INDUSTRIAL INTERNSHIP REPORT

COMPANY NAME:
ISHAN EQUIPMENTS PVT LTD
(UNIT -2)
144 -145, N H-8 AT SANKHARDA-391350
DIST- BARODA (GUJARAT),INDIA

Submitted in the partial fulfillment of the

Requirement for the award of
Degree of Bachelor of Technology in Mechanical Engineering
Submitted by:
NAME: PATEL TAPAN MAHESHBHAI
ROLL NO: 17BE02025
BRANCH: MECHANICAL ENGINEERING

Submitted to:
Mr. Dhruv Prajapati

---------------------------------------------
GSFC UNIVERSITY, BARODA
INTERNSHIP INSTITUTION: GSFC Ltd.
INTERNSHIP PERIOD:10/06/2019 to 22/06/2019
 INDEX.

Sr no Topic Page no

1 INTRODUCTION ABOUT COMPANY 1-7

(PLANT OVERVIEW, PLANT DETAIL DESIGN)

2 INFRASTRUCTURE, MACHINERY’S, INSPECTION 8-10

INSTRUMENTS DETAILS

3 DETAILS ABOUT MACHINERY’S AND INSPECTION 11-30

INSTRUMENTS

4 MAJOR DIVISION OF THE COMPANY 31-36

(FABRICATION AND RUBBER LINING DIVISION)

5 LEARNING OUTCOME 36-37

 INTRODUCTION

Our internship was in the most famous and well-known fabrication company that’s
ISHAN EQUIPMENTS PVT. LTD. {UNIT – 2}
Located at :- 144 -145, N H-8 AT SANKHARDA-391350
DIST- BARODA (GUJARAT),INDIA

1) Mainly the company produces the product such as boilers, pressure vessels,
storage tanks, heat exchangers also.
2) In pressure vessels the make mostly Cylindrical types of pressure vessels
(horizontal and vertical types) and Spherical also.
3) The company is divided into 5 shades (Bays) where the manufacturing and
fabrication works go on.
4) They also prepare their own rubber sheets for lining the vessels which is located at
Bay - 5
5) The details infrastructure will be discussed below.
So now let us discuss about the Infrastructure of the company
Plot Area 22500 square meters

Covered Area 87 Mtr. width X 110 Mtr. Length with Heavy duty concrete flooring (Total
- 9570 Sq. mtr.)

Uncovered Area 12930 Sq. Mtr. - Uncovered Area with heavy duty concrete flooring
Suitable for plate storage / fabrication
Office & Stores 400 sq. Mtr. & 700 sq. Mtr.

Handling Facility
(A) 2 Nos. 30 MT & 1 No. 10 MT EOT w/ 5 MT Auxiliary & 12.5 Mtr Clear
Hook Height
(B) Size of shed No-2 16.5 mtr W X 110 mtr Long
1 No. 60 MT Goliath crane with 15 MT Auxiliary & 12.5 Mtr. Clear Hook
Height
1 No. 20 MT Goliath crane with 15 MT Auxiliary & 12.5 Mtr. Clear Hook
Height
(C) Size of shed No- 3: - 18.5 Mtr. W X 110 Mtr. Long
2 Nos. 30 MT EOT with 5 MT Auxiliary & 12.5 Mtr. Clear Hook Height
(D) Size of shed No- 4: -18.5 Mtr. W X 110 Mtr. Long
2 No. 20 MT EOT Crane with 12.5 Mtr. Clear Hook Height
(E) Size of shed No- 5: - 15 Mtr. W X 110 Mtr. Long.
(Dedicated for SS work)
2 Nos. 16 MT - HYDRA mobile crane
Blasting Booth 1 No. 8 Mtr W X 8 Mtr. HT X 15 Mtr Lg. - with dust collecting system
1 No. 6.5 Mtr W X 8 Mtr HT X 15 Mtr Lg. - with dust collecting system
Painting Booth 1 No. 8 Mtr. W X 8 Mtr. HT X 15 Mtr Lg. - with Backing system
1 No. 6.5 Mtr W X 8 Mtr HT X 15 Mtr Lg. - with dust collecting system
Furnace Size for Normalizing: - 6 Mtr X 6 Mtr X 3.5 Mtr Lg.

Inter connection 100 MT & 50 MT Internal Rail to connect all four Nos. shed

Bad Plate 4 Mtr. Width X 10 Mtr. Long

Power Back up 200 KVA Kirloskar make DG Set

Water Resources 2" Θ Water Pipeline from irrigation dept, Optional 6" Θ Tube well 600 Ft
Deep.
1,00,000 Ltr. Water Reservoir
Now discussing about the Machinery, the company have
Bending/Rolling Machine 02 Nos. 1.7 M W X 10 mm thk.
02 Nos. 2.5 M W X 20 mm thk.
01 No 3.0 M W X 50 mm thk.

Hydraulic Press 01 No (4800 mm width X 50 mm thick plate

Bending Capacity)

S.A.W Welding Machine (With auto roller of 02 Nos. (6000 mm Vertical & 6000 mm
30 MT Cap.) horizontal)

Plasma Cutting TIG Welding Unit Cutting 03 Nos.

