NALLA MALLA REDDY ENGINEERING COLLEGE

An Autonomous Institution
(Affiliated to JNTUH, Hyderabad & Approved by A.I.C.T.E.)
(Accredited by N.B.A. & Graded “A” by NAAC)
DIVYA NAGAR, MALKAJGIRI-MEDCHAL (DIST), HYDERABAD- 500088.

DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE
This is to certify that the mini project entitled “Study on welding” is a bonafide work
carried out by S.V.Nagarjuna (21B65A0343) is submitted in fulfilment for the
award of the Degree of Bachelor of Technology in Mechanical Engineering by
Jawaharlal Nehru Technological University Hyderabad, during the academic year
2023-24.

Mr. C. BALARAM Dr. T.V.S.M.R. Bhushan

Associate Professor & Guide Head of the Department
Dept. of Mechanical Engineering Dept. of Mechanical Engineering
 ACKNOWLEDGEMENT
With a deep sense of gratitude, I acknowledge the guidance, help and
active Cooperation by the following people whose guidance has sustained
the effort which led to the successful completion of this work.
I am very much thankful to my guide Mr. C. BALRAM, assistant
professor in the Mechanical Engineering Department, at Nalla Malla Reddy
Engineering College, for his valuable guidance and suggestions.
I am especially thankful to Dr. T.V.S.M.R. BHUSHAN, Associate
Professor and Head of the Mechanical Engineering Department during the
progress of a project, for his timely suggestion and help inspired us to
complete this project.
I wish to express my sincere gratitude to Dr. M. N. V. RAMESH,
Principal, of Nalla Malla Reddy Engineering College, for his consistent help
and encouragement.
I extend my special gratitude to Dr. DIVYA NALLA, Director,
Nalla Malla Reddy Engineering College, for her help and support in
completing this project.

BY

S.V.NAGARJUNA (21B65A343)
 TABLE OF CONTENTS

CHAPTER NO. DESCRIPTION PAGE NO:

1 INTRODUCTION 1-8
1.1 HISTORY
1.2 SAFETY CLASSESS
1.3 APPLICATONS
1.4 OBJECTIVES
2 WORK SHOP SECTIONS -
&MACHINES 9-10
2.1 MACHINE SHOP (MCS)
2.2 MACHINE BUILDIND
SHOP(MBS)
3 ROLLING OF PLATES 11-12
3.1 PLATE ROLLING MACHINE
4 HUB & SHAFT
PREPARATION 13-14
4.1 LATHE MACHINE
5 ASSEMBLING & CENTRING 15-16
5.1 MANUAL ASSEMBLING
5.2 MANUAL CENTRING
6 WELDING 17-22
6.1 ARC WELDING
6.2 GASS WELDING
6.3 BRAZZING
7 DYNAMIC BALANCING &
VULCANISED RUBBER
LAGGING 23-26
7.1 DYNAMIC BALANCING
7.2 VULCANISED RUBBER LAGGIG

8 CONCLUSION 27-
 CHAPTER 1
INTRODUCTON

The Singareni Collieries Company Limited, often referred to as SSCL, is a

government-owned coal mining company in India. It was established in 1920,
in Kothagudem, Telangana. SCCL plays a significant role in coal production and
supply, primarily catering to the energy needs of the southern region of India. The
company operates coal mines in various parts of Telangana and Andhra Pradesh.

In addition to coal mining,SCCLalso operates workshops that are essential for

the maintenance and repair of mining equipment, machinery, and infrastructure.
These workshops are crucial in ensuring the smooth and efficient operation of the
mines. They employ skilled personnel and use advanced technologies to maintain and
repair the equipment that is crucial for the extraction of coal.

SCCL's workshops are an integral part of the company's efforts to maintain

safety, productivity, and sustainability in its mining operations. They contribute to the
overall success of the company by ensuring that the mining activities run smoothly
and efficiently.

1.1HISTORY

Sccl was founded on december 23, 1920, as a public-sector coal mining

company. It was named after the village singareni in telangana, where coal was first
discovered. The company's establishment was aimed at developing coal resources in
the region to meet the growing demand for coal.

During and after world war ii, sccl witnessed a period of growth and
expansion. This growth was driven by increased demand for coal to support
industrialization and infrastructure development. The company expanded its mining
operations and workforce during this period.

