original project 8th sem

7/25/2019 ORIGINAL Project 8th Sem

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LARSEN AND TOUBRO LIMITED

S.B.M.P., MUMBAI ENROLLMENT NO. 0705068


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SUBMISSION CERTIFICATE

I, DAVE HIRENDRA B.Roll No.Y720059,a student of fifth semester ofDiploma

course inMechanical Engineering, hereby submit my report.

The In-plant Training work as described in this report is completed by me with

own skills andstudyfrom1st Dece!er 2010 to "0th

Ma# 2011 as per guidance of

Mr. An$%sh &a'ha(..

I certify that I have not copied the report or its any appreciable part from any

other literature in contravention of academic year.

R)** N) + Y720059

Date !!!!!!!!!!!! ignat%re+ !!!!!!!!!!!!



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NO OBJECTION CERTIFICATE

This to certify that Mr.DAVE HIRENDRA BH-A/RAI student of HRI

BHA-BHAI MAA/*A* )*Y/EHNI,VI*E AR*E has completed his In-plant

training from 0131232010T" "030532011in our #uality $ontrol Department at M/s.

Larsen & Toubro Ltd . Powai Campus.

%e has been allowed to include the documents, data and sketches for which we

have no ob&ection.



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ANKUSH R A!HA" M.S.RAU

' (sst. )anager,#$ *+ ' /r. D0), #$-*+

A4N)*EDEMEN/

The success of my training at 1(R/N 2 T"34R" 1TD., +"5(I1(R/N 2 T"34R" 1TD., +"5(I

$()+3/$()+3/ is not only due to my work alone, but also due to interest, help 2 guidance

offered to me by employees of the company.

I would like to e6press my deepest sense of gratitude to Mr. M..Ra6%Mr. M..Ra6%

r.DM 8r.DM 8 8E:;8E:;,, Mr.An$%sh &a'ha(Mr.An$%sh &a'ha( 2 Mr. an$a6Mr. an$a6ach'e(aach'e(a for their valuable

guidance, their helping hand 2 fruitful advice during my pro&ects, which gave me

immense confidence and widened my knowledge.

I can7t forget, Mr A!hishe$ ara(a'e$ar , Mr 4iran agar, Mr AAR

B)ADfor guiding and encouraging me throughout my work. 1ast but not the least8 I

would like to appreciate the kindness 2 co-operation e6tended by all the employees 2

the trainees in the department that helped in making my training a grand success.



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(bove all, I am deeply grateful to R.R.A!a'e 'Training /upervisor of

.B.M.)*Y/EHNI.B.M.)*Y/EHNI for giving me this opportunity to undergo this training

successfully.

This report is an account of my experiences and the knowledge

gained while working atM/s LARSEN AND TOUBRO LTD.,during my in plant

training.

Since, I was placed inQC-FPEXQC-FPEX,a central department; I was

exposed to many functional areas such as E Shop inspection, Heavy Shop

inspection, and Documentation etc. I gained experience and knowledge about

the important of the work culture and planning, which is one of the best at the

establishment. I had the privilege of working in theINSPECTION & QUALITY

CONTROLDepartment, HED during my in plant training

This exposure gave me an idea of the various functional aspects

linking an organization together.

During the training I was also involved in preparation of different

documents likeHTR, DCR, OPERATION CARD, NCR, QCP, PROCEDURES,

and PROGRESS REPORT.I also have the experience onBAAN.



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Finally concluding, I would like to thank my colleagues for

allowing me to work in these projects by keeping their full faith in me. I have

tried to put sincere efforts to make my training as fruitful as possible.

INDEX



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CHAPTER 1

INTRODUCTION TO L&T

*arsen < /=%!r= *iite' *


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Two Danish engineers, Henning H=lc$8*arsen and =ren 4ristian /=%!r=

founded 12T, in 19">.4eginning with the import of machinery from urope, 12T rapidly

took on engineering and construction assignments of increasing sophistication. It now

has a ma&or presence in key sectors of the economy.

( strong, customer-focussed approach and the constant :uest for top-class :uality

have enabled the $ompany to attain and sustain leadership in its ma&or lines of

business across seven decades.

5ith factories and offices located around the country, further supplemented by a

comprehensive marketing and distribution network, 12T en&oys an image and e:uity in

virtually every district of India.

The $ompany has an international presence, with a global spread of offices and

&oint ventures with world leaders. 12T7s large technology base and pool of e6perienced

personnel enable it to offer integrated services in world markets.

12T is India7s largest builder of world-class, custom-made engineering e:uipment

with logistics capabilities of supplying it to a tight delivery schedule worldwide. It has

globally-

4enchmarked workshops at =?ai in M%!ai, Ha@iraan'Bar='ain%6arat,

and 4ans!ahal in )rissa.

12T are consistently e6panding the magnitude, scope and range of its operations

to offer value-addition to client and shareholder alike. 5ith its uni:ue strengths ;

technological sophistication, :uality consciousness, top-class manpower ; 12T strides

into the future, confident of con:uering the challenges ahead.

The Beginning -

12T7s record of outstanding achievements coupled with its uropean name lead

many to believe that it is the Indian arm of foreign corporation. The truth is that genesis



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was very much on the Indian soil. It was set up by two Danish engineers )r. %enning

%olck 1arsen 2 )r. /oren ?@ to asses the value of various cement

manufacturing groups on behalf of *.1./mith 2 $o. (fter having completed their task

they stayed in India to open *.1./mith7s local office. During course of their work they

came to know about India and there people 2 decided to build their own business.

They started a partnership concern on = /t. )ay =>?A in 4ombay and started

undertaking the repair &obs on the improved machinery.

