INDUSTRIAL REPORT-2011

SUBMITTED BY
ANURAG GUPTA (08ESKME010) PANKAJ GOYAL (08ESKME032) JITENDRA KUMAR (08ESKME020) DEEPAK KUMAR (08ESKME016) VIKAS PALLIWAL (08ESKME058) RAVINDRA YADAV (08ESKME040) AKASHDEEP SHARMA (08ESKME003) LOKRANJAN PANDEY (08ESKME022)

SUBMITTED TO
MR SB BHEEM READER MECHANICAL DEPARTMENT

Industrial Report-2011

Acknowledgment
THIS IS TO ACKNOWLEDGE THAT THE FOLLOWING STUDENTS OF VI SEMESTER ARE SUBMITTING THEIR INDUSTRIAL TOUR REPORT -2011.

WE ARE ALL THANKFUL TO THE TOUR COORDINATOR MR. S.B. BHEEM FOR HIS EFFORTS FOR SUCH A GREAT INDUSTRIAL TOUR. THANKS ARE DUE TO MR. PRAVEEN SARASWAT AND MR. ANKIT AGARWAL FOR SPARING THEIR VALUABLE TIME ON TOUR WITH US AND WE ARE ALSO THANKFUL TO OUR CLASSMATES FOR THEIR GREAT COOPERATION DURING THE TOUR.

Industrial Report-2011

INDUSTRIES VISITED

1. IIT BOMBAY
2. SUZLON, VAPI 3. SHREEJI PRINTS Pvt. Ltd., SURAT
4. AMBICA ENTERPRIZES, BARODA 5. GROW-WELL INDUSTRIES, BARODA 6. ONGC Central Workshop, BARODA

Industrial Report-2011

1. INDIAN INSTITUTE OF TECHNOLOGY, BOMBAY

WE VISITED THE POWAI CAMPUS IN BOMBAY ON 30TH MARCH 2011.THERE WE WENT TO TWO FLUID MECHANICS LABS AND ONE MACHINING TOOLS LAB.

FLUID MECHANICS LAB 2HERE WE WERE SHOWN A THREE WAY PATHED CHIP WHICH SERVES AS A COOLANT IN VARIOUS LAPTOPS(THE LAPTOPS ARE IMPOSSIBLE TO BEAR ON THE LAPS AS THEY GET EXTREMELY HOT AFTER A USAGE OF A CERTAIN AMOUNT OF TIME) AND ELECTRONIC ITEMS.THE CHIP BASICALLY IS MODELLED ON A CONVERGING DIVERGING DUCT WHICH TAKES THE HEAT OUT OF A SYSTEM

A SENSOR IS BEING WORKED UPON WHICH DETECTS THE POSSIBILITY OF A HEART ATTACK TO A PERSON BY ANALYSING HIS PLASMA LESS PINK BLOOD.PLASMAS ARE TAKEN OUT OF THE BLOOD EXTRACTED FROM THE HUMAN BODY.

MACHINING TOOLS LABAS WE ALL KNOW SAPPHIRE IS A WELL KNOWN CRYSTAL.IN THIS LAB A VERY FINE SAPPHIRE TIP IS USED IN POLISHING A GIVEN SURFACE SYMMETRICALLY.THE MACHINE WHICH PERFORMS THIS TASK HAS BEEN SENT TO THE JURISDICTION FOR PATENT. ANOTHER EQUIPMENT WHICH WE SAW WAS THE CLADDING MACHINE.CLADDING IS NOTHING BUT COATING ON A GIVEN SURFACE.A TANK CONTAINING A SPECIAL KIND OF CHEMICAL SUPPLIES THE JET WHICH COMES OUT OF THE TIP OF THE NOZZLE AND FORMS A COATING ON THE SURFACE

Industrial Report-2011

FLUID MECHANICS LAB 1A ROCKET LAUNCHER SET UP WAS UP FOR DISPLAY IN THIS LAB.HERE A LAUNCHING PAD IS USED TO ABSORB THE HEAT WHICH IS THEN MEASURED TO DESIGN THE FLAME.A DOWNWARD THRUST IS CREATED TO PUSH THE ROCKET UPWARDS. PELTON TURBINE IS USED TO WORK AT HIGH HEAD AND LOW DISCHARGE.THIS TURBINE IS OF THE PARALLEL FLOW IMPULSE TURBINE.IT HAS A VENTURIMETER WHICH GIVES US THE READING OF THE PRESSURE DIFFERENCE.WATER FROM A DUCT FLOWS IN AND COMES OUT OF THE SPEAR TO ROTATE THE ROTOR.

