INDUSTRIAL TRAINING REPORT

AT
JAYASWAL NECO INDUSTRIES LIMITED, SILTARA
Submitted in partial fulfillment of the

Requirements for the award of

Degree

Of

Bachelor of Technology

In

Mechanical Engineering

Submitted By

Name : Tushar kumar verma

University Roll no. 300103720104 , Semester /Branch: 4th/ Mechanical

SUBMITTED TO:

Head Of Department Of Mechanical Engineering

JAYASWAL NECO INDUSTRIES LIMITED ,SILTARA

Siltara Raipur (Chhattisgarh)

DECLARATION

I, TUSHAR KUMAR VERMA, student of Bhilai institute of technology Durg, Mechanical

branch hereby declare that this vocational training report is mine and it is a result of my daily
work I conducted in a monthly training at JAYASWAL NECO INDUSTRIES LTD, SILTARA
from 15th may to 15st June, 2022 as required by the Bhilai institute of technology Durg in partial
fulfillment of the requirements for the Bachelor Degree in mechanical branch.

.
Signature of the student

Name : Tushar kumar verma

University Roll no. 300103720104

Date…………………………………………
ACKNOWLEDGEMENT

First of all I thank the almighty God for His blessing and mercy to me. My appreciation
is addressed to the people who have contributed their time, efforts, ideas and encouragement in
order to accomplish this vocational training work successfully. I want to thank the Managing
Director of “JAYASWAL NECO INDUSTRIES LTD, SILTARA” to give us chance to
complete our vocational training at jayaswal neco.
I deeply thank to varun kalra incharge of central utility and water controlling
department, ,because of their kind cooperation during vocational training period and other
laboratory technicians in the water quality analysis and water controlling in this company for
their support and assistance during this vocational training work and they provided me the
practical knowledge of the water treatment plant (utility) , without their guidance and help I
could not completed my vocational training.
I also like to thank other workers and staff of JAYASWAL NECO PVT LTD,
SILTARA for their cooperation with me. I would like to extend my special thanks to my
parents because of their advice, material and moral support they gave us during this vocational
training. I thank all people participated near or far so that I could accomplish my intended task.
Finally I want to thank head of Mechanical department Mr. Firoj Pathan sir for their assistance.
ABOUT COMPANY

1.1. Introduction
Jayaswal Neco Industries Limited (JNIL), the flagship company of the NECO group in India, is
the largest producer of Iron and Steel Castings, Pipes and Fittings. Originally incorporated as a
small scale Iron Foundry Unit at Nagpur in 1976, it has grown to be a pioneer in the Steel
Production Industry. It caters to various industries like Automotive, Power, Railways, Bearings,
Structural and Fasteners industries, Heavy Engineering Sector, Refineries, Power Plants, Steel
Plants, Chemical Plants and Pipelines, Material Handling Equipment manufacturers, Crane
Manufacturers, Sugar Crushing Mills, etc.

An authority in manufacturing, NECO makes the most diverse range of casting in the Industry.
Special-ized in the production of large-scale Iron and Steel Castings, we cater to Automotive,
Engineering, Power, Railways, Bearings, Structural and Fastener industries in India. Our
products include high-quality fabricated speciality steel products.

Jayaswal Neco Industries Limited (Foundry Division) has grown to be India's largest producer
of Iron & Steel castings with an installed capacity of 140,000 MTPA. Its foundries are located
across the states of Maharashtra & Chhattisgarh.

With a view to diversify its activities, NECO established a 1,000,000 MTPA Integrated Steel
Plant at Sitara Growth Centre, Raipur, in 1996, located on 1600 acres of land in the reputed
Steel belt of the country. It is Number One in India for making Alloys Steel.

The plant was commissioned for Iron Making by Blast Furnaceand in 2004, steel-making by
Electrical Arc Furnace was added. The Rolling Mills was inaugurated in 2009. The Steel Plant
is equipped with a 15 km long internal railway siding and five captive power plants, which
produce about 60 MW/day. It manufactures products that include Specialty Steels - Hot Rolled
Bars, Wire Rods and high strength Leaf Springs. The Steel plant is under expansion that will
see its capacity to be enhanced to about 2 Million MTPA by 2025.
1.2. Legacy of Company

Born in August 1933 to an agriculturists family in a small village of eastern Uttar Pradesh, Shri
Basant Lall Shaw is one of the most prominent visionaries and steel industry leaders. Back in
the day, no steel was produced in the country, and all of it was imported from England.
However, inspired by Mahatma Gandhi and the swadeshi movement, Shri Shaw saw a dream
he set out to fulfill.