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 In 1974, as a part of the nationalization of the coal industry in india, the
government of india acquired a majority stake in sccl. This move was in line with the
broader strategy of consolidating coal resources under state control

Recent developments: As of my last knowledge update in january 2022, sccl

was actively involved in increasing coal production to meet the growing energy needs
of southern india. The company has been working to ensure environmental
sustainability and employee welfare while pursuing its mining activities.
1.1.1 Coal demand

Singareni Collieries Company Limited (SCCL) where the present study is

undertaken is one of the largest public sector undertakings in India. It is jointly owned
by the Government of Andhrapradesh and the Government of India with equity
participation in the ratio of 51:49.

The company's accredited function is to explore and exploit coal deposits in

the Godavari Valley Coal Field Area, which includes the four districts of Telangana
Region namely, Adilabad, Karimnagar. Khammam and Warangal in Andhra Pradesh.
The company markets its coal to several thermal power plants including NTPC
(Ramagundam), APGENCO power stations, and power stations in Karnataka.
Maharashtra, and Gujarat. It is to be noted that the power sector consumes 78 percent
of its coal while around 50 cement plants situated in the States of Andhra Pradesh,
Karnataka, and Tamilnadu consume 13 per cent of coal.
The balance 9 per cent coal is marketed to about 3,400 small and medium
scale industries. With spurt in industrial growth in Southern States and the resultant
huge increase in demand for electricity, the SCCL has been playing a key role in
empowering the economies down south of the country. Further, with the new
Electricity Act providing opportunities for independent production and distribution,
the demand for coal has increased phenomenally leading to its improved performance
as evident from the huge profit of Rs.268.11 crores it made in 2009-10. In fact, it has
been making profits.

2
 continuously since 1997-98. Further, it contributed a huge amount of Rs.886
crores to the State Government and Rs.541 crores to the Central Government in the
form of taxes and dividends in 2009-10.

The good performance of the SCCL can be largely attributed to its strong will
power and determination, teamwork and commitment to pre-defined goals. All the
same, the visionary political leadership of the state, smart management, qualitative
and motivated work force also contributed a lot to the growth and development of the
company.

1.1.2Role of SCCL Employs

Employees play an important role in the industrial production of the country.
Hence, organisations have to secure the cooperation of employees in order to increase
the production and to earn higher profits.
The cooperation of employees is possible only when they are fully satisfied
with their employer and the working conditions on the job. In the past, industrialists
and the employers believed that their only duty towards their employees was to pay
them satisfactory wages and salaries.
In course of time, they realised that workers require something more
important. In addition to providing monetary benefits, human treatment given to
employees plays a very important role in seeking theircooperation. Further, human
resource managers realised that the provision of welfare facilities contribute a lot
towards the health and efficiency of the workers. All the same, organisations need to
provide various social security benefits such as medical care, mortality benefits,
pension etc., as specified by law.
It is a fact that the provision of social security benefits is a kind of wise
investment that offers good social dividends in the long run. The company having
realised the importance of welfare and social security measures introduced several
welfare schemes for its workers and the families. For instance, the company provides
3statutory welfare facilities like drinking water, conservancy, medical appliances,
canteen, rest shelters, crèches etc.

3
 It also provides various non-statutory welfare facilities such as medical,
education, recreation, housing/quarters, consumer co- operative stores, consumer co-
operative credit society etc. Further, it provides social security measures like
provident fund, gratuity, pension, dependent employment etc. It is to be noted that the
company spent a huge amount of Rs.32,090 lakhs on total employees welfare and the
average welfare expenditure per employee stood as high as Rs.46,478 in 2009-10.

It shows that the SCCL is highly employee welfare-cum-social security

oriented. In short, due to the welfare and social security measures provided by the
company, its employees have been working with involvement and commitment.
Consequently, the performance of the company is quite commendable. Against this
background, a study has been undertaken on the research topic-A Study on Welfare
and Social Security Measures in Singareni Collieries Company Limited, Khammam
District, Andhra Pradesh (with reference to Kothagudem Mines).

1.2 SAFETY CLASS

 Safety class are conducted y mvtc (mines vocational training center)

 Ppc (personal protective equipment) differs from section to section

 Protective equipments provide in mines

1. Safety helmets:
Helmets are approved after being certified by the central mining research
station, Dhanbad, as conforming to bss 2826 1957. Industrial safety helmets. Under
these specifica- tions the helmets have to pass successfully (a) shock absorption test,
(b) penetration test and (c) inflammability test (d) heat resistance test.

2 safety and industrial gloves.

3 sleeve guard.

4
4 knee pads.

5 chin guard

6 breast plate.

7 safety harness belts:

8 safety eye wear

9 dust respirators

10 hearing protector

 Legal aspects as per c.m.r. 1957.

1991 use and maintenance of protective foot wear.

1991(a)- use and supply of helmet.

1991(b)- supply of other protective equipments.