Cap. Up to 50 mm thk Plate.

Welding Machine 25 Nos. Welding Rectifiers 600 A

05 Nos. Welding Air Cooler 600 A
02 Nos. Welding Oil Cooler 600 A

Radial Drill Machine 1 No (Up to 50 mm Dia 03 Nos. (Up to 80 mm Dia Drilling)

Drilling )

Automatic Drill Machine 02 No. (Up to 30 mm dia drill 50 mm thick))

Profile Cutting Machine 03 Nos

Pug Cutting Machine 10 Nos.

Hand Cutting Set 20 Nos.

Grinding Machine 25 Nos.

Lathes (8',10',16') 05 Nos.

Loading / Unloading Facilities 20 M.T Cap. Electric Hoist.

03 Nos.- 14 T cap. Hydra Mobile crane
01 No. Goliath crane 50/5 T, Ht. under crane
hook 10M

Equip. Moving Facility for Welding Rotators 30 M.T. Each - 5 sets

Size of Shed 35 M W X 82 M L X 7.5 M Ht.

Now discussing about the Inspection equipment’s, the company have
Ultrasonic Thickness tester up to 300 mm thick

Vernier calipers. up to 610 mm thick

Micrometer. up to 150 mm thick

Dial Vernier calipers up to 300 mm thick

Dial gauge up to 10 mm 0 to 1 mm micron

Hardness tester B.H. & V.H.

Air compressor pneumatic testing to 100 kg. /cm2g 6 kg. /cm2g

Dye penetration test kit. 1 No.

Go–no–go gauges for heat exchanger holes – ¾ “– 1“ 1 No.

Thickness gauge. 1 No.

Now discussing the machines in details

1) LATHE MACHINE
2) DRILLING MACHINE
3) CNC GAS CUTTING MACHINE
4) PUG MACHINE
5) ROLLING MACHINE
6) WELDING MACHINE (ARC)
7) EOT (ELECTRIC OVERHEAD TRAVELER)
8) SHIELDED ARC WELDING
9) PORTABLE SHAPE CUTTING MACHINE.
10) HYDRALIC PRESS
Now looking at the inspection instruments and methods of doing inspection.

• NDT
• Radiography
• Thickness measurement gauge.
 The company is divided into two sections
• Rubber lining division
• Fabrication section
As shown in the plant overview.
Now looking at each section in details
1) RUBBER LINING DIVISION
The rubber lining division consist of three machines which are as follows
1) Rubber making machine
2) Mixing machine
3) Calendar machine
1)Rubber making machine
In this machine the chemicals from the chemical store is being taken as mixed according to the client
requirements
The ingredients which are added to make the machine are as follows (100 kg batch each)
1) Natural rubber
2) Reclaim sheet rubber
3) SBR
4) Loosing powder
5) China clay
6) Sulphur powder (as per the hardness required)
7) Chloroprene rubber (eddy rubber)
8) Accelerator TMTD and many more.
Are dump into the machine and the machine has two rotors which rotates and mix this all mixture and
make a lump out it, and further pass to the mixing machine.
2) Mixing machine
In this the machine has two rotors in which water (room temp) is passed while mixing the rubber to
keep it cool. Here the rubber is also turn into small thickness greater than the client requirements.
3) Calendar machine
Here the thin rolled sheet is being further rolled to make it thinner as per the requirements, steam is
passed into the rollers to make the roller hot and not allow the rubber to stick onto it.
 LEARNING OUTCOME

1. It was honor for get internship in ISHAN EQUIPMENT’S PVT. LTD.

2. From this company I understood the sequence/procedure of how a component like pressure

vessels and storage tanks are made.

3. The use of different chambers like blasting, vulcanizing, painting etc.

4. I got to learn about the process of making rubber sheets

5. Different types of welding process, gas cutting by different equipment, Inspection procedures.

6. CNC gas cutting was a new technology that have been seen by me.

7. Store managements, how to understand the design given by the clients to the company.
 Bay- 5 Bay- 4 Bay- 3 Bay-2 Bay-1 SCRAPE
AREA

SHADES OF THE PLANT

MAIN
OFFICE

QUENCH

MAIN STORE

SECURITY
OFFICE

TEMPLE

SCRAP AREA

PARKING
AREA

TAPAN M PATEL
 RESTING PLACE RESTING PLACE

1
1 2

DRILLING
SECTION 2
3
LATHE MACHINES
3
4

ROOM NO 12
TROLLEY PATH

ROOM NO 11

ROOM NO 10
EOT - 3 (30MT CAPACITY)

SAW
ROOM NO 9
WELDING
COLUMN
WORKING AREA
ROOM NO 8

REST ROOM

EOT - 2 (30MT CAPACITY)

ROOM NO 7
WALKING PATH
ROLLER PATH

ROOM NO 6

WORKING AREA ROOM NO 5

ROOM NO 4

REST ROOM

EOT - 1 (10 MT CAPACITY)