In the 1960s, Shri Basant Lall Shaw lay the foundations of what has become today the flagship
company of the NECO Group. Spread over 2200 acres and in production since 1976, Jayaswal
NECO Industries Limited specializes in the production of large-scale iron and steel castings.
Driven by innovation and powered by technology, the NECO Group of Industries have earned
a reputation in the industry for its high-quality fabricated specialty steel products.

1.3. Plant under this company

1.SMS PROPOSED
2.ROLLING MILL-PROPOSED
3.SMS-11
4.ROLLING MILL-II
5.SMS-1
6.ROLLING MILL-I
7.OXYGEN PLANT-1
8.OXYGEN PLANT-II
19.BF POWER PLANT
10.SINTER PLANT
11.SINTER PLANT-PROPOSED
12.BLAST FURNACE
13.BLAST FURNACE-PROPOSED
14.PCI
15.PCM
16.COKE OVEN
17.COKE OVEN-PROPOSED
18.COKE OVEN POWER PLANT
19.COKE OVEN POWER PLANT-PROPOSED
20.RMHS
21.RMHS-PROPOSED
22.WAGON TIPPLER
23.WAGON TIPPLER-PROPOSED
24. STACKER RECLAIMER
25. STACKER RECLAIMER-PROPOSED
26.MUUL POWER PLANT
27. DRP-1
28.DRP-I POWER PLANT
29. DRP-II
30.DRP-II POWER PLANT
31. PELLET PLANT
32.GRINDING UNIT
33. PIG STORAGE YARD
34.USHA FULES PVT. LTD.
35. JNIL-FPD

1.4. Vision & Mission

Vision

To be an organization that continuously achieves economic value by optimizing resources

through op-erational excellence, powered by technology, driven by innovation, creating delight,
and to be a globally admired organization that enhances sustainable industrial and business
development and be the global benchmark in the field of:

 Steel Plant products

  Iron & Steel Castings
 Ferrous & Non-Ferrous Valves and Services
 Ceramic products
 Defence Equipment

Mission

Sustainable Growth and Return on Investment by continuous improvement of Human

Resources, Environment, Technology and Product. We intend to achieve this through :

There people
 By inculcating a culture of constant product innovation and process improvements
 By nurturing human capital through training, education and exposure
 By providing opportunities for growth and development
 By fostering teamwork and mentorship
 By developing leadership capability
 Above all, work with Passion, Pride, Transparency and Honesty

There society

 Being a responsible corporate citizen: Giving back to the environment what we take
 Adopting cleaner and greener technologies
 Providing a safe and healthy work environment
 Caring for the communities in which we work
 Demonstrating high ethical standards

There costomer

 By helping them stay ahead of the curve by delivering innovative products and services
  By helping them grasp every opportunity by delivering on-time every time
 By ensuring transparency in our dealings

There supplies

 Quality starts from incoming material: We believe in developing our suppliers to our
level of competence and quality assurance
 Ensuring fairness and equitable transactions to all our suppliers in accordance with
internally established procedures
 Ensuring our procurement activities comply with all relevant laws, social norms,
standards and treaties worldwide
 Building a relationship of trust with all our suppliers through reciprocal efforts

Awards and Achievement

Quality Awards

 19th TPM National Conference - Award by CII in 2019

 TPM Certificate 2019 – presented to Jayaswal Neco by CII
 6th National Conference on ‘5S’, 2019 – Awarded Par Excellence by Quality Circle
Forum of India
 National Convention on Quality Concepts (NCQC) – 2018 – numerous team awards
 National Convention on Quality Concepts (NCQC) – 2017 – numerous team awards
 National Convention on Quality Concepts (NCQC) – 2016 – numerous team awards
 CCQC 2017 – numerous team awards
 CCQC 2016 – numerous team awards
 QFCI Appreciation for Driving Effective QC Movement in the Organization