In =>BB, the company stepped into the construction business and started the

$onstruction $ompany Cngineering $onstruction $ompany '$$. 1ater the company

became private limited on Th. *ebruary =>BE. In the early @F7s 12T has became public

company limited.

L&T at Present:-

5ithin span of four decades 12T has achieved leadership position in designing,

manufacturing 2 installing plants 2 e:uipment for vital industries.

Today it pro&ects many-sided image of an organi9ation involved in over thirty

distinct fields of engineering. It has gradually e6panded over the years with its branch

offices at )adras, (hmadabad, 1ucknow, 4hopal, $handigarh, Durgapur, Rurkela etc. It

employees about G@FFF personnel. (t present 12T7s turnover ranks third largest

companies in India 'Rs.BG? crores for the year ended =>>>. In =>>B, the I/" >FF=

certificate was awarded to group three of 12T. "ver the years of its e6istence, the

company has established a reputation of having a strong customer orientation,

technological sophistication displayed by its products and pro&ects, and an impression

record of achievements.



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LARSEN & TOUBRO LIMITED

Company :Public limited

Founded :In the year 1938

No. Employees :25,000

Turnover :!! 10 "illion

#$%& 43000 Cr&'

(ar)et Capital :!! 20 (illion

#$%& 250 Cr&'

*o& +, !-are .older% : /ppro& one million

+ver%een "y :"oard o, director%

.ead oce :ndia !/ +man *epal



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(alay%ia

actorie% :26 %pread over 20

location

CHAPTER 2

L&T HEAVY ENGINEERING DIVISION

ig%re1. )(er(ie? = =?ai , ca%s



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INTRODUCTION:-

%eavy ngineering deals with the marketing, designing, engineering and

manufacturing of Cone offH e:uipment and machinery7s re:uired for basic industries

in the core sector, such as *ertili9er, $hemical, +etrol $hemical +ower, $ement,

Nuclear, (erospace, Defense, "il, etc. The unit is headed by a ice +resident and

has manpower of over ?FFF personnel, including =FFF at %a9ira works near /urat.

12TJs %eavy ngineering Division activities are organi9ed under self-reliant

/trategic 4usiness 3nits '/43s catering to the needs of core sector industries

through supply of e:uipment to r=cess lant In'%stries and Deense, N%clear

=?er < Aer=sace ect=rs. The Division operates at the upper end of the

technology spectrum and has been at the forefront of introducing new processes,

products and materials into manufacturing sector, for over si6 decades. %eavy

ngineering Division has the state of the art manufacturing facilities, which are

capable of meeting the challenges of technology, :uality conformance 2 delivery,

while ensuring cost competitiveness.

%D *abrication shops have a built-up area of BE,FFF s:.m 2 e:uipped with

sophisticated facilities for fabrication, machining, handling and :uality control. The

DivisionJs advanced technology and high standard of speciali9ation facilitate the

manufacture of high :uality heavy e:uipment of thick nesses up to G@Fmm in mono-

block construction with individual sections weighing over ?FFt.

eciali@e' a!ricati=n acilities incl%'e+

$N$-controlled gasKplasma profile cutting machine.

dge planningKmilling machine.



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=FF,FFF class dust-free enclosure with an area of BFF s:.m.

=FFFt hydraulic press.

%eavy-duty plate bending rolls of capacity >Fmm thickness in cold and =AFmm

thickness

in hot condition.

Deep hole drilling capabilities of up to >FFmm thickness.

$N$ hori9ontal boring machines with GFFmm spindle dia

$N$ vertical boring machines of up to A@FFmm dia. and EFt load

*acing and turning lathe of EFFFmm dia 2 =FFt weight between centers

5elding machines for a variety of processes '/(5, TI0, )I0, automatic pulseTI0

tube-to-tube sheet welding, strip cladding, *$(5 over-lay, internal bore welding,

etc.

STRATEGIC BUSINESS UNITS -

4usiness activities of %eavy ngineering are overseen by three self reliant

/trategic 4usiness 3nits '/43s. These three /43s are formed on the basis offollowing sub-divisions

(part from marketing teams, /43s comprise of design and engineering teams

who work on state of art software packages developed in-house on account of our

being member of %TRI, 3/( 2 %T*/, 3


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E: *ertili9ers, petroleum 2 %eat Transfer :uipment

4usiness

$oal 0asifier 2 Thermal +ower +lant :uipment 4usiness

R) Refinery, $racker +lant an "il 2 0as :uipment 4usiness

/E Technology Development $enter for +rocess +lant.

R +7s "ffice- /43 $luster C4H

* +7s "ffice- /43 $luster C$H

AER)(erospace 2 (viation

MARI )arine :uipment 2 /ystems

N-* Nuclear 4usiness

A 5eapon /ystem 2 /ensors

ARMY (rmy 4usiness

/E Technology Development $enter for /pecial +ro&ects

IB- International 4usiness $oordination 3nit

PRODUCTS

12T fabricate ultra high pressure - high temperature e:uipment using a wide

variety of materials of thickness ranging from G mm to G@F mm for various

applications. The e:uipment can be manufactured and supplied in monowall or

multiwall construction depending upon design re:uirements. "ur 5orkshops have

been approved by /namprogetti, /tamicarbon, 1loyds, T3, 3%D,


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/he r='%cts an%act%re' c=(ers ?i'e range = aterials incl%'ing+

$arbon and $arbon )anganese steels

3rea 0radeKDuple6K(usteniticK)artensitic 2 *errite /tainless /teels

1ow (lloy creep resistant and %igh Temperature /teels

1ow (lloy /teels 2 %igh (lloy /teels

3ltra high strength $r-)o /teels and )araging /teels

Non-ferrous metals such as Ni, Ti, $u-Ni, Mr, Inconel, )onel, Ta, and %astelloy...