1991 (c) obligation of persons provided with protective equipment.

1991(d)- use supply and maintenance of self rescuer

1.3 APPLICATIONS

Especially in the mining industry like Singareni Collieries Company Limited.

They have several important applications in such mining operations:

5
Material Transport:
Conveyor drums are used to transport mined coal and other materials from the
underground mining areas to the surface or between various processing units. They
play a crucial role in the continuous and efficient movement of materials.

Loading and Unloading:

Conveyor drums are employed in loading and unloading materials onto and
from the conveyor belts. This is essential for the transfer of coal between different
stages of processing and transportation.

Belt Tensioning:
Conveyor drums help maintain proper tension in the conveyor belts. This
ensures that the belts are running smoothly and can carry heavy loads without
slipping, which is especially important in mining operations where large quantities of
coal need to be moved.

Directional Control:
By using different types of conveyor drums, it's possible to control the
direction of material flow on the conveyor belts. This is important for guiding
materials through the various stages of processing and transport.

Speed Control:
Conveyor drums, in combination with motorized drive systems, allow for
precise control of conveyor belt speed. This is crucial to adapt to changing operational
needs and maintain optimal processing rates.

Wear and Tear Resistance:

Given the harsh conditions in underground mines, conveyor drums are
designed to be durable and resistant to wear and tear. They are typically made of
heavy-duty materials and coatings to withstand the abrasive nature of the transported
materials.

6
Safety:
Conveyor drums play a role in ensuring the safety of mining operations.
Properly maintained drums reduce the risk of belt slippage and other potential hazards
associated with material handling.

1.4 OBJECTIVES

Equipment Maintenance:
Ensuring that all mining equipment, such as coal cutters, conveyors, and
heavy machinery, is properly maintained to prevent breakdowns and downtime, which
can be costly in a mining operation.

Safety Compliance:
Maintaining and servicing equipment to meet safety standards and regulations
to minimize the risk of accidents and ensure the well-being of the workforce.

Efficiency and Productivity:

Improving the efficiency and productivity of mining operations by ensuring
that equipment is in optimal working condition, thereby increasing coal production.

Cost Control:
Controlling maintenance and repair costs through efficient workshop
operations, which is vital for the company's financial performance.

Inventory Management:
Properly managing spare parts and supplies to reduce downtime and ensure
that replacement components are readily available when needed.

Training and Skill Development:

Providing training and skill development opportunities for the workshop staff
to enhance their capabilities in equipment maintenance and repair.

7
Environmental Compliance:
Ensuring that equipment and machinery meet environmental standards and
regulations, especially in coal mining, where environmental considerations are
significant.

Innovation and Technology Integration:

Incorporating advanced technologies and innovative maintenance practices to
improve equipment reliability and reduce maintenance frequency.

Quality Control:
Ensuring the quality of maintenance and repair work to extend the lifespan of
equipment and minimize the need for replacements.

Resource Optimization:
Maximizing the use of resources, including manpower, equipment, and
materials, to minimize downtime and improve workshop efficiency.

Emergency Response Preparedness:

Being prepared for emergency situations, such as equipment breakdowns or
accidents, to minimize disruptions in mining operations and ensure the safety of the
workforce.

Documentation and Reportin:

Keeping comprehensive rec ords of maintenance and repair activities, which
is essential for tracking equipment performance and compliance with regulations.

8
 CHAPTER 2
WORKSHOP SECTIONS & MACHINES

2.1 MACHINE SHOP (MCS)

There are many number of machines used to machine the work piece as per
the required dimentions there are:

 Lathe machines
1. Turret lathe
2. Hexagonal turret lathe
3. Round turret lathe
4. Copy lathe
 Millimg machines
1. Horizontal milling machine
2. Vertical milling machine

 Grinding machine
1. Surface grinding machine
2. Internal grinding machine

 Cutting machines
1. Ban saw machine
2. Hack saw machine

 Slotting machine
 Planning machine
 Radial drilling machine
 Shaping machine

9
2.2 MACHINE BUILDING SHOP
Fabrication of various parts are prepared as per the required dimensions by
using the following machines

 Drum rolling machine

 Gas welding
 Arc welding

10
 CHAPTER 3
ROLLING OF PLATES
Plate rolling is an incredibly essential part of any metal industry. The task of
these rolling machines is simple: shaping metal plates into cones, cylinders, and
curved shapes.

