Training

In
Jayaswal Neco Industries limited

By
Gaurav Rambhau Akotkar
About industry

 The plant is situated in MIDC Hingna Road, Nagpur.

 It manufactures Cast Iron Pipes, Joints & Gratings.
 The plant was Incorporated In 1972.
 It is an ISO 9001:2008 Certified company.
Centrifugal Casting

 Centrifugal casting or rotocasting is a casting technique

that is typically used to cast thin-walled cylinders.
 Itis used to cast such materials as metal, glass, and
concrete.
 Itis noted for the high quality of the results attainable,
particularly for precise control of their metallurgy and
crystal structure.
Process of Casting

 The mould is mounted on rollers.

 Mould is rotated at high speed about its axis.
 Whilemould is rotating, the molted metal is poured
from basin and pipe is casted due to centrifugal force.
Melting of iron

 Melting of iron is done in two furnaces:

 Firstly in Cupola furnace
 Finally in Induction furnace.
Cupola Furnace

 Preparation of Furnace using refractories bricks and

fireclay.
 Fire is burnt from bottom.
 Chargingis done from top using rope and pulley
arrangement.
 For melting 1 ton of iron 65 kg of LAM coke and 35 kg
of limestone is required.
Induction furnace

 Lining of furnace.(Once in month)

 Melt iron (from cupola furnace) is poured in Induction
Furnace and slag 30 powder is added for removing slag.
 Silicon, Manganese, Phosphorous is added. Amount of
this elements is different for different pipes which is
shown in next slide.
 Pi p e S i z e   T e m p er at u r e i n ˚C  

Sr.No     %C %S i %M n %P C .E    

                   

1 3 2
3.40-3.75 0 .5 -0 .7 0 .2 5 4 .2 0 147 0 -15 20
 

       

               

2 4
3.30-3.75 1 .9 0 .5 -0 .7 0 .2 5 4 .2 0 138 0 -15 00
 

     

               

3 6
3.30-3.75 1 .9 0 .5 -0 .7 0 .2 5 4 .2 0 138 0 -14 50
 

     

               

4 8
3.30-3.75 1 .9 0 .5 -0 .7 0 .2 5 4 .2 0 135 0 -14 50
 

     

               
Casting in duker machine

 It
is multi mould machine because four moulds are
mounted on machine.
 Hub Core is mounted and Celite powder is sprayed on
internal suface.
 While mould is rotated melted metal is poured.
 Speed of mould is set on control panel.
 Mould is rotated at 1100-1200 RPM and pipe is extracted
by extracting car.
Casting in single mould Machine

 Mould is mounted on machine and Celite powder is

sprayed on internal surface of mould.
 Hub Core is mounted.
 While mould is rotating melted iron is poured from
basin.
 It takes 2-3 minutes for one pipe.
 Pipe is extracted by extracting car.
Pipe Testing

 Following are the Non-Confirmatory and rejectory:

Rejectory Non Confirmatory

1. Broken Pipes 1. Short Pour 7. Leakage
2. Bend 2. Hub Metal 8. Depression
3. Broken Hub 3. Pin Hole 9. Spiral
3. Over Weight 4. Rough Surface
4. Low Weight 5. Core Shift
5. Cracks 6. Thickness Variation
Finishing

 Cutting
 Brushing using wire brush.
 Internal Grinding
 Painting:-Black Bitumen Paint, Red Oxide Mat finish
Paint, Red Oxide Glossy Paint
Conclusion

 Hence the training program has given experience about

what we have studied in our theory.
 Given us knowledge about working environment.
 Ithelped us to improve our soft skills, communication
skills etc.