$lad /teels in various configurations 2 materials indicated above

EQUIPMENTS Reactors 2 +ressure essels -

$olumns 2 Towers -

%eat 6changers-

/IT 5"R< 2 (*TR /(1/ /RI$

/ite work

(fter sale service



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CHAPTER 3

INTRODUCTION TO MY (INSPECTION)

DEPARTMENT

INTRODUCTION

#uality control is one of the most important aspects of engineering today.

4ecause of the re:uirement of higher :uality standards 2 fierce competition in the

engineering field, the importance of inspection department has been very much

emphasi9ed. The :uality re:uirements of a particular &ob are mentioned in the

specifications 2 the inspection has to work according to those specifications to maintain

the :uality. *or this, individual member of the department, who is called as inspector,may be re:uired to carry out different tests 2 inspection activities.

*irst of all, all the inspector should be a :ualified :uality control engineer in order

to carry out those tests 2 inspection activities, which also should be as per the customer

and the &ob re:uirements. Inspection is the department, which releases the &ob for



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further work8 thus it is the last department in the se:uence of manufacturing process. /o

the role of inspection department is to find out or point out or detect the flaws in the &ob

at any stage in the manufacturing cycle 2 get it rectified from them. Thus a ma&or chunk

of the :uality standard re:uirements rests on the inspection department.

Depending upon the stages of inspection department is divided into few groups

such as

=?ai central st=res ; insecti=n.

late rearati=n sh= ; insecti=n.

a!ricati=n sh= insecti=n.

POWAI CENTRAL STORES (PCS) INSPECTION

+$/ inspection, also known as Receipt /tores inspection, is responsible for

inspection of incoming raw materials which are in the product from 2 which are being

sub-contracted to the vendors. e.g. forging hardware7s, e6ternal attachments etc

The inspector in this department reviews the test certificate 'T$ of the product 2

confirms that the material supplied by the vendor is as per T$. (fter ensuring this, the

inspector makes )aterial $learance Record ')$R 2 releases the material for further

inspection.

PLATE PREPARATION SHOP (PPS) INSPECTION

++/ inspection is concerned with the inspection of raw material, which is in the

plate form. The company keeps the plates in spare 2 uses it for the &ob as 2 when

re:uired. The inspector in ++/ inspection ensures that the plate being taken in use for a

&ob confirms to the re:uirement of that &ob. "nce this is ensured, the inspector makes

)$R 2 releases the plate for further inspection.



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FABRICATION SHOP INSPECTION

The two ma&or activities of this department are

In-process inspection.

*inal or outgoing inspection.

The inprocess inspection involves inspection of product at various

intermediate stages of manufacturing. Non-destructive testing is also included in

in-process inspection.

The outgoing inspections carried out after the fabrication of &ob is over 2 the

inspection work mainly consists of the overall final dimension check of various

components of the &ob.

FUNCTIONS OF INSPECTION DEPARTMENT

Raw material inspection.

#uality 2 standard of the product.

(s the part In-process inspection.

*inal inspection.

)aintain of management.

Implementation of ideas.

Documentation.

RAW MATERIAL INSPECTION

Inspection department identifies the re:uired raw material8 it should be as per the

re:uired

/i9e

/hape

#uality

#uantity.

IN PROCESS INSPECTION



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Inspection department inspect the product, when it is under production, by

applying various inspection techni:ues 'destructive 2 non destructive. If any

problem is there, it is rectified at the instant of detection. /o, in future it will not

create any cause of concern 2 reduce the work 2 there is time saving.

FINAL INSPECTION

Inspection department inspects the product prier to the time of dispatch.

Inspection department has to inspect

*inal dimension of the product.

(ppearance of the product.

+acking 2 loading of the product etc.

MAINTAIN QUALITY & STANDARD OF THE PRODUCT

There is a very important function of inspection department as far as

:uality of the product is concerned. (s the inspection is done at every stage,

such as

Raw material inspection

In-process inspection

*inal inspection(ll these activities lead to the following production parameters

Reduce the work

/horten the production cycle.

Increase the production rate.

Increase the :uality of product

AS THE PART OF MANAGEMENT

It forms the important link between supervisors and management. Thus the

management is at all time working in coordination with the shopfloor to ensure

ma6imum :uality conformation.

IMPLEMENTATION OF IDEAS



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It plays an important role in issuing Design $hange Re:uirements 'D$R, if

any alteration to be made in the original blue print. If a particular dimension or

part is not according to the drawing or specification 2 if a design change is not

feasible then, it stands out as an non-conformity in the pro&ect&

DOCUMENTATION

This department prepares all the documents related to

Raw material of product.

Tests carried out 2 result obtained.

*inal product.

In sh=rt insecti=n 'eartent has t= er=r the =ll=?ing acti(ities .

+reparing inspection checklist

5itnessing different tests such as %ydro-test 2 other NDT7s.

$o-ordination with #( '#uality (ssurance Dept. *or different gauges to

be used for inspection tests.

$o-ordination with third party or inspection agencies for clearing

inspection stages.

Reporting non-conformities for deviations, if any.

+reparing a list of balance work on &ob.

In-process inspection of set-up, dimensions, seam finish etc.

rearing inal '=c%ent s%ch as+

12T compliance certificate.

Reports of various tests.

+T$, +T2 )T reports.

/eam wise welder7s record.

Obtann! release note "rom thrd party # nspe$ton a!en$es.

INSPECTION REQUIREMENTS

)aterial identification.



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)aterial cutting.

*orming of pressure e:uipment components.

Dimensional tolerances on formed components and pressure e:uipments.

(ssembly of &oints prior to welding.

5elding procedure :ualifications.

5elding consumables.

5elding e:uipment.

$ondition prior to welding.

$ondition during welding.