General Awards
 CII Chhattisgarh Excellence Award in Safety, Health & Environment, 2017-18
 Pantomath Investor Awareness & CSR Foundation Award 2017 for SME Development
in Chhattisgarh
 National Convention on Quality Concepts (NCQC) Excellence Award, Raipur 2016
 Greentech Environment Award 2015
Table of Contents
DECLARATION.....................................................................................................................................ii
ACKNOWLEDGEMENT.............................................................................................................iii
ABOUT COMPANY......................................................................................................................iv
1.1. Introduction.............................................................................................................................iv
1.2. Legacy of Company..................................................................................................................v
1.3. Plant under this company........................................................................................................v
1.4. Vision & Mission.....................................................................................................................vi
Awards and Achievement............................................................................................................viii
General Awards............................................................................................................................viii
CHAPTER 1 : INTRODUCTION ( OVERVIEW OF THE WHOLE REPORT).....................1
I.1. ORGANIZATION OF REPORT............................................................................................1
I.1.1. METHODOLOGY.................................................................................................................1
CHAPTER 2 : INDUSTRIAL TRAINING..................................................................................3
2.1. OBJECTIVES OF VOCATIONAL TRAINING..................................................................3
2.1.1. THE MAIN OBJECTIVES..................................................................................................3
2.1.2. THE SPECIFIC OBJECTIVES ARE:................................................................................3
2.2. TOOLS AND TECHNOLOGY USED...................................................................................3
2.2.1. Flat file...................................................................................................................................3
2.2.2. Hack saw................................................................................................................................3
2.2.3. Try square.............................................................................................................................3
2.2.4. Steel rule/ Brass rule.............................................................................................................4
2.2.5. Ball peen hammer.................................................................................................................4
2.2.6. Punches..................................................................................................................................4
2.2.7. Chipping hammer.................................................................................................................4
2.2.8. Electrode holder....................................................................................................................4
2.2.9. Tongs......................................................................................................................................4
2.2.10. Wire brush...........................................................................................................................4
2.2.11. Apron...................................................................................................................................4
2.2.12. Face shield / eye shield ( Welding screen).........................................................................5
2.2.13. Hand gloves..........................................................................................................................5
2.2.14. Earth clamp.........................................................................................................................5
2.2.15. safety shoes for welders.......................................................................................................5
2.3. TECHNIQUES USED IN DEPARTMENTS:........................................................................5
STEPS TO BE FOLLOWED FOR DYE PENETRANT TEST:.................................................5
2.3.2. ANGLE GRINDER:...................................................................................................................7
 2.3.3. WELDING POSITION...............................................................................................................7
position of pipe welding........................................................................................................................8
2.3. HIGHLIGHTS OF TRAINING EXPOUSURE.............................................................................8
CHAPTER 3: PROBLEM IDENTIFICATION/CASE STUDY (DISCUSSIONS)..............................9
ARC WELDING:.................................................................................................................................9
Metal Arc Welding.............................................................................................................................10
Arc Welding Machines.......................................................................................................................10
Welding transformer...........................................................................................................................11
Welding generator...............................................................................................................................11
Welding rectifier.................................................................................................................................11
Welding Electrode..............................................................................................................................11
Weld Defects:-....................................................................................................................................12
Welding-properties:............................................................................................................................13
3.2. WEAR PLATE/ COMPOSITE LINER PLATE..........................................................................13
Wear Plate Manufacturing Process.....................................................................................................13
The Importance of Using Wear Plates in Industrial Equipment..........................................................14
Uses for Wear Plates...........................................................................................................................14
Wear Plate Material............................................................................................................................15
CHAPTER 4: RECOMMENDATIONS :...........................................................................................15
REFERENCE:....................................................................................................................................16
1.About industries NECO GROUP OF INDUSTRIES (necoindia.com).........................................16
2.www.hardfacingfty.com...............................................................................................................16
3. wikipedia.....................................................................................................................................16
DATA SHEET....................................................................................................................................16
CONSUMPTION: Consumption of electrodes...................................................................................16
CONSUMPTION: Consumption of wear plate...................................................................................18

Table of figure:
Figure 1: After Welding penetrant test & dye penetrate............................................................................6
Figure 2: AG9...........................................................................................................................................7
Figure 4: Four basic welding positions......................................................................................................7
Figure 5: pipe welding position.................................................................................................................8
Figure 6: wear plate.................................................................................................................................15