Industrial Report-2011

2. SUZLON
SUZLON ENERGY LTD WHICH COMMENCED OPERATIONS IN INDIA IN 1995 WITH JUST 20 PEOPLE,HAS NOW GROWN INTO ONE OF THE MAJOR GLOBAL LEADERS IN WIND POWER INDUSTRY. SUZLON ENJOYS MARKET LEADERSHIP EDGE IN INDIA WITH A CONSISTENT MARKET SHARE OF OVER 50% CONSECUTIVELY IN THE LAST 10 YEARS.IT IS THE UNION OF COMPANY,SHAREHOLDERS,VENDORS,CONTRACTORS AND EMPLOYEES. WE HAD A LOOK AT THE WIND TURBINE ASSEMBLY,UNIT 5.THERE WAS A MAIN FRAME YAW BASE ASSEMBLY.THERE ARE DIFFERENT TYPES OF YAW BASE ASSEMBLY OF DIFFERENT BULK AND DESIGN PRODUCING POWER TO THE TUNE OF 600KW,1.25KW AND 2.1KW.ITS CASTING AND FORGING IS CARRIED OUT IN COIMBATORE WHICH IS ASIA S LARGEST PLANT. WIND BAND SENSOR-IT IS USED TO SENSE THE DIRECTION AND SPEED OF THE WIND ROTOR SHAFT ASSEMBLY STANDS FOR 600KW,1250KW AND 2100KW

GEAR BOX ASSEMBLY-IT HAS A GEAR RATIO OF 63.633.IT HAS A ARPEN COUPLING FOR GENERATOR AND SHAFT.IT HAS A BRAKE DISC AND A HYDRAULC SYSTEM COMPLETE ASSEMBLY-IT COMPRISES OF THE GEAR BOX AND ROTOR SHAFT ASSEMBLY ROTOR HUB ASSEMBLY-IT CONSISTS OF A PITCH DRIVER AND A PITCH BEARING

Industrial Report-2011

BLOW OR PREVENTOR(B.O.P)-10,000 PRESSURE SQUARE PER INCH` IS PRODUCED.IT IS CONSTRUCTED FROM CAMERE,HYDRILL AND SHAPER.DRILLING BOP IS MADE BY SUBMERGED ARC WELDING. F.R.P MATERIAL EXPORTED TO COUNTRIES LIKE AUSTREALIA,USA,PORTUGAL,SPAIN,SRILANKA AND BRAZIL THERE IS A TOTAL OF 350 WORKERS WORKING IN THE PLANT TO BUILD AN AVERAGE OF 70 TO 77 TURBINES EVERY MONTH,WITH EACH TURBINE WEIGH 25 TONNES. IT HAS A MONTHLY TURNOVER OF ABOUT 600cr.

ILLUSTRATIVE FIGURES

Industrial Report-2011

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3. SHREEJI PRINTS PVT.LTD

PLOT NO.411&412-A, G.I.D.C., PANDESARA,SURAT 394221

PRODUCT AND ITS USES;

THE COMPANY S MAIN ACTIVITY IS PROCESSING OF GREY CLOTH (SYNTHETIC FABRICS) INTO FINISHED CLOTH FABRICS,SHIRTING,SAREES & DRESS MARERIALS ON JOB CHARGES BASIS.