ROOM NO 3

ROOM NO 2
PRODUCTION - 1
(ROOM NO 13) ROOM NO 1

BAY -1
TAPAN M PATEL
 SIMPLE PLATE ROLLING MACHINE
(SEMI AUTOMATIC)

CNC GAS CUTTING

MACHINE

TROLLEY PATH

PLATE ROLLING MACHINE

( AUTOMATIC)

EOT - 5 (20 MT CAPACITY)

WORKING AREA HYDRALIC PRESS (1000 T)

PRE - PUNCHING MACHINE

HYDRALIC PRESS
(1200 T)
ROLLER PATH

PLATE ROLLING MACHINE

WORKING AREA
( AUTOMATIC)( SPARE)

EOT - 4 (60 MT CAPACITY)

BAY - 2
TAPAN M PATEL
STEAM FROM BOILER

VULCANIZING
VULCANIZING CHAMBERS - 1
CHAMBERS - 2
SECTION

TROLLEY PATH

EOT - 7 (20MT CAPACITY)

50 T CAPACITY

ROLLER
SUPPORT -5
SUPPORT -1
ROLLER

WORKING AREA

EOT - 6 (20MT CAPACITY)

ROLLER
SUPPORT -4

SAW
WELDING
ROLLER PATH

COLUMN

WORKING AREA
ROLLER
SUPPORT -3
SUPPORT -2
ROLLER

SAW
WELDING
MACHINE

PRODUCTION - 2
(ROOM NO 14)

BAY -3
TAPAN M PATEL
 BOILER SECTION

TROLLEY PATH FOR PAINTING CHAMBER

TROLLEY PATH FOR BLASTING CHAMBER 2

TROLLEY PATH FOR BLASTING CHAMBER 1

EOT - 9 (20MT CAPACITY)

50 T CAPACITY

ROLLER
SUPPORT -5
SUPPORT -1
ROLLER

STORAGE AREA

EOT - 8 (20MT CAPACITY)

ROLLER
SUPPORT -4
SUPPORT -2
ROLLER

ROLLER
SUPPORT -3

ENTRY FOR BAY 5

WORKING AREA

PRODUCTION - 5 PRODUCTION - 3 & 4

(ROOM NO 17) (ROOM NO 15 -16)

BAY - 4
TAPAN M PATEL
 PAINTING SECTION

BLASTING CHAMBER 2

BLASTING CHAMBER 1

CHEMICAL STORAGE ROOM

RUBBER MAKING MACHINE

(2 ROLLERS)
COMPRESSOR
OIL DRUM

MIXING MACHINE
(2 ROLLERS)
22''Ø X 60'' L

GRINDING CALENDAR MACHINE

MACHINE (3 ROLLERS)
22''Ø X 60'' L

RUBBER LINING
DIVISION TESTING MACHINE

EOT - 10 (20MT CAPACITY)

STORAGE AREA

BAY - 5
TAPAN M PATEL
 Lathe Machine
What is Lathe Machine?
A lathe is a machine tool which is used to rotate a work piece to perform various operations such as
turning, facing, knurling, grooving etc., with the help of tools that are applied to the work piece.

Working Principle of Lathe Machine

The function of lathe is to remove metal from a piece of work to give it a desired shape and size. In a
lathe machine, the work piece is rotate against the tool. The tool is used to remove material from the
work piece. The direction of motion of tool is called feed.

Main Parts of Lathe Machine

The various main parts of lathe machine are
1. Headstock
It is present at the left-hand side of the lathe. It holds the gear train, main spindle, chuck, gear
speed control levers and feed controllers. It is aligned with the tailstock. The head stock is
made up of cast iron.

Chuck
It is that part of lathe machine which is used to hold the work piece. It is attached to the main
spindle of the headstock. It rotates with the spindle and also rotates the work piece. In the
lathe machine we generally use three jaw or four jaw check. The three jaw of the three-jaw
chuck is made to move simultaneously but the jaws of the four-jaw chuck moves
independently.

Main Spindle

This part of the lathe machine is used to hold cylindrical work piece within it. It is a hollow shaft
on which the chuck is mounted.

Feed Selector
It is used to select the direction of the feed i.e. whether we want to move the tool from left to
right or right to left. Feed selector is present on the headstock.

2. Tailstock
It is present at right hand side of the lathe. It is used to provide supports to the work piece. It
supports the work piece from one end i.e. right end.

3. Bed
It is the main part of the lathe. All the parts of the lathe is bolted on the bed. It comprises of
headstock, tailstock, carriage guide ways and other parts. It is made of cast iron.

4. Carriage
The carriage is present in between the headstock and tailstock. It carries apron, saddle,
compound rest, cross slide and tool post.
Tool Post: It is used to hold the tool. It has T-slot for holding the tool. Tool post is bolted on
the carriage.
Compound Rest: It is used to set the tool at desired angle for taper turning and other
operations.
Cross Slide: The cross slide is used to move the tool perpendicular to the axis of the lathe.
Saddle: The top portion of the carriage is called saddle. Cross slide is mounted on the saddle.
Apron: The front portion of the carriage is called apron. It contains all the moving and control
mechanism of the carriage.

