review by inspecting authority.
18) Take the final dimensions of parts prepare the final dimension report & make as
built drawing.
19) Check the final finishing & painting quality & prepare the final dispatch clearance report.
20) Make the maker’s file documents.
21) Take the approval of maker’s file from boiler office.
22) Renewal of erection licence & welder certificate from inspecting authority as
per requirements.

 At Site
1) Prepare the boiler erection document & submitted to inspecting authority.

2) Take boiler erction permission by inspecting authority (if applicable) follow up of
boiler online registration by client.
3) Prepare the pipeline drawing approval & erection document & submitted to
inspecting authority.
4) Take pipeline drawing approval & erection permission by inspecting authority prepare
the boiler parts & pipe line material ground inspection reports inspection of boiler
parts & pipe line material & report review by inspecting authority.
5) Prepare the boiler weld tack setup inspection report (if applicable).
6) Inspection of boiler weld tack setup & report review by inspecting authority check
the. welding & finishing quality at site by taking photos & follow up.
7) Arrange the radiography & stress reliving process at site (if applicable).
8) Take radiography & stress reliving approval from inspecting authority.
9) Submite the boiler maker's file to inspecting authority prepare the boiler hydro
test inspection report.
10) Inspection of boiler hydro test & report review by inspecting authority.

 Quality control in Welding/Fabrication field :
Quality control in welding is the process of ensuring that welded structures meet the
desired quality standards. Welding is a critical process that can impact the safety,
reliability, and longevity of a structure. Therefore, it is essential to have a robust quality
control process in place to ensure that the welding process meets the required
specifications and standards.
Here are some of the key aspects of quality control in welding:
 Welding procedures: A welding procedure is a set of guidelines that specifies

how a particular welding process should be carried out. A well-defined welding
procedure can help ensure that the welding is done consistently and meets the
required standards. The welding procedure should include details such as the
welding process, the type of filler material, the welding parameters, and the
inspection requirements.
 Welder qualification: Welders must be qualified to carry out specific welding

tasks. Qualification involves testing the welder's skills and knowledge to ensure
they can produce high-quality welds. The qualification process should include
both practical and theoretical assessments.
 Inspection: Inspection is a critical component of quality control in welding. The

inspection process should involve both visual and non-destructive testing
methods to detect any defects in the welds. The inspection should be carried out
at various stages of the welding process, including pre-weld, during welding, and
post-weld.
 Documentation: Proper documentation is essential for quality control in welding.

Documentation should include the welding procedure, welder qualification
records, inspection reports, and any other relevant information related to the
welding process.
 Training: Proper training is crucial for ensuring high-quality welding. Welders

and inspectors should receive training on the welding process, welding standards,
and inspection techniques.
In summary, quality control in welding involves a range of measures to ensure that the
welding process meets the required standards. A well-designed quality control process
can help ensure that the welding is done consistently and produces high-quality welds.

 Quality checking methods in Welding :
Welding is a critical process that can affect the safety and reliability of the structure.
Therefore, it is essential to have a robust quality checking process in place to identify
any defects in the welds and rectify them before they cause any issues.
Here are some of the key aspects of quality checking in welding:
 Visual inspection: Visual inspection is the most common method of quality checking
in welding. It involves examining the welds with the naked eye or with the help of a
magnifying glass or a borescope to identify any visible defects such as cracks,
porosity, or lack of fusion.
 Non-destructive testing (NDT): NDT methods are used to detect defects that are not
visible to the naked eye. These methods include ultrasonic testing, radiography,
magnetic particle inspection, liquid penetrant inspection, and eddy current testing.
NDT methods can detect internal defects in the welds and are often used in critical
applications.
 Destructive testing: Destructive testing involves cutting out a portion of the weld and
subjecting it to various tests to evaluate the quality of the weld. Destructive testing
can provide information about the weld strength, ductility, and toughness.
 Acceptance criteria: Acceptance criteria are the minimum standards that the welds
must meet to be considered acceptable. The acceptance criteria are usually defined in
the welding procedure specification (WPS) and are based on the applicable welding
standards.
 Documentation: Proper documentation is essential for quality checking in welding.

The inspection reports should include details of the inspection methods used, the
results of the inspection, and any defects found. This documentation helps track the
progress of the welding project and can be used to demonstrate compliance with the
welding standards0
In the Quality Department welding is checked by Non Destructive methods and

Destructive methods.
 Non Destructive Testing:
Non-destructive testing (NDT) in welding is a set of techniques used to evaluate the

quality of welded joints without damaging the structure. NDT methods are critical in
welding because they allow for the detection of defects in the welds that are not
visible to the naked eye. This can help identify potential issues before they cause any
damage or failure.