5eld non-destructive e6amination.

Repair of welds.

+roduction test plates.

%eat treatment.

*inal cleaning, surface treatment.

+rotection for transport.



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S T U D Y P R O J E C T O N A M M O N I A C O N V E R T E R

) E N E R A L

1&1 *T$+CT+*

%ore than 99 & o" the 'orld ntro!en "ertl(er produ$ton s based on the

produ$ton o" ammona. )mmona s bas$ally produ$ed "rom ar, 'ater * ener!y.

+he sour$e o" ener!y s normally "rom $oal or hydro$arbons that are rea$ted 'th

'ater at h!h temperature and ele$tr$ty to dre the $ompressor.

) modern ammona plant has a typ$al $apa$ty o" 1000#2000 t#d per stream.

)bout 85& o" ammona produ$ton s based on steam re"ormn! $on$epts. )

typ$al ammona plant s sho'n n F!ure 1.



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For synthess o" )mmona the $onerter may be o" t'o types:

1. Axi! F!"#

2. R$i! F!"#

In both the pro$esses, the rea$ton s n the bas-et, and the $onerter shell s

the essel "or holdn! the pressure. +he spe$al adanta!e o" the radal $onerter s

to allo' the use o" the $atalyst small part$les 'thout a prohbted pressure drop.

+he aera!e l"etme o" the $atalyst s around 10 years but at h!h temperature the

rea$ton s "ast and hen$e the deteroraton o" $atalyst too. o'er temperature

de$reases $atalyst a$tty * hen$e prode h!h l"etme. )mmona $on$entraton

at the $onerter nlet should be mnmum as t !es h!h rea$ton rate * thus a

h!h produ$ton $apa$ty. Inert !as /)r dssoled n the lud ammona produ$t s

"lashed o"" n the let do'n essel 'here the pressure s de$reased to 25 -!#$m 2!.



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ro$ess $ondensate used l-e O2, %ethanol, ammona separated at d""erent

pressure 'th the help o" steam.

B%"'% ()% *(%'i! +"*%, (" ,)"- !""' "' 'i+(i"/ -'"+%,,0 i( ), ("" ()'") "!!"#i/ ++!%4



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I/p"cio P1i!

I-Proc"// I/p"cio

Fi1 I/p"cio

#. 231i4 Coro1 P1

%. I/p"cio C"c1i/

*. I/p"cio Proc"3r"/

+. I/p"cio For/

M"ri1 I/p"cio A S3pp1i"r $9"r r"c"ip

%. 'i/31 I/p"cio

*. Di"/io1 C"c/

+. :"1i! I/p"cio

5. &" Tr""

6. NDT ;RT


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CALIBERATION4

5 I/,('*%/(, C!i'(%$ (" N(i"/! 6 M/+('%'7, 6

I/(%'/(i"/! S(/$'$,.

5 W'i((%/ P'"+%$'%, "' C!i'(i"/.

5 U/i8% I$%/(ii+(i"/ " I/,('*%/(, #i() $i,-!.

" C!i'(i"/ S((,.

5 P",i(i9% R%+!! S,(%* #i() '%%'%/+% (".

C!i'(i"/ P'"'**%.

4 C!i'(i"/ R%+"'$, *i/(i/%$.

MAIN PARTS REQUIRED IN THE MANUFACTURING PROCESS OF

AMMONIA CONVERTER ARE AS FOLLOWS4

lates

sh End6s

No((le For!n!s

Flan!es

7as-ets

Fasteners

pes



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FASTENERS

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PLATESFOR)IN)S

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#. M0"ri1 I7"0i>c0io $ Mr6i!

%. Di8"/io1 C5"c6

L ? : ? 05ic6"//

*. 'i/31 I/p"c0io Pi00i! , D8!", L8i0io

+. M0"ri1 T"/0 c"r0i>c0"

Tr/9"r o9 Mr6i!/ I0"8, Pro@"c0, M0"ri1 Sp"c.,&"0 No. < P10" No.

C5"c6 0"/0 ;PMI= I9 r"3ir"7 B4 c3/0o8"r /p"ci>c0io .

MATERIAL IN PE TI N



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FOR)IN)S

PIPES

TUBES&EET

SA5#6

)r70

&"o.

76000+

P1"o.+

00067

v

32


TRANSFER OF MAR:ING4

+rans"er o" mar-n! s bas$ally done "or dent"$aton o" the same materal

'heneer t 'll be $ome n use a!an n "uture.

e.!. suppose " the one lon! plate s ta-en then t must be han! ts o'n

dent"$aton as heat no., suppler pun$hn!, thrd party pun$hn! et$. no' " ths

plate s to be $ut n t'o d""erent parts then ths all n"ormaton s trans"erred to theother part as t s so that both the part s han! ther o'n dent"$aton mar-s

'h$h 'll be use"ul to dent"y the parts.



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SA5#6

)r70

&"o.

76000

+

P1"o.

+000

67

TRANSFER OF MARIN)

TO ENSURE TRACEABILIT( TO T&E DRA:IN) PART $ MTC

33


7ENE) )E%; )


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PLATE CUTTING & WEP PREPARATION4



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!. P/T

$+* $&

*o .ard Punc-in; on

1' ( "elo< 6 mm t-ic)

2' *( "elo< 12 mm t-ic)

35



1


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%ar- a re"eren$e lne 100mm "rom nnermost pont.

+he re"eren$e lne should be only at one lo$aton as nd$ated aboe.

%nmum 3mm ma$hnn! allo'an$es ta-n! on ether sde o" the plate.

+he d""eren$e n da!onal #d1=d2# > 1mm /ma?.

For ma-n! the plate a per"e$t suare, re"eren$e lne s ta-n! "rom the

ma$hned "a$e at all sdes.

ound=o"" ed!es o" plate to 3 mnmum.