Table of table:
Table 1:Consumption of electrodes in COKE OVEN PLANT (2021-2022)...........................................16
Table 2: Consumption of electrodes in DRI PLANT (2020-2021)..........................................................16
Table 3: Consumption of electrodes in RMHS PLANT (2020-2021)......................................................17
Table 4: Consumption of electrodes in SINTER PLANT (2020-2021)...................................................17
Table 5: Consumption of electrodes in PELLET PLANT (2020-2021)...................................................17
Table 6: Consumption of electrodes in GRANDING STORE.................................................................18
CHAPTER 1 : INTRODUCTION ( OVERVIEW OF THE WHOLE REPORT)
The vocational training program is designed to provide students engaged in a field experience
with an opportunity to share their insights. Bhilai institute of technology, Durg has added this
vocational training program for the graduating students to introduce them to the professional
life, to explore the links between students’ academic preparation and their field work, and to
assist participants in developing and carrying out the major research project which will serve to
culminate their vocational training experience.
Vocational trainings are individualized and tailored to the needs and interests of each student in
the program. As part of the vocational training experience, I select JAYASWAL Neco
industries ltd ,siltara as an interest to serve as a transition from the academic experience to the
professional setting, I had given water treatment as a topic for training and here I have to
understand the whole water treatment processes and utility in three different department of that
company which are central utility ,steel melting shops.
Since the vocational training is designed to meet our needs and interests, This requires careful
thought, planning, and an initiative on my part to locate an appropriate water treatment site.

I.1. ORGANIZATION OF REPORT.

This report at JAYASWAL Neco industries ltd ,siltara is divided into four chapters; the first
chapter deals with General introduction. The second chapter deals with industrial training the
third is discussion. The fourth chapter is related to the conclusion problems encountered and
recommendations.

I.1.1. METHODOLOGY
The different techniques are used, include:
 General Interview
Interviews were held with different workers mainly in three departments of JAYASWAL Neco
industries ltd ,siltara such as physico-chemical parameters analysis, bacteriological parameters
analysis and epuration departments.
 Documentation
Different documents were consulted to learn more about the quality control of water and its
treatment in JAYASWAL Neco industries ltd ,siltara
 Observation
We tried to observe the way activities were done in different departments of the plant organs
particular in department of physico-chemical parameters analysis, pH parameters analysis and
epuration (Water purifying unit).
1
  Participation
It was required to participate in the named departments with other employees to gain
knowledge and practice different experiments.
 Data processing and analysis
The necessary result obtained and their interpretations on a daily basis using the above
mentioned techniques was recorded and written in a note book and were finally analyzed to
make final report.
CHAPTER 2 : INDUSTRIAL TRAINING

2.1. OBJECTIVES OF VOCATIONAL TRAINING

2.1.1. THE MAIN OBJECTIVES

The aim of this vocational training is to permit students to practice theoretical or academic
knowledge required during four years of student and to familiarize to professional realities. To
provide the student an opportunity to apply knowledge, skills and experiences gained during
the academic program to a professional setting

2.1.2. THE SPECIFIC OBJECTIVES ARE:

 To learn theory in a practical environment.
 To establish groundwork and provide networking for professional development and
growth
 To further help students recognize their own strengths and weaknesses both personally
and professionally.
 To facilitate students as they assess personal ambitions in their chosen field.
 To prepare students for employment or graduate education.

2.2. TOOLS AND TECHNOLOGY USED

2.2.1. Flat file

A file is a hardened piece of high grade steel with slanting rows of teeth and is used for
removing excess material to smooth or fit metal parts. Files are generally forged out of high
carbon steel or tungsten steel followed by cutting of teeth, hardening and tempering.

2.2.2. Hack saw

The hack saw is used to cut metals of different sections. The main parts are frame, handle and a
replaceable blade. The blades are available in standard lengths 225, 250 and 300mm.

2.2.3. Try square

Try square is mainly used for checking the squarness of surfaces or edges which are adjacent,
flatness of a filed surface and for marking out lines on workpieces. It consists of a blade and
stock which are made of steel fixed rigidly at 900 to each other.
2.2.4. Steel rule/ Brass rule
The steel rule consists of a hardened steel strip having line graduations etched or engraved in it.
They are usually 150mm or 300mm long and is used to take linear measurements to an
accuracy of 1mm or 0.5mm. The brass rule is similar to steel rule, but it is made of brass. Since
the brass possess low coefficient of linear expansion, its dimensional accuracy will be more
reliable in heated regions.