Here are some of the most common NDT methods used in welding:
1) Visual Inspection:
Visual inspection is a non-destructive testing (NDT) weld quality check

process. During the testing method, the weld is examined visually through the
eyes to determine surface discontinuities. The process must be conducted by
an experienced welding inspector.
Quality welders often use visual inspections to detect component defects like
burnt edges, corrosion, erosion, cracks, and lack of fusion or thickness. A
reputable welding inspector can make the right choice of visual inspections
and any subsequent tests required to ensure it meets the product acceptance
criteria.
2) Radiography Testing:
Radiography testing (RT) is a non-destructive testing (NDT) method used to

inspect the internal structure of an object using X-rays or gamma rays. It is
commonly used to inspect welds, castings, and other materials for defects or
flaws.
During radiography testing, the object being inspected is placed between the X-
ray or gamma ray source and a detector. The radiation passes through the object
and interacts with the detector, producing an image that can be interpreted by a
trained technician. The resulting image can show the presence of defects such as
cracks, voids, and inclusions.

Radiography testing is widely used in industries such as aerospace, automotive,
construction, and manufacturing. It is a useful tool for ensuring the quality and
safety of critical components and structures. However, it also carries a risk of
exposure to ionizing radiation, so proper safety measures must be taken to protect
workers and the environment.
3) Hydro Test:
A hydrostatic test is a type of pressure test used to check the structural integrity
of a component or vessel by subjecting it to water pressure. It is commonly used
in industries such as oil and gas, chemical, and construction to test the strength
and durability of pipelines, tanks, and other equipment.
During a hydrostatic test, the component is filled with water, and the pressure is
gradually increased to a level that exceeds the maximum operating pressure. The
pressure is then held for a set period of time to check for leaks or other defects.
The test is typically performed using specialized pumps and pressure gauges, and
the results are recorded and analyzed by trained technicians.
Hydrostatic tests can be used to detect defects such as leaks, cracks, and
deformities in the component being tested. It can also be used to ensure that the
component can withstand the maximum pressure it is designed to handle, and to
verify compliance with industry standards and regulations.
While hydrostatic testing is generally considered a safe and effective method for
testing the structural integrity of components, it does carry some risks, such as
the potential for water damage or injury due to sudden failure of the component
being tested. Proper safety measures must be taken, and the test should only be
performed by trained and experienced personnel.

4) Dye Penetrant Testing:
Dye penetrant testing (DPT), also known as liquid penetrant testing or penetrant
inspection, is a non-destructive testing (NDT) method used to detect surface
defects and cracks in materials. It is commonly used in industries such as
aerospace, automotive, and manufacturing.
During a dye penetrant test, a liquid dye is applied to the surface of the object
being tested. The dye is allowed to penetrate any cracks or defects in the surface,
and excess dye is then wiped away. A developer, typically a white powder, is
then applied to the surface, which draws out the dye and makes any defects
visible. The resulting image can then be interpreted by a trained technician.
Dye penetrant testing can detect surface defects such as cracks, porosity, and laps
in materials such as metals, ceramics, and plastics. It is a relatively simple and
inexpensive method, and can be performed on large or complex-shaped objects.
However, it is limited to detecting surface defects and may not detect defects that
are deeper in the material.
Dye penetrant testing must be performed in a controlled environment to ensure

accurate results, and the materials being tested must be thoroughly cleaned and
prepared beforehand. The test should only be performed by trained and certified
technicians, and proper safety measures must be taken to protect workers and the
environment.
 Steps in DPT Testing:
1) Pre Cleaning
2) Application of Penetrant
3) Excess Penetrant Removal
4) Application of Developer
5) Visual Inspection
6) Post cleaning

 Types of Welding Defects :
1) Cracks:
Weld cracking refers to a depression left at the termination of a weld where the weld
pool is left unfilled. Most forms of weld cracking result from the shrinkage strains
that occur as the weld metal cools. If the contraction is restricted, the strains will
induce residual stresses that cause cracking.
We can divide weld metal cracks into three types: Transverse, longitudinal
and crater cracks.
2) Distortion:
Welding methods that involve the melting of metal at the site of the joint necessarily
are prone to shrinkage as the heated metal cools. Shrinkage then introduces residual
stresses and distortion. Distortion can pose a major problem, since the final product
is not the desired shape. To alleviate certain types of distortion the workpieces can
be offset so that after welding the product is the correct shape. The above picture
describes various types of welding distortion.
3) Gas Inclusion:

Gas inclusions is a wide variety of defects that includes porosity, blow holes, and
pipes (or wormholes). The underlying cause for gas inclusions is the entrapment of
gas within the solidified weld. Gas formation can be from any of the following
causes- high sulphur content in the workpiece or electrode, excessive moisture from
the electrode or workpiece, too short of an arc, or wrong welding current or polarity.
4) Inclusion:
There are two types of inclusions: linear inclusions and rounded inclusions.
Inclusions can be either isolated or cumulative. Linear inclusions occur when there
is slag or flux in the weld. Slag forms from the use of a flux, which is why this type
of defect usually occurs in welding processes that use flux, such as shielded metal
arc welding, flux-cored arc welding, and submerged arc welding, but it can also
occur in gas metal arc welding. This defect usually occurs in welds that require
multiple passes and there is poor overlap between the welds. The poor overlap does
not allow the slag from the previous weld to melt out and rise to the top of the new
weld bead. It can also occur if the previous weld left an undercut or an uneven
surface profile. To prevent slag inclusions the slag should be cleaned from the weld
bead between passes via grinding, wire brushing, or chipping.
Isolated inclusions occur when rust or mill scale is present on the base metal.
5) Lack of Fusion / Incomplete Penetration:
Lack of fusion is the poor adhesion of the weld bead to the base metal; incomplete
penetration is a weld bead that does not start at the root of the weld groove.
Incomplete penetration forms channels and crevices in the root of the weld which
can cause serious issues in pipes because corrosive substances can settle in these
areas. These types of defects occur when the welding procedures are not adhered to;
possible causes include the current setting, arc length, electrode angle, and electrode
manipulation.[23] Defects can be varied and classified as critical or non critical.
Porosity (bubbles) in the weld are usually acceptable to a certain degree. Slag
inclusions, undercut, and cracks are usually unacceptable. Some porosity, cracks,
and slag inclusions are visible and may not need further inspection to require their
removal. Small defects such as these can be verified by Liquid Penetrant Testing
(Dye check). Slag inclusions and cracks just below the surface can be discovered by
Magnetic Particle Inspection. Deeper defects can be detected using the Radiographic
(X-rays) and/or Ultrasound (sound waves) testing techniques.
6) Lamellar Tearing:

Lamellar tearing is a type of welding defect that occurs in rolled steel plates that
have been welded together due to shrinkage forces perpendicular to the faces of the
plates.[24] Since the 1970s, changes in manufacturing practices limiting the amount
of sulfur used have greatly reduced the incidence of this problem.[25]
Lamellar tearing is caused mainly by sulfurous inclusions in the material. Other

causes include an excess of hydrogen in the alloy. This defect can be mitigated by
keeping the amount of sulfur in the steel alloy below 0.005%.[25] Adding rare earth
elements, zirconium, or calcium to the alloy to control the configuration of sulfur
inclusions throughout the metal lattice can also mitigate the problem.[26]
Modifying the construction process to use cast or forged parts in place of welded
parts can eliminate this problem, as Lamellar tearing only occurs in welded parts.
7) Undercut:
Undercutting is when the weld reduces the cross-sectional thickness of the

base metal and which reduces the strength of the weld and workpieces. One
reason for this type of defect is excessive current, causing the edges of the
joint to melt and drain into the weld; this leaves a drain-like impression along
the length of the weld. Another reason is if a poor technique is used that does
not deposit enough filler metal along the edges of the weld. A third reason is
using an incorrect filler metal, because it will create greater temperature
gradients between the center of the weld and the edges. Other causes include
too small of an electrode angle, a dampened electrode, excessive arc length
and slow speed.

Figure 3.4 ASME Water quality guidelines
 Increase Visibility - Visibility is a key component within manufacturing

operations. The manufacturing process is a chain of separate events but dependent
assembly and testing processes, which ultimately come together toward a final
product. A prevalent issue is having a technical problem in stage one, only to be
discovered in a later stage, ultimately holding the product up. This is why
visibility within your operation is a must. You should expect tests results from any
of your manufacturing stages to influence other stages in the process. In order to
see the entire picture, it is important to collect and analyse the end to end results
and frequency of each problem.

3.3 PURCHASE DEPARTMENT
 Purchasing is the process of buying or acquiring goods and services to make

supply chain management more efficient. Goods, materials, and equipment
procured in this process play a key role in improving the quality of
products/services produced by the organization. Ultimately, the purchasing
process impacts the product quality and helps in optimizing costs in the value
chain.
 he purchasing department of a company is responsible for procuring the goods,

raw materials & services required to operate the organization effectively.
 Now, every organization has its specific needs when it comes to the sourcing and
procurement of equipment, raw materials, and services. These needs define the
purchasing process and how its purchasing department functions.
 Based on these needs, an organization sets the purchasing department’s
responsibilities and streamlines its procurement plans to guard against demand-
supply hurdles. Let’s understand the role of a purchasing department in this
process.