MANUFACTURING PROCESS;
BROADLY SPEAKING THE PROCESS FLOW CHART OF PRODUCT IS AS UNDER: STEP 1. GREY CLOTH FABRICS RECEIPT AT FACTORY 2. GREY CLOTH FABRICS INSPECTION 3. ACCEPTED GREY CLOTH FABRICS SENT FOR PROCEESING AFTER DOING NECESSARY FORMALITIES 4. ACTUAL PROCESSING 5. PROCESSED FABRICS DISPATCH PROCESS FLOW CHART INPUT ACCEPTED(GREY CLOTH FABRICS) : : PROCEESING ON JIGGERS : : DYEING ON JIGGERS/JET DYEING

Industrial Report-2011

: : FOR PRINTING ON PRINTING MACHINES : : FINISHING ON STENTER : : FOR WASHING : : STENTER FINAL FINISH : : ZERO ZERO PROCESS : : FOLDING : : DESPATCHING

PRODUCT DETAILS
y LOADING-WATER IS POURED INTO THE JET DYING MACHINE PRIOR TO DIPPING CLOTH INTO THE MACHINE AND MACHINE LID IS CLOSED y WASHING-CLOTH INSIDE THE M/C IS WASHED WITH COLD WATER y SCOURING-TO REDUCE THE WEIGHT AND REMOVE THE SOLVENTS HOT ALKALINE LIQUORS UNDER A PRESSURE AND A TEMP OF 130C IS CIRCULATED FOR 30 MINS

Industrial Report-2011

y ACID WASH-ACID IS ADDED SIMULTANEOUSLY WITH WATER AND STEAM AND CLOTH IS KEPT UNDER THE CONDITIONS FOR ABOUT 15 MINS AND THRERAFTER WASTE WATER IS DISCHARGED. y DYEING-IN THIS PROCESS DYES OF REQUIRED COLOR IS ADDED ALONG WITH WATER AND CHEMICALS LIKE LEVELING AGENTS,DEFAMERS,SWELLING AGENTS,SOFTENING AGENTS,DISPERSING AGENTS ETC. y UNLOADING-THE CLOTH AFTER BEING REMOVED THE JET DYEING M/C IS TRANSFERRED TO HEAT SETTLING MACHINE y HEAT SETTLING-THE CLOTH IS THEN SENT TO HEAT SETTLING MACHINE & ROLLED ON A BEAM. y PRINTING-THE ROLL OF CLOTH IS LOADED ON THE PRINTING M/C AND IS MADE TO MOVE THROUGH A BLANKET.THE CLOTH CAPERS B/W THE BLANKET AND THE SCREEN ON THE PRINTING M/C AND DURING THIS PERIOD ACQUIRES COLOR ACCORDING TO THE REQUIREMENT y LOOP AGER-THIS IS AN OPERATION OF COLOR FIXATION AFTER PRINTING. y WASHING-AFTER THE ABOVE MENTIONED PROCESS CLOTH IS WASHED IN WASHING KUNDI IN DIFFERENT WAYS y FINISHING-THE CLOTH IS THEN TRANSFERRED TO THE STENTER AND ROLLED ON BEAM FOR FINISHING y ZERO ZERO PROCESS-THE CLOTH IS THEN PASSES THROUGH A Z.Z M/C WHERE THE CLOTH IS ROLLED B/W 2 ROLLERS AND A PARTICULAR TEMP TO FIX IT UP y FOLDING-FOLDING TAKES PLACE.

Industrial Report-2011

4. AMBICA ENTERPRIZES

AMBICA ENTERPRIZES IN VADODARA WAS VISITED ON 5th APRIL 2011.HERE IMPELLERS ARE MANUFACTURED WHOSE SHAPE,SIZE AND DESIGN IS OBTAINED FROM A CASTING SET UP MADE UP OF WOOD AND ALUMINIUM.

An impeller is a rotating component of a centrifugal pump, usually made of iron, steel, bronze, brass, aluminum or plastic, which transfers energy from the motor that drives the pump to the fluid being pumped by accelerating the fluid outwards from the center of rotation. The velocity achieved by the impeller transfers into pressure when the outward movement of the fluid is confined by the pump casing. Impellers are usually short cylinders with an open inlet (called an eye) to accept incoming fluid, vanes to push the fluid radially, and a splined, keyed or threaded bore to accept a drive a drive

shaft.