2.2.5. Ball peen hammer

Hammer is a hand tool made of tool steel, largely used for striking on the metals. A hammer is
named by its peen. The ball shaped peen hammer is known as ball peen hammer. The peen and
face are hardened.

2.2.6. Punches
Punches are percussion tools and are manufactured from tool steel. They are used on any
scribed lines by indentations. Tips are tapered, hardened and tempered. The shanks are knurled
for easier handling and gripping. The punch whose tip is tapered at an angle of 90 o is known as
centre punch used to mark centres to be drilled or to mark centre of an edge. A dot punch with
tip tapered at 60 is used to punch a chain of dots on a scribed line.

2.2.7. Chipping hammer

It is a welding tool used to remove slag from the weldment.

2.2.8. Electrode holder

It is used to hold the electrode properly. Its mouth grips the electrode and passes current to the
electrode through the welding cable connected at the other end of the holder. It should be well
insulated.

2.2.9. Tongs
They are used to handle the hot metal (welding job) for positioning or while cleaning.

2.2.10. Wire brush

It is used for cleaning the surface of the metal as well as for the slag from the welds. The wire
brush is made of steel wires fitted on a wooden piece.

2.2.11. Apron
It protects the welder’s body and clothes from heat and sparks. Usually leather apron is
employed.
2.2.12. Face shield / eye shield ( Welding screen)
It is used to prevent direct rays of arc, weld spatter and slag and protects the operator’s eyes
and face. It consists of a cover slag and a dark filter glass. The filter glass absorbs the ultra
violet rays radiated by the arc.

2.2.13. Hand gloves

Mainly leather gloves are used to protect arm from welding spark and heat.

2.2.14. Earth clamp

It is used to connect the return lead firmly to the work piece or to the welding table.

2.2.15. safety shoes for welders

If at work you need work shoes that can protects you from sparks due to welding work, then I
recommend you get a pair of safety shoes for welders.

2.3. TECHNIQUES USED IN DEPARTMENTS:

2.3.1. DYE PENETRANT TESTING (DPT) : In JNIL siltara for penetrant testing they are
using DYE TESTING KIT for checking welding defect .

DPT used to check the surface irregularities.

STEPS TO BE FOLLOWED FOR DYE PENETRANT TEST:

i. Surface Preparation: The surface must be thoroughly cleaned, to make it free from
dirt, oil, paint, grease, water, or other contaminants. For cleaning one can use penetrant
remover.
ii. Penetrant Application: After a thorough cleaning, Penetrant is applied. Penetrant is a
red dye penetrant . It can be applied on the surface by spraying (most common) or by
brushing or by immersing the entire surface in a penetrant bath.
iii. Dwell period: Leave the penetrant, as it is, on the surface for a minimum period of time
(Known as Dwell Time or Dwell Period). During the dwell period, the penetrant seeps
into the flaws (if present on the surface being inspected), due to Capillary action. The
dwell period varies from 5 minutes to 15 minutes, one should strictly restrict to the
recommended dwell time.
 iv. Application of Developer: After a thorough cleaning, a thin layer of developer is
applied. Two things shall be taken care of while spraying the developer;
 Shake the bottle rigorously
 Maintain a distance of 10 to 12 inches from the surface, while spraying the
developer
 After spraying the developer wait for 5 minutes to 15 minutes (development
time)

The developer sucks the trapped penetrant on the surface, from the flaws (if
present). That is the penetrant bleeds out on the surface and it appears in sharp red
color. The developer is a white color liquid and hence the penetrant appears in a
sharp red color, hence we can easily identify the flaws.

Ⅴ. Inspection: After the application of the developer wait for 10 to 60 minutes and then
perform the inspection. Appropriate lighting is necessary to detect the indications from any
flaws which may be present. The minimum light required is 1000 Lux or 100 foot-candles.

Figure:
Figure Dye Welding
1: After penetrantpenetrant
testing kittest
& dye penetrate
2.3.2. ANGLE GRINDER: In JNIL siltara for use AG9 (Angle grinder)

For the modern metalworker, an angle grinder is one of the most essential tools of the trade.
Welding is discussed so much more regularly that the Angle Grinder is often forgotten while in
reality, most welding procedures would not be as straightforward or aesthetical without its
assistance.

There’s a good reason for that: angle grinders are extremely versatile tools. They can be used to
cut, shape, weld, and polish metal.