 3.7 HUMAN RESOURCE DEPARTMENT
 Human resources (HR) is the division of a business responsible for finding,

screening, recruiting, and training job applicants.
 HR also administers employee-benefit programs.
 A human resources department also handles compensation and benefits, and
employee terminations.
 It must keep up to date with any laws that may affect the company and its
employees.
 Many companies have moved traditional HR administrative duties such as
payroll and benefits to outside vendors.
 An HR department is an essential component of any business, regardless of an
organization's size. It is tasked with maximizing employee productivity and
protecting the company from any issues that may arise within the workforce.
 HR responsibilities include compensation and benefits, recruitment, firing, and
keeping up to date with any laws that may affect the company and its employees.

References
1. https://www.parboiler.com/
2. https://en.wikipedia.org/
3. https://openai.com/blog/chatgpt

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8th SEMESTER INTERNSHIPN AT

PAR TECHNO HEAT PVT. LTD.

In partial fulfillment for the award of the degree of

Government Engineering College, Modasa

Gujarat Technological University, Ahmedabad

Gujarat Technological University, Ahmedabad.

Shamlaji road,Aravalli District, Modasa, Gujarat-383315.

entitled 8th Semester Internship(3181901) has been carried out by

DHAMELIYA JAYDIP ATULBHAI(200160119516) under my guidance

in partial fulfilment for the degree of Bachelor of Engineering in Mechanical

Engineering, 8th semester of Gujarat Technological University, Ahmedabad

during the academic year 2022-23.

Dr. J.C. GAMIT Dr. J.A. VADHER

Internal Guide Head of the Department

Shamlaji road, Aravalli District, Modasa, Gujarat-383315.

Internship entitled To study about manufacturing of water and fire tube

Bechelor of Engineering in Mechanical engineering to Gujarat

Technological University, Ahmedabad, is a bonafide record of original

Name of the Student Sign of Student

co- ordination in completing this internship.

Dhameliya Jaydip Atulbhai 200160119516

Figure 1.1 Industry layout 1

TFH Thermic Fluid Heater

HAG Hot Air Generator

DHAG Direct Hot Air Generator

IHAG In Direct Hot Air Generator

APCEs Air Pollution Control Equipments

FBC Fludized Bed Combustion Boiler

Pvt. Ltd. Private Limited

MDC Mechanical Dust Collector

ESP Electrostatic Precipitator

WTB Water Tube Boiler

List of Abbreviations and Symbols...................................................................................VI

1.1 Introduction about Industry...........................................................................................1

Chapter 2 Company Products...........................................................................................2

2.1 Steam Boilers.................................................................................................................2

2.1.1 Multi-Fuel 4 Pass Single drum 100% water tube boiler...................................3

2.1.2 Multi-Fuel single drum in corner tube type boiler...........................................4

2.1.3 Multi-Fuel BI Drum water tube boiler..............................................................5

2.1.4 D-type mobile BI Drum water tube boiler........................................................6

2.1.5 Mobile Steam Generator..................................................................................7

2.2 Thermic Fluid Heater....................................................................................................8

2.2.1 4 Pass Vertical Thermic Fluid Heater..............................................................8

2.2.25 Pass Vertical TFH...........................................................................................9

2.2.3 3 Pass Horizontal TFH UPS...........................................................................10

2.3 Hot Air Generator.......................................................................................................11

2.3.1..................................................Multiple Direct type hot air generator (DHAG)

2.4.1 Electrostatic Precipitator................................................................................13

2.4.2 Pulse jet bag filter..........................................................................................14

2.4.3 Wet venturi Scrubber.......................................................................................15

2.4.4 Mechanical dust collector................................................................................16

Chapter 3 Introduction About Department...................................................................17

3.1 Project Management................................................................................................18

3.2 Production Department............................................................................................19

3.3 Quality Department................................................................................................20

3.4 Design Department..................................................................................................22

3.5 Purchase Department..............................................................................................23

3.6 Marketing Department............................................................................................24

3.7 Human Resources Department................................................................................25

1.1 INTRODUCTION ABOUT INDUSTRY

Figure 1.1 Industry Layout

GUJARAT TECHNOLOGICAL UNIVERSITY 1 GEC MODASA