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PLATE EDGE BREA:ING

late ed!e brea-n! s $arred out on press ma$hne 'th the help o" lode

ed!e brea-n! de.

Ed!e brea-n! s done n $old $ondton.

o' n the plate ed!e s $orre$ted 'thn 1mm " present.

hape s $he$-ed 'th template.

+he same s $orre$ted on the other sde o" the plate.



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ROLLING OF SHELL4

ROLLING OF SHELL

)"ter shot blastn! * ed!e brea-n! rolln! s done at room temperature.

No. O" rolln! passes as per th$-ness o" plate * pressure appled

CHEC:ING OF SHELL PROFILE0 OVALITY & CIRCUMFERENCE4

he$-n! shape 'th d#@ template durn! rolln! "rom nsde and outsde

'th 2 ply /1#2A th- template o" B len!th.

%a?mum !ap 'th template s allo'ed to 1mm.



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/CT/ T.=&

ma > min ? 0&5 @ #1@ o, *ominal a% per /!(

P/= *P/= +T

A4 T/(PT

39




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A C.C= * .+$B+

40




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A4 Template

A4 Template

41




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Pea)+

42


LONGITUDINAL SET=UP OF SEAM

oston the shell on "?ture saddle 'th lon! seam at C6o $lo$-.

Insert o""set $orre$ton bo? beam at ert$al se$ton nto the shell, rest t on

ert$al support $olumn.

orre$t o""set n shell lon! seam 'th the t!htenn! or loosenn! o" bolt o"

bo? beam.

rode Da$- support "rom bottom 'hereer reured * $orre$t the s-e' n

the shell.

+hen ta$-n! s done n the lon! seam.



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INSPECTION OF LONG=SEAM SETUP

he$- "or materal dent"$aton, tem no., and shell $ourse no.

he$- 'eld !rooe !eometry .e., land an!le root !ap et$.

he$- o""set.

he$- $r$um"eren$e at both ends and at $enter.

he$- oalty * shape 'th /d#@ template.

he$- ta$-n! on the lon!tudnal seam as also ta$-n! o" supports et$.

+a$-n! should be "ree "rom de"e$ts l-e under$ut, $ra$-s, porosty

mproper "uson et$.



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he$- ta$-n! o" the run=n#run=out $oupons # produ$ton $oupons plates "

reured.

he$- lon!tudnal as 'ell as $r$um"erental ed!es "or lamnaton et$.

PREHEATING OF LONG SEAM4

reheatn! noles heatn! the base metal, ether n the entrely or Dust the

re!on surroundn! the Dont to spe$"$ desred temperature $alled the pre=heat

temperature.

eatn! may be $ontnued durn! the 'eldn! pro$ess, but "reuently the

heat "rom the 'eldn! s su""$ent to mantan the desred temperature 'thout

$ontnuaton o" the e?ternal heat sour$e.

In determnn! 'hether or not to preheat, the "ollo'n! should be

$onsdered: $ode reurement, se$ton th$-ness, base metal $hemstry, restrant,

ambent temperature, "ller metal hydro!en $ontent * preous $ra$-n!

problems.

In !eneral preheat s usually not reured on lo' $arbon steel less than

1n /25mm th$-. o'eer as the $hemstry, d""usble hydro!en leel n 'eld

metal, restrant or se$ton th$-ness n$reases, the need "or preheat s also

n$reases.



45/74

45


WHY PREHEATING4

It slo's the $ooln! rate n the 'eld metal * base metal, produ$n! a more

du$tle metallur!$al stru$ture 'th !reater resstan$e to $ra$-n!.

lo'er $ooln! rate prodes an opportunty "or hydro!en that may be

present to d""use out harmlessly redu$n! the potental o" $ra$-n!.

It redu$es the shrn-a!e stress n the 'eld and adDa$ent base metal , 'h$h s

espe$ally mportant n h!her restraned Donts.

It rases same steel aboe the temperature aboe the temperature at 'h$h

brttle "ra$ture 'ould o$$ur n "abr$aton.

INTERPASS4

+he nterpass temperature s the base metal temperature at the tme o"

'eldn! s to be per"ormed bet'een the "rst * last 'eldn! pro$ess,

$annot be permtted to "all belo' the preheat temperature.



46/74

46


LONGITUDINAL SEAM WELDING4

on!tudnal seam 'eldn! dre$tly start "rom nsde by )< 'eldn! *

the eupment used s )< boom.

tr$tly mantan the nterpass temperature o" 250G.


47/74

47


+hen ta-e out the 'eldn! boom and remoe the o""set $orre$ton beams by

EO+ $rane.

+hen $he$- the shape * oalty a"ter $ompleton o" partal lon!tudnal

seam 'eldn! by the metall$ template * "ll n the parameter=montorn!

$hart.

rode lo' elo$ty $andle burners 'th hood "rom nsde 'thout startn!

the burner.

o'er the Da$- * rotate the shell so that lon! seam 'll $ome at topmost

poston

%oe trolley alon! 'th shell to $hp=ba$- !rndn! staton /handln! o"

shell 'th $rane n hal"='elded $ondton str$tly prohbted.

+hen $arry out the lon!=seam $hp=ba$- !rndn! * $he$- $hp=ba$-

$on"!uraton 'th the template, ensure su""$ent uantty o" templates *

re$ord the $hp=ba$- depth.

lear hot ma!net$ part$le test

+hen moe the trolley to $hp=ba$- 'eldn! staton, put the hose

$onne$ton * start the burners, poston * ta$- the ds$har!eable

thermo$ouples at reured lo$atons at 100mm on ether sde o" the lon!

seam on outsde sur"a$e.