 To cut metal
 Preparing the base metal
 Preparing welding joints
 Finishing the weld
 Removing the weld

Figure 2: AG9

2.3.3. WELDING POSITION

Welding is often done on structures in the position in which they are found and in the position
the part will be used.

All welding can be classified according to

the position of the workpiece or the position
of the welded joint on the plates or sections
being welded.

There are four basic welding positions.

 Flat position
 Horizontal position
 Verticle position
 Overhead position

Figure 3: Four basic welding positions

A number is used to define the position, and an F for Fillet or G for groove refers to the type of
weld. An architect’s blueprints would indicate the welding symbol.

 1 refers to a flat position – either 1F or 1G

 2 refers to a horizontal position – either 2F or 2G
 3 is a vertical position – either 3F or 3G
 4 is an overhead position – either 4F or 4G

position of pipe welding

Different Pipe Welding Positions

 1G – Horizontal Rolled Position.

 2G – Vertical Position.
 5G – Horizontal Fixed Position.
 6G – Inclined Position.

Figure 4: pipe welding position

2.3. HIGHLIGHTS OF TRAINING EXPOUSURE

We, the NECO Group of Companies, take immense pride in being the Indian corporate par
excellence. We groom our business leaders to play a significant role in living our
organizational values and firmly believe that the future belongs to those who dream and work
towards making their dream a reality. We value people with high integrity, innovation quotient,
intensity, will, and determination to succeed.

At NECO, we leverage human capital by nurturing knowledge, entrepreneurship, and

creativity. We strongly believe that our values are our strength and help us successfully
compete in a global environment and make use of the emerging opportunities.

We keep our personnel intellectually stimulated to give them the freedom to make their own
decisions and the responsibility to make NECO grow through innovation and experimentation.
Our prime focus is on relentless value addition to enhance the competencies. We believe
professional growth is the responsibility of both the individual and the organization and provide
opportunities for value addition in our employees' careers through our many initiatives.

o Learn your way through our World Class Manufacturing facilities and practices under
the Specialist Training Programme.
o Work your way through our internationally recognized Benchmark practices in all
fields.
o Expose you to the latest in the world through journals, seminars, training sessions, and
conferences held in-house and in other locations.
o Introduce you to cross-functional and cross-business opportunities within our
organization.

CHAPTER 3: PROBLEM IDENTIFICATION/CASE STUDY (DISCUSSIONS)

3.1. WELDING:

Welding is a process by which metals are joined by heating them to a suitable

temperature with or without the application of pressure and addition of filler materials. Welding
processes are employed in most of the modern fabrication works and industries.

ARC WELDING:
Arc welding is a fusion welding process in which welding is done by producing heat from an
electric arc between the work and electrode. Both D.C. and A.C. electric supply are used for
this. The arc between the two terminals produces heat to melt the metal. If two pieces of metal
that are to be joined are placed so that they touch or almost touch one another and the arc from
the electrode is directed at this junction, the heat generated by the arc (approx. 3500 oC) causes
a small section of theedges of both pieces to melt. These molten portions along with the molten
portions of the electrode flow together. As the arc column is moved, the molten puddle
solidifies joining the two pieces of metal with a combinmation of electrode and base metal.

There are different methods of arc welding in practice as listed below:

i) Metal Arc Welding

ii) Carbon Arc Welding

iii) Atomic Hydrogen Arc Welding

iv) Tungsten inert gas Arc Welding (TIG)

v) Metal inert gas Arc Welding (MIG)

vi) Submerged Arc Welding

vii) Plasma Arc Welding

Metal Arc Welding

The commonly used arc welding method is metal arc welding. In this process a metal electrode
is used. The metal electrode itself melts and acts as a filler material.

An arc welding circuit consists of the following essential items:

a) The power source ie the Welding machine

b) Welding lead cable and electrode holder

c) Welding return cable and clamp

d) Welding earth

Arc Welding Machines

There are three types of welding machines in use:

i) Welding transformer

ii) Welding generator

iii) Welding rectifier

Welding transformer

It is used to change the voltage and current to the desired range suitable for welding. Normally
low voltage high current (high amperage) supply is preferred for welding. The welding
transformer operates on A .C. supply only and it has no rotating parts. It is a step down
transformer which reduces the main supply voltage (220 or 440 V) to the welding supply open
circuit voltage between 40 and 100 V.

Welding generator

It is used to generate D.C supply for arc welding. It may be driven by an A.C. motor or driven
by a petrol or diesel engine. It can be used anywhere in the field work, away from the electric
lines.