5. Lead Screw
Lead screw is used to move the carriage automatically during threading.

6. Feed Rod
It is used to move the carriage from left to right and vice versa.

7. Chip Pan
Chip pan is used to collect the chips that are produced during the lathe operation. It is present
at the bottom of the lathe.

8. Hand Wheel

It is the wheel which is operated by hand to move cross slide, carriage, tailstock and other
parts which has hand wheel.
 Operations on lathe
1) Facing: -
Facing is used to make a flat surface at the end of the

work piece. The work part should be rotating and the

implied feed should be radial

So, the Feed for facing operation in lathe machine:

Radial feed.

2) Turning:-
The turning process requires a turning machine or lathe,

workpiece, fixture, and cutting tool. The workpiece is a piece

of pre-shaped material that is secured to the fixture, which

itself is attached to the turning machine,

and allowed to rotate at high speeds.

3) Taper Turning: -
Like contour turning the tool is not fed parallel to the axis of

rotation of the work part. The tool is fed at an angle.

This turning operation gives a conical and taper cylindrical

shape. Feed: radial (in an angle)

4) Grooving: -
The process of creating a narrow slot on the work piece is called

grooving. It is also known as recessing or necking

5) Knurling: -
It is a metal forming method which creates a regular

cross hatched pattern. It is not a machining process.

It does not involve any cutting of the metal

 DRILLING MACHINE
Introduction: The drilling machine or drill press is one of the most common and useful machines
employed in industry for producing forming and finishing holes in a workpiece. The unit essentially
consists of:
1. A spindle which turns the tool (called drill) which can be advanced in the workpiece either
automatically or by hand.
2. A work table which holds the workpiece rigidly in position.
Working principle: The rotating edge of the drill exerts a large force on the workpiece and the
hole is generated. The removal of metal in a drilling operation is by shearing and extrusion.
Radial Drilling Machine:
Drilling Machine is to make circular holes on the components with the help of Drill bits. But, the
purpose of the Radial Drilling Machine is used to drill the holes in the given radial distance and this
will be used, when the component size is large in terms of height.
When the component is large, it cannot fit its structure in the Machine vice. Therefore, the
component has to be placed on the ground and the Radial arm of the drilling machine has to be
rotated w.r.t the component to do the operation.
The Angle of a Drill bit is 118 Degrees.
Working Principle of Radial Drilling Machine:
When the power supply is given, the spindle rotates which was in conjunction with the motor. The
Radial arm is adjusted w.r.t the type of operation and height of the workpiece. The spindle is
connected to the chuck and the drill bit is placed in between the jaws of the chuck. The Drill head
is adjusted on to the workpiece and a suitable feed is given. Then the drill bit drives into the
workpiece very easily.
Drive Mechanism: Rack and Pinion Mechanism
When the hand wheel is rotated, then the Pinion which is attached to the rack also rotates which
can convert the rotary motion to the linear motion and the driving mechanism is called as Rack
and Pinion mechanism.
Construction of Radial Drilling Machine:
Base: It is made up of Cast Iron which possesses high compressive strength and good wear
resistance. The base is used to support the assembly of parts on it and also absorbs the vibrations
induced by the machine parts.
Column: It is exactly placed at one end of a bed which can act as a support for rotating the radial
arm in 360 degrees.
Radial Arm: It is the arm which is connected to Column. The Drill head slides from one end to
another end by the guideways.
Motor: It is placed on the drill head for driving the work unit (Spindle of the Drill bit)
Table: The machine vice is connected to a swivel table which can hold the workpiece for further
operation.
Flywheel or Hand wheel: It is connected to the spindle arrangement which is used to move up
and down wrt. the workpiece.
Drive Head: It generally consists of two levers which by varying can increase or decrease the
speed of chuck.
Chuck: One end of the chuck is connected to the spindle arrangement and another end is
connected to the drill bit(tool).
Tool-Drill bit: The drill bit is used to drill the holes on the specimens.
Workpiece: It has to be fixed in the machine vice provided on the table.
 CNC PROFILE GAS CUTTING MACHINE
A CNC profile cutter is a metal plate cutting machine that utilizes plasma and or oxy-
fuel cutting technology to cut through metal
In thus company mostly oxy-fuel cutting system is used (oxygen and LPG).
Oxy-Fuel Cutting
Oxy-fuel flame cutting is the most economical process for the cutting of mild and low
alloy steel, even with weld preparations. It is one of the most important production
processes in the metal industry.

THE PROCESS OF OXYFUEL PLATE CUTTING

Oxyfuel or flame cutting is a combustion process using oxygen/fuel gas flame. The
heating flame brings the material up to its ignition temperature. Then a jet of oxygen
at least 99.5% pure is blown onto the heated spot. The oxygen jet oxidizes the metal
then the torch is moved and a narrow cutting kerf is created, removing the slag from
the kerf. The quality of the cut depends on the surface condition of the material, cut-
velocity, and thickness.

Oxyfuel cutting ensures reliable hole-piercing, high cut quality which the production
of components to their finished sizes without the need for further processing. For
weld seam preparations V, Y, and K cuts can be produced.