48/74

48


arryout lon! seam $hp=ba$- 'eldn! by )< boom * re$ord

temperature durn! 'eldn!.


49/74

49


ut =o"" burner, remoe blan-et * allo' seam to $ool do'n stll n stll ar ,

temperature should be re$orded $ontnuously "rom start o" preheatn! to

the $ompleton o" post=heatn!.

he$- the shape, oalty, * bo' at the end o" the $omplete 'eldn! * "ll

the parameter=montorn! $hart $ompletely.

+hen moe the trolley to seam "lush !rndn! staton * !rnd the 'eld

seam "lush#under"lush "rom nsde * outsde

Ensure that the th$-ness o" the shell=$ourse dose not "all belo' the

th$-ness mentoned n the dra'n!.

arryout the lon! seam + /penetraton test * H+ /ultrason$ test * then

poston shell nto "urna$e.

arryout I as per + * shape $orre$ton by rolln! ma$hne * "ll the

parameter montorn! $hart $ompletely.

lear shape, oalty, $r$um"eren$e, N+ /+, tou$h up by nspe$ton

department * then release the shell "or shrn- "ttn!.

INSPECTION OF SEAM FINISH

Inspe$t the root run "or penetraton.



50/74

50


he$- the dressn! o" 'eld "rom nsde # outsde "or adeua$y "or

rado!raphy # ultrason$ testn!.

he$- "or presen$e o" any under$uts or e?$ess ren"or$ement and o""sets.

he$- the nter=bead alley and under$uts.

he$- "or 'eld Fnnsh reurement as per dra'n!.


51/74

51


+he mnmum produ$ton test plate s(e reured s :=

1. 150mm 'de "or steel J> Cmm th$-

2. 225mm 'de "or steel K Cmm th$- * "or non"errous metal J> Cmm

th$-

3. 300mm 'de "or non"errous metal KCmm th$-.

+he ammona $onerter reured shell o" th$-ness around 235 mm. so as per

the dra'n! "e d""erent sub shell o" $on$entr$ dameter are rolled and then

a"ter "nshn! o" all the "e sub shell, they are put n to one other one by one

to "orm a shell o" reured th$-ness. +hs s done by the pro$ess o" INL

FI++IN7 the dameter o" the "nal shell s mantaned.


SHRIN: FITTING


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52


PROCEDURE FOR SHRIN: FITTING

+he outer layer o" the shell s ta-en n to the "urna$e and atta$hes all the

thermo$ouples at the spe$"ed poston.

+hen outer layer s heated n the "urna$e, so that t su""$ently e?pands "or

shrn-n! the $old shell nto t.

+he heatn! rate, temperature and hold tme are spe$"ed and do not e?$eed

the lmts o" the materal n relaton to ts propertes.

ooln! "rom the shrn- stress n ether n stll ar or n the "urna$e.

+he shrn- "ttn! o" the shell s done n su$h a 'ay that lon! seams o"

the ea$h sub shell should $ome n the orentaton as sho'n n the

dra'n!.a"ter $ompleton o" shrn- "ttn! the shell s subDe$ted to re"eren$e

lne mar-n! and DEGREE MAR:ING /0G, 90G, 180G * 2M0G TOP *

BOTTOMsde o" the shell s also mar-ed 'th the help o" pun$hn! on the

shell. * then the shell s a!an o""ered "or nspe$ton.

VISUAL CHEC: & GAP CHEC:4



53/74

53


+here should be no dust part$les or burrs /obsered durn! !ap $he$-

n the nterlayer !aps. Insst o" $leann! the same be"ore start o" !ap $he$-n!

he$- and note the orentaton o" seams. /+hs s reured at eery !ap $he$-

sta!e subseuent to shrn- "ttn! on"rm the top # bottom sde or le"t # r!ht

sde o" shell and note the same.

Ea$h o" the sub shell s 'th ts o'n dent"$aton, so be"ore !ap $he$- "rst

the dent"$aton pun$hn! o" the shell near the lon! seam o" the shell *

lon! seam no. /


54/74

54


$ompleton o" ma$hnn! the shell s a!an o""ered to nspe$ton "or !ap

$he$- a"ter ma$hnn! to ensure that there s no $onsderable !ap.

+hen ent hole mar-n! * drlln! s done a$$ordn! to dra'n!.

CIRCUMFERENTIAL SEAM SET=UP & WELDING4

+a-e the reured s(e * th$-ness o" plate * pla$e the plate at 'eldn!

staton on "loor.

Leep the reured no. o" rollers on ths plate at part$ular lo$atons /one

motor(ed * rest s dler rollers * lo$- the rollers 'th plate, a"ter leeln!.

omplete the +i'+=,%* ,%(=-, by stron! ta$- ta$- 'eldn! nsde the seam

!rooe 'th proper -'%=)%(i/temperature.

arry out -",( )%(i/ " ()% (+> #%!$up to the reured temperature.

orre$t Dob s$re's moton and lo$- the rollers * prode ant=dr"t at

reured sde o" shell.

rode reured no. o" lo' elo$ty $ured burners "rom nsde * prode

!lass'ool blan-et on both sde o" $r$. eam.

rode 2#3 ba""le hoods at 500mm on ether sde o" the $r= seam

tart rotaton, start $r$=seam 'eldn! * smultaneously re$ord the

temperature. Ensure pre=heatn! as per the spe$"ed temperature * re"er


55/74

55


Interpass temperature to be $he$-ed at re!ular nterals by n"ra=red non=

$onta$t sensor.

Fnal 'eld run should oerlap only up to the spe$"ed lmt on ether sde o"

the shell * then 'eld temper beads.