Welding rectifier

It is used to convert A.C. into D.C welding supply and does not have any rotating parts. It is
basically a transformer, but the output of which is connected with a rectifier to change the A.C
in to D.C.

“According to my report, only ARC WELDING is done in JAYASWAL NECO INDUSTRIES

Ltd.”

Welding Electrode

Electrode is a conductor from which an arc struck. The arc melts electrode and parent metal.
They join together to form a good weld when solidifies. The electrode is a core, coated with a
solid flux acts as a filler material and is consumed during welding by keeping a constant arc
length. The flux when melts produces a slag which floats on the metal pool, protects the weld
from oxidation.The flux of electrode mainly contains cellulose (burns and produces a gaseous
shield around the arc), calcium carbonate and calcium fluoride (impart fluidity to the slag), Iron
powder (for higher penetration and deposition), Titania (for stabilising the arc), asbestos etc.

Weld Defects:-

1. Incomplete Penetration:- It is the failure of the filler metal to penetration into the joint. It is
caused by

a. Incorrect edge preparation

b. Incorrect welding technique

c. Faster welding speed

2. Excessive Penetration:- Excessive Penetration is caused by

a. Incorrect edge preparation

b. Slow welding spene

c. Tro big a heat connection

3. Poor Fusion:- It is failure of the filler metal to fuse with the parent metal. It is caused by

a. Insufficient heat

b. Fast welding speed

c. Incorrect welding technique

4. Porosity:- Porosity is a group of small holes throughout the weld metal. It is caused by the
trapping of the gas during the welding process due to chemical in the metal dumping or too
rapid cooling of the weld.

5. Cracks:- Crack may occur in the weld surface or in the parent metal. It is caused by

a. Bad welding technique

b. Unsuitable parent metal used in the weld

6. Under cut:- Undercut are grooves or slots along the edges of the weld caused by

a. Too fast a travel

b. Bad welding technique

7. Overlays:- Overlays consist of metal that has fluxed on to the parent metal without fusing
with it. The defect is caused by

a. Insufficient heat

b. Bad welding technique

8. Inclusion:- The pressure of non metallic substance in the metal inclusion are due to
contaminated of the base metal deposited by oxide, slag, electrode coating material.

9. Distortion:- Distortion is the changes in the shape and difference between the positions of the
two plates before welding and after welding. It is due to

a. High residual stresses in plates to be welded

b. Slow arc travel speed

c. Type of joint.

Welding-properties:

are strength, hardness, ductility, fracture toughness.

3.2. WEAR PLATE/ COMPOSITE LINER PLATE

A wear plate is an item that you use to keep your machines and equipment safe. You can apply
and install it to a wide range of equipment, like crushers, buckets, chutes, etc. to secure and
keep their performance.

Wear Plate Manufacturing Process

The procedure of manufacturing a wear plate is easy.Wear Plate Manufacturing You can easily
summarize it by following these steps:

o Raw Material Cutting

o Welding
o Inspection or Assessment
o Repair Welding
o Precise Cutting
o Leveling

You might find it different, but other manufacturers can have different procedures. This is just
the raw or the general process on how it’s done.

The Importance of Using Wear Plates in Industrial Equipment

Industrial equipment are usually the machines that undergo the most wear.You use them 100%
of the time, sometimes even 24 hours a day! Its importance in the industrial sector encompasses
layering.In fact, it’s also important because:

o They can prolong the lifespan of a part or a component

o Wear resistant plates can increase productivity and efficiency
o Wear plates can enhance the quality of results

Uses for Wear Plates

You can choose to use wear resistant plates for many things.Uses for Wear Plates But, among
the versatility of its uses, the most common reasons why it’s used are:

o Prevent excessive and premature wear

o Avoid damages like scratches, cracks, burrs, etc.
o Increase or prolong the life expectancy of a part
Wear Plate Material

Wear resistant plates are made out of different materials.Wear Plate Material You can have
wear plates made out of abrasion resistant (AR) steel, aluminum steel, mild steel, etc.

APPLICATION OF WEAR PLATE

Pulveriser mills, cyclones, receiving hoppers, chute

liner plates, coal handling systems, coal buckets,
conveyors, impeller, fan blades and housings.