According to the thickness of the plate the nozzle is decided.

The below given table give the range of the nozzles with its pressure range.
Sr no Nozzles range(mm) Pressure range(bar)
1 3-10 1-5
2 7-15 5-7
3 15-25 6-7
4 25-40 6-7.5
5 40-60 5.5-7.5
6 100-200 7.7-9.5

ADVANTAGES OF GAS CUTTING

Good cut quality
Smooth, vertical planes of cut
Metallurgical perfect surfaces (oxidized)
Carbonizing and hardening within the area of the heat affected zone
High heat input
Wide range of material
Low cutting speed
 PUG MACHINE
1. The machine is also designed to enhance its
commercial value by keeping low cost manufacturing,
simplified operations, compact, least maintenance and
using standard parts.
2. The machine has been successfully used for Mild
Steel. It has also been used for various profiles such
as circular, elliptical and other complex profiles.
3. This gas cutting equipment can be an aid to the
present small-scale fabricators and steel
4. plate cutting dealers in India.
5. The present work can reduce cost of acquiring two
products
i.e., Pug cutting machine and Profile cutting
machine.
6. The trend of having two products was found in most of small-scale industries and shops in
India.
7. The present work can replace these two products with a single product providing functionality
of both the products.
8. Thus, this product will prove to be a boon to the present fabricators as well as
9. promote the growth of those new to the fabrication industry.

The machine has the following features:

(1) Portability
(2) Maintainability
(3) Usability
(4) Easy to assemble
(5) Can be used for complex profile.
(6) Light weight
(7) Can be used for large plate.
(8) Flexible height adjustment of radial arm and torch
(9) 360-degree movement of radial arm.
 PLATE ROLLING MACHINE
INTRODUCTION
A plate rolling machine is a machine that will roll different kinds of metal sheet into a round or
conical shape. It can be also called a “roll bending machine”, “plate bending machine” or “rolling
machine”.
There are different kinds of technology to roll the metal plate:
1. Four-roller machines have a top roll, the pinching roll, and two side rolls.
The flat metal plate is placed in the machine on either side and "pre-bent" on the same
side. The side rolls do the work of bending. The pinching roll holds the plate.
2. Three-roller machines have one pressing top roll and two pressing side rolls.

In this company we have looked upon three roller machines Roll bending machine.
1. The three-roll variable pitch works by having all three rolls able to move and tilt.
2. The top roll moves in the vertical plane and the side rolls move on the horizontal plane.
3. When rolling, the top roll presses the metal plate between the two side rolls. The advantage
of having the variable three roll is the ability to roll many thicknesses and diameters of
cylinders.
For example; The side-rolls are what produce the mechanical advantage. With the side rolls all the
way open, one has the maximum mechanical advantage. With the side rolls all the way in, you
have the least mechanical advantage. So, a machine has a capability of rolling 2-inch-thick
material with the maximum mechanical advantage, but a job is only 1/2 inch thick. Reduce the
mechanical advantage and one has a machine that can roll from 1/2 to 2 inches thick.
 ARC WELDING

Arc Welding Processes

In arc welding process, an electric arc between an electrode and a workpiece or between
two electrodes is utilized to weld base metals. The basic principle of arc welding is shown in below
Fig. 1. However, the basic elements involved in arc welding process are shown in the below Fig. 2.
Most of these processes use some shielding gas while others use coatings or fluxes to prevent the
weld pool from the surrounding atmosphere.

Arc Welding Equipment

Arc welding equipment, setup, related tools, and accessories are shown in Fig. 2.
 (1) Switch box.
(2) Secondary terminals.
(3) Welding machine.
(4) Current reading scale.
(5) Current regulating hand
wheel.
(6) Leather apron.
(7) Asbestos hand gloves.
(8) Protective glasses strap.
(9) Electrode holder.
(10) Hand shield.
(11) Channel for cable
protection.
(12) Welding cable.
(13) Chipping hammer.
(14) Wire brush.
(15) Earth clamp.
(16) Welding table (metallic).
(17) Job
.