+hen $arry out post heatn! up to the spe$"ed temperature.

arryout $hp=ba$- !rndn! as per spe$"ed * $he$-s the $hp=ba$-

$on"!uraton 'th the template.

ut lo' elo$ty $ured burner * hood "rom outsde * 'eld "rom nsde

alon! 'th temper beads * then pre=heatn! s $arred out.

POSTWELD HEAT=TREATMENT ;PWHT


56/74

56


"abr$aton the t'o most $ommon pro$edures used are -",( )%(i/and ,('%,,

'%!i%9i/.

STRESS RELIEVING4 tress rele" heat treatment s used to redu$e the stresses that reman

lo$-ed n a stru$ture as a $onseuen$e o" manu"a$turn! pro$esses. +here are many

sour$es o" resdual stresses, and * those due to 'eldn! are o" a ma!ntude rou!hly

eual to the yeld stren!th o" the base materal. Hn"ormly heatn! a stru$ture to a

su""$ently h!h temperature, but belo' the lo'er trans"ormaton temperature

ran!e, * then un"ormly $ooln! t, $an rela? these resdual stresses. arbon steels

are typ$ally held at 1,100 to 1250GF /C00 to CM5G "or 1 hour per n$h /25mm o"

th$-ness

)"ter all the pro$ess, +hese all lon! seam6s * $r$ seam6s are subDe$ted to

NDT /Non=estru$te +est to ensure that the seam6s are "ree "rom any de"e$t

* 'th the assembly o" e?ternals l-e HO+ )LE+, E)+ et$. the

shell assembly o" the eupment s $ompleted.


INE/I)N) DIHED END


57/74

T(PE OF DIS&ED ENDS

&"i/p"ric1

E11ip/oi1

Tori/p"ric1

57


+he 6 End6s 'h$h are used n the ammona $onerter eupment are o"

hemspher$al type. +hs 6 End6s are n the "orm o" ra' materal * 'h$h areben! sub$ontra$ted to endor.

IDENTIFICATION OF MAR:ING4

#E No.

roDe$t No.

%ateral pe$"$aton

eat No. * late No



58/74

*T$/ P/$T + "/*=

(/$=*

C*T$ $ $

A "/*=

CT $+* !(++T.

C+$*$! $+* +

58




59/74

59


PROCEDURE FOR NO??LE TO @D7 END SET UP4

tudy o" ra'n!s * +oleran$e heet

eelopment o" utout

%ar-n! on hell

%a-e utout

o No((le et Hp

mensonal he$-up

STUDY OF DRAWING4

No((le %ar-

No((le (e, ppe $hedule, pe +h$-ness

Eleaton From ottom +an # e" ne

e!ht "rom entre ne

Orentaton o" No((le

+oleran$e heet

etals o" ar No((le " any

eleased or under old

HYDROTEST OF EQUIPMENT4



60/74

60


ENSURE PRIOR TO WATER FILLING4

ompleton o" 'eldn! on pressure part.

ompleton o" all N+ to the a$$eptable sta!e.

learan$e o" all N# " any.

Fnal $learan$e o" materal $leared prosonally.

+estn! o" +#%+, " any, to the a$$eptable test result.

)ll dmensonal $he$- 'thn the a$$eptable lmt.

Pessel s -ept on hydrotest saddle n the spe$"ed orentaton as per dra'n!

)ll lon!=seam * $r$=seam are made sble "or nspe$ton.

I" Dob s prmer $oated, all pressure 'eld Dont are $leaned "ree "rom pant.

7as-ets * !as-et seatn! are $he$-ed "or any dama!e.

Insde sur"a$e s $leaned.

)r endn! arran!ement 'hereer s reured.

)ll "asteners are t!htened to the reured torue.

)ll openn!s are $losed e?$ept top one "or "lln! 'ater.

)rran!ement o" pressur(n! shall be throu!h one o" the no((les "rom the

bottom.



61/74

61


uare bar arran!ements on nlet * outlet $onne$ton.

)rro' "or dre$ton o" 'ater "lo' on "ttn!s to be er"ed * $on"rmed.

+'o pressure !au!e or one * one transdu$er to be made aalable.

% reurement o" test 'ater shall be er"ed * $on"rmed.

ydrotest pump, h!h ds$har!e pumps shall not be used "or essel 'th

olume 10 $ub. %tr.

WATER FILLING0 PRESSURISING & INSPECTION4


62/74

62


+est blan- shall be 'th npple, suare bar, pressure !au!e * ppe

$onne$ton "or endn!.

Inlet ale shall reman $losed tll 'ater "lln!.

)"ter blan-n! the top no((le 'th !au!e * end ppe, 'ater shall be

pumped "rom bottom.

Pend ppe shall be -ept open n a bu$-et "ull o" 'ater to obsere ar bubbles.

Pendn! shall be $ontnued tll the ar bubble n the bu$-et s dsappeared.

lose the outlet ale on top * $onne$t the !au!e to lne pressure.

Isolate the !au!e at the bottom "rom lne pressure * pump the 'ater n.

ase the pressure tll 50& o" test pressure.

Open the nlet !au!e to pressure lne * er"y the pressure on both !au!es.

In$rease the pressure n n$rements o" 10& o" test pressure.

top pumpn! "or 5 mnutes a"ter ea$h n$rement o" 10& o" rse n pressure.

Isolate the nlet pressure !au!e 'hen pump s operaton.

onne$t the nlet pressure !au!e to lne pressure 'hen pump s stopped "or

pressure er"$aton



63/74

63



64/74

64


4 ran the essel only 'hen top out let s -ept open

4 Hse mnmum 2 !au!es "or any hydrotest

4 Neer use h!h ds$har!e pumps "or testn! lo' olume essels. /Polume

less than 10 m3. Neer pressur(e any essel aboe test pressure.