Figure 5: wear plate

CHAPTER 4: RECOMMENDATIONS :

I gain the information for water treatment plant and how the water can be treated by using
different techniques

Some recommendations are given for the students who want to do their vocational training
program,

Students must complete the courses related to their vocational training before beginning the
program. Completing the related courses before the vocational training helps the students to
understand the topic better.

➢ JNIL for controlling the water quality in different network and the oldest pipes should
be replaced due to their negative effect degraded to the users.
➢ The Bhilai institute of technology, Durg must help the students to find the vocational
training place related to their course and the vocational training budget for the students
to be available before the work,to fulfill their objectives.
➢ It would be better to the Bhilai institute of technology, Durg to make relationship with
many industries (factories), laboratories and other companies where chemistry can be
applied in order to get enough knowledge for the students.
REFERENCE:

1.About industries NECO GROUP OF INDUSTRIES (necoindia.com)

2.www.hardfacingfty.com

3. wikipedia
4. (www.scribd.com) Arc welding.

5. www.cuttingedges.com

DATA SHEET
CONSUMPTION: Consumption of electrodes

Table 1:Consumption of electrodes in COKE OVEN PLANT (2021-2022)

S.no. Electrodes name Size(thikness) Length(mm) Consumption /

(mm) year
1. SS 308 3.15 350 8kg
2. LH 7018 3.15 450 36pkt.
3. LH 7018 4 450 28pkt.
4. MS 6013 2.5 350 nill
5. MS 6013 3.15 350 106pkt.
6. MS 6013 4 450 164pkt.
7. 309MO 3.15 350 20kg
8. 309GR 3.15 350 50kg
9. XHD 2222 nill

Table 2: Consumption of electrodes in DRI PLANT (2020-2021)

S.no. Electrode name Size (mm) Consumption/ year

1. 6013 3.15/4/2.5 121/84/2 pkt.
2. 7018 3.15/4/2.5 40/58/2 pkt.
3. 660NH 3.15/4 10kg/ nill
4. 680CGS 3.15/4 15/ 67.5 kg
 5. cutrods 3.15 6 pkt.
6. L&T 400 3.15/4 8/11 kg
7. L&T 700 3.15/4 20/15 kg
8. ARF RB 4 8 KG
9. CP EM 021 3.15/4 5 kg /nill
10. CP EM 011 3.15/4 6 kg/nill
11. L&T 2222 3.15/4 5/5/nill kg
12. 2233 3.15/4 Nill/5 kg
13. Stainrode D 3.15/4 10 kg/10 kg

Table 3: Consumption of electrodes in RMHS PLANT (2020-2021)

1. 308 3.15 26kg

2. cutrod 3.15/4 27 pkt/ 20kg
3. 7018 3.15/4 90/4 pkt
4. 6013 2.5/3.15/4 8/172/107 pkt.
5. 6180 3.15/4 15kg/25kg
6. Electrode 2B 4 1 pkt.
7. Abrocar 4 25 kg

Table 4: Consumption of electrodes in SINTER PLANT (2020-2021)

1. 6013 3.15/4 360 /300 pkt

2. 7018 3.15/4 96/96 pkt.
3. SAN-74 4 300 kg
4. Unitrode mv-73 4 240kg
5. 680 CGS 4 180kg
6. Cutrode 3.15 36 pkt.
7. CPBF-024 4 120 kg

Table 5: Consumption of electrodes in PELLET PLANT (2020-2021)

1. CGS 680 2.5/3.15/4 5 KG

2. cutrode 3.15 13 kg
 3. 7018 3.15/4 21 pkt /18 pkt.
4. 6013 2.5/3.15/4 3pkt/ 317/104
5. D2D2 4/3.15 5kg/5kg
6. TF 81 8MM 25kg
7. 2233 3.15/4 5kg
8. BU 400 4 5 kg
9. 2240 3.15/4 9kg/5kg
10. 2222 3.15/4 10kg/15kg

Table 6: Consumption of electrodes in GRANDING STORE

1. 7018 3.15/4 23/10 pkt

2. 6013 3.15/4 264/210 pkt
3. 308 3.15 18kg
4. cutrode 3.15 16pkt
5. 309 3.15 43 pkt

CONSUMPTION: Consumption of wear plate

RMHS COMPOSITE LINER PLATE

92 sq.m.(2020-2021)

DRI

Wear plate 15 sq.m.

CLP dia. 350×6m. 2 pice