1. Arc welding power source

Both direct current (DC) and alternating current (AC) are used for electric arc welding process, each
having its particular applications. DC welding supply is usually obtained from generators driven by
electric motor or if no electricity is available by internal combustion engines. For AC welding supply,
transformers are predominantly used for almost all arc welding where mains electricity supply is
available. They have to step down the usual supply voltage (200-400 volts) to the normally open
circuit welding voltage (50-90 volts). The following factors influence the selection of a power source:
1. Type of electrodes to be used and metals to be welded
2. Available power source (AC or DC)
3. Required output
4. Duty cycle
5. Initial costs and running costs
6. Efficiency
7. Available floor space area and
8. Versatility of equipment
2. Welding cables
Welding cables are required for conduction of current from the power source through the electrode
holder, the arc, the workpiece and back to the welding power source. These are insulated copper
or aluminum cables.
3. Electrode holder
Electrode holder is used for holding the electrode manually and conducting current to it. These are
usually matched to the size of the lead, which in turn matched to the amperage output of the arc
welder. Electrode holders are available in sizes that range from 150 to 500 Amps.
4. Welding Electrodes
An electrode is a piece of wire or a rod of a metal or alloy, with or without coatings. An arc is set up
between electrode and workpiece. Welding electrodes are classified into the following types
1. Consumable Electrodes
i. Bare Electrodes
ii. Coated Electrodes
2. Non-consumable Electrodes
i. Carbon or Graphite Electrodes
ii. Tungsten Electrodes
Consumable electrodes are made up of different metals and their alloys. The end of this electrode
starts melting when the arc is struck between the electrode and workpiece. Thus, consumable
electrode itself acts as a filler metal. Bare electrodes consist of a metal or alloy wire without any flux
coating on them. Coated electrodes have flux coating which starts melting as soon as an electric
arc is struck. This coating on melting performs many functions like prevention of joint from
atmospheric contamination, arc stabilizers etc.
Non-consumable electrodes are made up of high melting point materials like carbon, pure
tungsten or alloy tungsten etc. These electrodes do not melt away during welding. But practically,
the electrode length goes on decreasing with the passage of time, because of oxidation and
vaporization of the electrode material during welding. The materials of non-consumable electrodes
are usually copper coated carbon or graphite, pure tungsten, thoriated or zirconiated tungsten.
5. Chipping hammer
Chipping Hammer (shown in Fig. 3.6) is used to remove the slag by striking.
6. Wire brush
Wire brush (shown in Fig. 3.7) is used to clean the surface to be weld.
7. Hand Screen
Hand screen is used for protection of eyes and supervision of weld bead.
8. Protective clothing
The operator wears the protective clothing such as apron to protect the body from the exposure of
direct heat to the body.
 EOT (ELECTRIC OVERHEAD TRAVELLER)
❖ Electric Overhead Traveling (EOT) Cranes, one of the most commonly used type of
overhead cranes, are very useful in critical industrial applications.
❖ These have parallel runways, where the gap is spanned by a traveling bridge on which the
hoist is mounted. As the name suggests, these cranes are operated electrically either
through a control pendant or an operator cabin that is attached to the EOT Crane.
❖ EOT cranes are equipped with the capacity to lower or raise heavy loads in addition to
travelling in both directions.
❖ There are two major types of EOT cranes that are generally supplied by EOT crane
manufacturers in India, which are: Single Girder EOT Crane and Double Girder EOT Crane.
Single Girder EOT Cranes

1. Single Girder Cranes have one main bridge and are comparatively much lighter in structure.
2. This makes it a very good option for light industrial applications.
3. The main components of the single girder cranes, manufactured by EOT Crane companies,
include an electrically managed hoist, a main bridge, and end beams.
Double Girder EOT Cranes
1. Comparatively, double girder cranes are much more cost effective and are used for
operations that require a higher load-carrying capacity.
2. These cranes have two main bridges which makes them much sturdier and more robust in
structure.
3. Designed to assist in heavy duty operations, these EOT cranes are built with better
aesthetics and utility than single girder cranes.
4. Considering the importance of this particular asset, one must always buy these cranes from
trusted EOT crane suppliers only.
5. Make sure that while buying an overhead crane you ask for specific quality assurances
offered by the manufacturer.
Application of EOT Cranes in the Material Handling Equipment (MHE) Industry
• EOT cranes are some of the most commonly used type of cranes in industries that have
heavy duty operational requirements.
• These cranes are used to lift or lower loads as well as to move heavy materials during daily
operations.
• The increase in demand for material handling equipment has made it more important for
EOT crane suppliers in India to focus on providing different customizable and configurable
options.
 Submerged Arc Welding or SAW

Submerged Arc Welding or SAW is one of the most occurring arc welding process. It needs a
electrode which may be solid of tubular. The electrode should be used in a continuous approach. It
should be fed continuously. Tubular electrode is the one which is flux shielded.

The main feature of this welding is that –

• The weld and the arc area is protected from environmental contamination by the application
of a granular flux which is fusible.
• The weld pool is protected by a blanket of flux.
• So that area is actually submerged under that flux.
• When temperature rises and molten the flux becomes conductive.
• And thus, this creates a path for electron flow between electrode and workpiece.
• SAW or Submerged Arc welding can be done by manual procedure or automatic process.
• But it can be done by semi-automatic process where welding gun is hold by hand. Here
pressurized gravity flux feed is given.

Both DC and AC can be used as power supply. In multiple electrode system DC – AC combination
is very common. Constant voltage power supply machines are used very frequently.

ADVANTAGES
o This welding process has high deposit rate. Almost 45kg/h can be deposited.
o In mechanized applications.
o Very little welding fume is seen. .
o No edge preparation is needed.
o This process is applicable indoor as well as outdoor.
o No chance of weld spatter as it is submerged in flux blanket.
 HYDRAULIC PRESS
Hydraulic press is a mechanical device which
is based on the ‘Pascal’s law’ which states that
equal intensity of pressure exerts on all the
directions in a closed system. It applicable here
in such a way that if there is any pressure
change at one point in a closed system then
same intensity of pressure will change at other
point in the same system.