SURFACE PREPARATION4

W)( i, ,'+% -'%-'(i"/

ur"a$e preparaton s the pro$ess n 'h$h the sur"a$e o" the 'or-=pe$e s

been $leaned "or ne?t pro$ess l-e pantn!, $oatn! et$.

W) i( '%8i'%$


65/74

65


BLASTINGs the pro$ess 'h$h s most $ommonly used n ndustry.

lastn! s one -nd o" sur"a$e preparaton pro$ess n 'h$h sur"a$e s $leaned

by mpa$tn! o" abrase.

T-%, " BLASTING:

I


66/74

66




67/74

67


CHAPTER

WORK IN DEPARTMENT

My role in the Department

1' errite c-ec) o, !!overlay&2' ap c-ec) in (ultioF o, punc-in; on Gob&

7' (a)e PTA(T report&

8' imen%ion c-ec) o, Tube>!-eet&

9' (a)e n%pection c-ec)li%t&

10' Preparation o, ,errite ;ap c-ec) t-ic)ne%% -ardne%% report&

11' C$AC$ updatin; on dra


68/74

68


CHAPTER

THE WORK I DID IN 6 MONTHS

-*/RA)NI /HI4NE A-E+8

3ltrasonic thickness gauge is to measure thickness of material by ultrasonic method.

)etals, plastics, ceramics, glass or virtually any other material which conducts

ultrasound can be accurately gauged over a wide range of thickness.

W"'>i/ -'i/+i-!4=

ery high fre:uency sound waves 'well above those heard by humans are sent

through a material by use of a transducer.

The same transducer or a second transducer can listen for the reflected or

transmitted sound.

(t end point of material, the sound energy is reflected back to the transducer

and recorded.

4y measuring the time it takes a sound wave to travel from one point to another,

distances can be measured.



69/74

69


EC%=ti Har'ness /ester

eat%res

:uotip ? is a hand-held metal hardness tester with a rugged shock-resistant

housing and sealed membrane keypad

The metal hardness tester :uotip ? converts directly to all common hardness

scales '%, %4, %R$, %R4, %R(, %/, Rm8 creates and uses another up to GF

customer-specific conversions for uncommon alloys

%ighly accurate B %1 'F.@O at AFF %1 with automatic correction for impact

direction

The :uotip ? metal hardness tester offers a wide measurement range

Internal storage of P=FF7FFF measured values in a fle6ible user-defined fileKfolder

structure

The metal hardness tester :uotip ? offers user profiles for a :uick change of

test setup 'with password protection

Down-Kupload data fromKto +$ via 3/4, thernet or R/-G?G

http://www.proceq.com/en/non-destructive-test-equipment/metal-testing/portable-hardness-testing/equotip-3/measurement-range.htmlhttp://www.proceq.com/en/non-destructive-test-equipment/metal-testing/portable-hardness-testing/equotip-3/measurement-range.html


70/74

70


errite eter+8

The rugged *RIT/$"+ with plug-in type smart probe is suited for fast, non-

destructive and accurate measurement of ferrite content on-site or in the lab accordingto the magnetic inductive method.



71/74

71


(pplications include measurement of the ferrite content in

austenitic steel welds 'of tubing etc.

normal construction steel with austenitic chrome

alloy steel welded cladding 'e.g., in boilers, vessels, etc.

duple6 steel.

a chec$ Meter=ating /hic$ness Meter;+8



72/74

72


+rinciple )agnetic Induction or ddy $urrent

A*IBRA/I)N

4 +lace probe on 4ase material /ample

4 /et Mero reading '/tabili9e by taking multiple readings

4 $alibrate using calibrated known thk. foils QRefer operating Instructions

4 $alibrate by applying probe on known lower 2 higher thickness foil

4 Recheck calibration using a mock-up block with known 4ase )etal to 1iner gap.

The reading observed should be near to known gap. '*ig -=



73/74

73


CHAPTER

CONCLUSION

$* T. /!T 46 =! + (I T$/** * /$!*

/* T+"$+ /C.H / +T + P$/CTC/ JP$*C *

T. + K/TI C+*T$+&

/T $!T 46 =! + (I T$/** T$( .C. $$

T+ /! (+!T JCT* *$C.* /* C./**

JP$*C H$ * (I **$*

C$$C(& ./H /$* T. (P+$T/*C + +$=

CT$ /* T/(+$=& $* T.! ./H /* H$I(P+$T/*T /!PCT + P/*** /* C+>+$*/TT+*&T.!

T$/** .P ( T+ "$ /P "T* T.+$I /*

P$/CTC/ =*+&T ./! (/ ( //$ T./T

H//T* / P$+LCT ! H$I (P+$T/*T /* C$TC/ L+"

+$ T. C+(P/*I /* T! +C/!& ./H /!+ /$*T

T./T C!T+($ !/T!/CT+* !/TI /* K/TI /$ +

(+!T (P+$T/*C&

++=* /T T. T$/** $+( / "$+/$ H ./H

+* T./T /P/$T $+( T. TC.*C/ =*+

(P/$T T+ ! T ./! /!+ T/.T ! T+ " /*

(/*T/* "TT$ .(/* *T$/CT+*! T+ *$!T/*

.(/* */T$ /T +$= /* JCT /* /!!* T/!=

CTHI&

T. C$T T+ ./T ./H /$*T $* T.

T$/** P$+ +! T+ T. C+(P/*I P$!+** /* +$

C+ /T.+$T!& /T /!T

C+*C (I $P+$T T. (+!T !/T!/CT+* /* "I T/=*

/ +T + ((+$! /* JP$*C! T. ( .C.

/!T +$H$&



74/74

74


CHAPTER 1

BIBLIOGRAPHY

-ad vi%ited t-e ,ollo

original project 8th sem

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