Industrial Report-2011

5.GROW-WELL INDUSTRIES
THE INDUSTRY GENERALLY DEALS WITH THE PRODUCTION OF CONNECTING RODS WHICH ARE EXTENSIVELY USED IN AUTOMOBILES. CONNECTING ROD IS USED TO CONNECT THE PISTON WITH THE CRANKSHAFT. PROCEDURE ADOPTED A FURNACE IS KEPT AT 1500C IN WHICH THE ALUMINIUM METAL IS INTRODUCED TO MELT IT BY KEEPING IT FOR ABOUT HALF AN HOUR. THE MOLTEN METAL IS THEN POURED INSIDE A PATTERN TO PERFORM A PERMANENT MOULD SAND CASTING WHICH IS A TYPE OF GRAVITY CASTING AS THE MOLTEN METAL IS DRAWN DOWNWARDS UNDER THE INFLUENCE OF GRAVITY. THE PATTERN IS ALLOWED TO COOL FOR SOMETIME BEFORE TAKING OUT THE FORMED JOB. THE RUNNER IS THEN CUT AND THE CONNECTING ROD SO PRODUCED IS DISPATCHED FOR FINISHING ON THE LATHE MACHINE.

Industrial Report-2011

FIG:PISTON WITH CONNECTING ROD AND CONNECTING RODS

Industrial Report-2011

6. OIL AND NATURAL GAS CORPORATION

Oil and Natural Gas Corporation Limited (ONGC) is a stateowned oil and gas company in India. It is a Fortune Global 500 company ranked 413, and contributes 77% of India's crude oil production and 81% of India's natural gas production. It is the highest profit making corporation in India, according to filings with the BSE of latest quarter results. It was set up as a commission on 14 August 1956. Indian government holds 74.14% equity stake in this company. ONGC is Asia's largest and most active company involved in exploration and production of oil. It is involved in exploring for and exploiting hydrocarbons in 26 sedimentary basins of India. It produces about 30% of India's crude oil requirement. It owns and operates more than 11,000 kilometres of pipelines in India. It is one of the highest profit making companies in India. In 2010, it stood at 18th position in the Platts Top 250 Global Energy Company Rankings.

We visited the ongc plant at vadodara on 5th april 2011 to get a lowdown on the various refurbishment and overhauling processes carried out in the grand plant. Workshops Visited:

y y y y y y

Fabrication shop Heavy equipment repair shop Diesel shop Production shop Machine shop Production and plant maintenance shop

Industrial Report-2011

Electrical repair shop. Ongc is asia s biggest exploration company.It is a integrated,geological,geographical,technical and engineering company,it has 80 rigs which after drilling determines the flow of oil and gas.Drill rig replacement and its refurnishing is done after every 5 years. Ongc,baroda has a manpower of about 400.The refurbishing and overhauling programme is mainly carried out in baroda and shivsagar(assam). Ongc retrieves 46 metric tonnes of oil and 20 metric tonnes of gas annually. Procedure adopted in the fabrication shop Lots of steps are taken to repair impaired and malfunctioning machinery that are brought to the plant.Machines are plate welded and three parts welded together to form one single part.steel plates are brought from SR Steel.Various storage tanks are also kept in this workshop. Fabrication shop 2 Blowout opearations are carried out in this workshops.large mud tanks are placed in this workshops.

Industrial Report-2011

Assembly shop Systematic repairing of 80 rigs is undertaken in assembly shop.it has following equipments: y Drawworks y Pump for pumping mud y Gown block y Travelling block y Hook y Rotary table y Swivel y Elmaco brake y Rotary drive y Pile hammer y Gear box y Hydrometric brake Machine shop: It has following machines; 1) V Boring machine 2) Milling machine 3) Lathe machine 4) Grinding machine 5) Hyd. Hackle saw.

Industrial Report-2011