Construction and working of Hydraulic Press:

1. In practical hydraulic press system, generally multiple rams are assembled together.
2. The number of rams used depends upon the working load. In hydraulic press multiple rams
of small sizes are preferred instead of a single large size ram to control the thrust forces
because it is easy to control the thrust forces on small size as compare to large size.
3. In press assembly one side/table is always fixed while the other is moving by the application
of ram force and in between fixed as free side pressing operation is take place.
4. Ram is operated by the hydraulic pressure of fluid.
5. The high-pressure liquid is supplied by using pump and hydraulic accumulator.
6. Hydraulic accumulator works as the junction between the pump and the rams. Hydraulic
accumulator stores the high-pressure liquid when press is at stationary position.
7. Hydraulic press is used where high thrust is required for operation.

Applications:
1. The major application of the hydraulic press is in industry where big size metal objects
transform into thin sheets by the application of pressure force.
2. Sheet metal operations such as drawing, deep drawing, punching and blanking etc
3. In crushing of scraps and old vehicles.
4. In Packaging industry.
 PORTABLE SHAPE CUTTING MACHINE
• The machine is designed with pantograph
type arms, which keeps the hinge points of
all the arms parallel to the line of the tracing
roller and the torch, thus providing a direct
line guiding system.
• The precession ball and needle bearing
design of the hinges ensure free and
frictionless tracing, hence enabling greater
cutting accuracy.
• This machine is primarily meant for cutting
different shapes such as stars, hexagons,
squares, rectangles, circles, triangles etc. it
can also cut straight lines.it can cut up to
max 150 mm thickness
• The basic system of the machine enables the torch to duplicate any intricate shape
provided on a template on the machine.
• The carriage arm consisting of a motor of a motor driven by electromagnetic tracing head
and a cutting torch travels round the template duplicating the exact shape of the template.
• The speed of the machine can be varied with an indexed selector knob.
• The tracing head can be moved in clockwise or anti-clockwise direction by a selector
switch.
• The uses of the portable shape cutting
machine are almost unlimited because of the
accuracy with which meatal templates ca be
made easily.
ADVANTAGES
1. Light weight and portable.
2. Large shapes cutting capacity.
3. Cut up to 150 mm thickness.
4. Accurate and easy to operate.
5. Precise control and proven performance.
 NDT (NON-DESTRUCTIVE TESTING)
DYE PENETRATION TEST
Introduction
Dye penetrant inspection (DP), also called liquid penetrate inspection (LPI) or penetrant testing
(PT), is a widely applied and low-cost inspection method used to check surface-breaking defects
in all non-porous materials (metals, plastics, or ceramics).
The penetrant may be applied to all non-ferrous materials and ferrous materials, although for
ferrous components magnetic-particle inspection is often used instead for its subsurface detection
capability.
LPI is used to detect casting, forging and welding surface defects such as hairline cracks, surface
porosity, leaks in new products, and fatigue cracks on in-service components.

Principal and Procedure of performing DPT

DPI is based upon capillary action, where low surface tension fluid penetrates into clean and dry
surface-breaking discontinuities.
Inspection steps
• Pre-cleaning:
• Application of Penetrant:
• Excess Penetrant Removal:
• Application of Developer:
• Inspection:
• Post Cleaning:

1. Penetrant may be applied to the test component by dipping, spraying, or brushing.

2. After adequate penetration time has been allowed, the excess penetrant is removed and a
developer is applied.
3. The developer helps to draw penetrant out of the flaw so that an invisible indication
becomes visible to the inspector.
4. Inspection is performed under ultraviolet or white light, depending on the type of dye used -
fluorescent or nonfluorescent (visible)
 PRINCIPLE OF RADIOGRAPHIC TESTING
Radiographic Testing (RT), or industrial radiography,
is a nondestructive testing (NDT) method of
inspecting materials for hidden flaws by using the
ability of short wavelength electromagnetic radiation
(high energy photons) to penetrate various
materials.