3.1 PLATE ROLLING MACHINE

Working principle
The movement form of the plate rolling machine The movement form of the
plate rolling machine can be divided into two forms of main movement and auxiliary
movement. The main motion refers to the movement of the upper and lower rollers
constituting the plate rolling machine to rotate and bend the processed plate, and the
main motion completes the processing tasks of the plate rolling machine. Auxiliary
movement is the form of movement of the loading, unloading and lifting of the upper
roller, the lifting and the turning of the headstock during the rolling process of the
plate bending machine.
The mechanism is a three-roller symmetrical type. The upper roll is vertically
moved at the symmetrical position of the two lower rolls. It is obtained by the screw
and screw worm drive. The two lower rolls are rotated. Engagement to provide torque
for rolled sheet.

11
Plate rolling machine fig(1)

Drum fig(2)

12
 CHAPTER 4
HUB & SHAFT PREPRATION
These are the parts which are used to support the drum and rotate smoothly on
the bearings
Hub:
The hub is the mechanism by which the conveyor pulley is affixed to the shaft.
There are many types of hub connections, all of which offer individual advantages
and disadvantages

Shaft:
It is a part which affixed between bearings and hub to run the sheel/drum
smoothly on the conveyor belt

4.1 LATHE MACHINE

A lathe is a machine tool that rotates a workpiece about an axis of rotation to

perform various operations such as cutting, sanding, knurling, drilling, deformation,
facing, and turning, with tools that are applied to the workpiece to create an object
with symmetry about that axis.

Working principle
It operates on the principle of a rotating work piece and a fixed cutting tool.
The cutting tool is feed into the work piece which rotates about its own axis causing
the workpiece to form the desired shape.

13
 Lathe fig(3)

Fig(4)

14
 CHAPTER 5
ASSEMBLING & CENTRING

5.1 MANUAL ASSEMBLING

After preparation of all the parts (shaft,hub&drum ) .All are placed in the
assemble section to assemble the parts .
The workers uses the appropriate material handling devices such as fork lifts
to assemble the parts togeather and send them to the centring section .

5.2 MANUAL CENTRING

The alignement of shaft,hub& drum can be done using manual centring
method. By using the measuring instruments like the shaft exactly in the center
position by using the measuring instruments like:
 Steelrule
 Vernier calipers
 Micrometer
After complitoin of centering process without changing the position of the
parts the welding between the parts takes place

15
Assembling fig(5)

Centring fig (6)

16
 CHAPTER 6
WELDING

Welding is the process of joining of two similar or dissimilar metals by

fusion. Now a days it has become so popular and necessary that without welding
action a work shop is incomplete.

After completion of centering process without changing the position of the

parts the welding between the parts takes place.

Welding may be divided into forge welding, are welding. The gas welding and
brazing. Most commonly used welding are arc welding gas welding are brazing.

6.1 ARC WELDING

Arc welding is further divided into metal arc, atomic hydrogen arc.,
carbon arc, submerged arc etc., In metal arc welding an arc passes
between

17
 fig(7)

18
6.2 GASS WELDING

Gas welding is fusion welding which heat is supplied by burning a mixture of

oxygen and; suitable combus tible gas. The gases are mixed in a flow pipe or torch
which gives control of welding flame. Acetylene is universally used as the
combustible gas because of its high flame temperature of about 600°F. Oxyacetylene
welding of steel is performed without any flux. For aluminum, magnesium, nickel and
their alloys.

19
 Fig(8)

20
6.3 BRAZZING

In brazing coalescence is produced by heating to above 800 OF and by using a

non-terrous filler metal having a melting point below that of base metals. Cleansing
before brazing is very necessary Brazing with bronze rods is used extensively on cast
iron, steel, copper, brass etc...

Common defects and safety measures:

 Welding is being done at every places even to explosives storage, gases etc..

 Welding section is not covered and painted property

 No precaution is taken for welding and cutting of containers which earlier had gas
or explosives.

 Gas cylinders are not properly stored and not properly handled.

21
 Brazzing fig(9)

22
 CHAPTER 7
DYNAMIC BALANCING & VALCANISED RUBBER
LAGGING

7.1 DYNAMIC BALANCING

A method through which we balance the moving parts of a machine, or piece

of industrial machinery. To do this, we rotate these parts at high speeds. When we do
this we are able to gain a measurement of the imbalance within each individual

Adding of mass to the shell at certain degrees where it required for

dynamically balance. Because to run the shaft properly on the bearings with out break
down of the bearings

23
Dynamic balancing machine fig(10)

24
7.2 VULCANISED RUBBER LAGGING
Increases the traction between the belt and the pulley, which in turn reduces
load and wear on the drive, belt, pulleys, bearings and take-up.

25
Vulcanised rubber lagging fig(11)

26
 CHAPTER 8
CONCLUSION

27

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