The part to be tested is placed between the radiation

source and a piece of film. The part will stop some of
the radiation. Thicker and more dense area will allow less radiation to pass through. The property
of the film will vary with the amount of radiation reaching the film through the test object. These
differences in “absorption” can be recorded on film, or electronically.
The energy of the radiation affects its penetrating power. Higher energy radiation can penetrate
thicker and denser materials. The radiation energy and/or exposure time must be controlled to
properly image the region of interest.
 ULTRASONIC THICKNESS METER.
In the field of industrial ultrasonic testing, ultrasonic
thickness measurement (UTM) is a method of
performing non-destructive measurement (gauging) of
the local thickness of a solid element (typically made of
metal, if using ultrasound testing for industrial
purposes) basing on the time taken by the ultrasound
wave to return to the surface. This type of
measurement is typically performed with an ultrasonic
thickness gauge.
Ultrasonic waves have been observed to travel through
metals at a constant speed characteristic to a given
alloy with minor variations due to other factors like
temperature.
ULTRASONIC THICKNESS GAUGE
An ultrasonic thickness gauge is a measuring instrument for the non-destructive investigation of a
material's thickness using ultrasonic waves.
The usage of an ultrasonic thickness gauge for non-destructive testing to check material
properties such as thickness measurement, is now regularly utilized in all areas of industrial
measurements. The ability to gauge thickness measurement without requiring access to both
sides of the test piece, offers this technology a multitude of possible applications, especially in
pipes. Paint thickness gauge, ultrasonic coating thickness gauge, digital thickness gauges and
many more options are available to test plastics, glass, ceramics, metal and other materials. Along
with coating thickness its widely being used for wall thickness for Glass, Wood, plastics and also
serves as major testing equipment in corrosion industry.
A rugged ultrasonic thickness gauge determines sample thickness by measuring the amount of
time it takes for sound to traverse from the transducer through the material to the back end of a
part and back. The ultrasonic thickness gauge then calculates the data based on the speed of the
sound through the tested sample.
Advantages
• Non-destructive technique
• Does not require access to both sides of the sample
• Can be engineered to cope with coatings, linings, etc.
• Good accuracy (0.1 mm and less) can be achieved using standard timing techniques
• Can be easily deployed, does not require laboratory conditions
• Relatively cheap equipment
Disadvantages
• Usually requires calibration for each material
• Requires good contact with the material
• Cannot take measurement over rust
• Requires coupling material between the measured surface and the probe.
• Interpretation needs experience
 2
3
1
5
6
4 COMPONENTS NAME
1 HEAD
HORIZONTAL STORAGE TANKS & PRESSURES VESSELS 2 SHELL
3 MAN HOLES
4 SADDLE SUPPORTS
5 DRAIN VALVE
6 PIPING SUPPORTS
TAPAN M PATEL
 4

COMPONENTS NAMES
1 SHELL
2 HEAD
6 3 MAN HOLES
4 NOZZLES
5 DRAIN VALVE
6 PIPING SUPPORTS
7 A (SADDLE) & B (LEGS)
{SUPPORTS}

B A

VERTICAL PRESSURE VESSEL

TAPAN M PATEL
 PUG
MACHINE

PREPARE SHEET FOR ROLLING BY SHEET ROLLING BY

CUTTING DOWN INTO REQUIRED THEN THE REQUIRED LENGTH OF
ROLLING MACHINE TANK OF BOUGHT BY JOINING
DIMENSIONS
EACH OTHER BY SAW WELDING

THEN AFTER THE HEAD OF REQUIRED SHELL IS BEING

INSPECTED BY
NDT TESTING ,AFTER THAT 1 HEAD IS WELDED ONTO THE
SUPPORT (LEGS OR SADDLE)

THEN INSPECTION IS
DONE
1) HYDRO-TEST
2) RADIOGRAPHY
ETC

B A

THEN THE VESSEL IS SEND TO

THE BLASTING CHAMBER AFTER THAT HOW VESSEL IS BEING MADE AND
FOR REMOVAL OF THE RUST ON IT ACCESSORIES ALSO BEING MOUNTED ON IT
(SAND BLASTING)
VERTICAL PRESSURE VESSEL
ACCORDING TO THE CLIENT
REQUIREMENTS IF IT IS SAID TO DO
RUBBER LINING THEN IT IS THEN SEND
FOR RUBBER LINING

AFTER THAT FINALLY TO THE VULCANIZING

CHAMBER FOR LETTING THE RUBBER STICK TO
THE SURFACE OF THE VESSELS

THEN FINALLY TO THE THEN DISPATCHED TO THE

PAINTING CHAMBER CLIENTS

PROCEDURE FOR MAKING VERTICAL PRESSURE VESSELS

TAPAN M PATEL
 PUG
MACHINE

PREPARE SHEET FOR ROLLING BY SHEET ROLLING BY

CUTTING DOWN INTO REQUIRED THEN THE REQUIRED LENGTH OF
ROLLING MACHINE TANK OF BOUGHT BY JOINING
DIMENSIONS
EACH OTHER BY SAW WELDING

THEN AFTER THE HEAD OF REQUIRED SHELL IS BEING

INSPECTED BY
NDT TESTING ,AFTER THAT 1 HEAD IS WELDED ONTO THE
SUPPORT

THEN INSPECTION IS
DONE
1) HYDRO-TEST
2) RADIOGRAPHY
ETC

THEN THE VESSEL IS SEND TO

THE BLASTING CHAMBER AFTER THAT HOW VESSEL IS BEING MADE AND
FOR REMOVAL OF THE RUST ON IT ACCESSORIES ALSO BEING MOUNTED ON IT
(SAND BLASTING)

ACCORDING TO THE CLIENT

REQUIREMENTS IF IT IS SAID TO DO
RUBBER LINING THEN IT IS THEN SEND
FOR RUBBER LINING

AFTER THAT FINALLY TO THE VULCANIZING

CHAMBER FOR LETTING THE RUBBER STICK TO
THE SURFACE OF THE VESSELS

THEN FINALLY TO THE THEN DISPATCHED TO THE

PAINTING CHAMBER CLIENTS

PROCEDURE FOR MAKING STORAGE TANKS AND HORIZONTAL PRESSURE VESSELS

TAPAN M PATEL