project prasad

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COLLEGE OF ENGINEERING, PUNE

(An Autonomous

Institute of Govt.

of Maharashtra)

DEPARTMENT OFPRODUCTION ENGINEERING

INPLANT TRAINING REPORT

SUBMITTED BY

YARGATTIKAR PRASAD BHALCHANDRA

B.TECH PRODUCTION (S/W)

ROLL NO : 709304

TICKET NO : 84454

2009 - 2010

DEPARTMENT OF PRODUCTION ENGINEERING

AND WORKSHOP

1



COLLEGE OF ENGINEERING, PUNE

(An Autonomous Institute of Govt. of Maharashtra)

CERTIFICATE

This is to clarify that Mr. YARGATTIKAR PRASAD

BHALCHANDRA has carried out his Industrial In Plant Training during the

course of his Training at THERMAX LTD. In partial fulfillment of the

requirement of the VII – VIII Semester B.Tech. Course of Production

Engineering (Sandwich), at the Department of Production Engineering and

Workshop, College of Engineering, Pune 411005. During the Second

Academic term : 2009 – 2010.

(EXAMINER) Dr. B.B.AHUJA MR.S.ANASANE(Prof & Head) (Guide)

DATE :

PLACE: PUNE.

2



ACKNOWLEDGEMENT

I wish to express my sincere gratitude and regards to my report

Prof.S.Anasane. His guidance and support throughout the program has been

a major factor in the successful completion of the present work. This work

would not have culminated in to the present form without his invaluable

suggestions and generous help. I am thankful to the faculty of COEP for

providing me with an excellent education during my B.Tech Program.

Also I am thankful to Mr.Rahul Joshi my company guide for hisguidance and support for completion of my project and also I would thank

Mr. Uttam Gaikwad and Mr. Laxmikant Malage who helped me in giving their

valuable ideas for my project .

I am thankful to all my seniors and friends who provided

valuable suggestions and constant help during my report making.

3



CONTENT

SR NO. TITLE PAGE NO.

1 COMPANY PROFILE.

2 ORGINISATION STRUCTURE FOR MFG.

3

4

5

6

7

8

9

10

COMPANY PROFILE

4



BIRTH OF THERMAX

In the beginning there was fire. Then there was steam. Steam heated

produced mechanical movement. It could be used to produce electricity too.

The use of steam rewrote the history of human civilization. It was the drivingforce of industrial revolution, the precursor of modern age, as we understand

it. Even in this age of cybernetics, genetic engineering and information

superhighways, boilers that produce steam are critical on-line equipment,

across diverse industry segments – be it a small-scale unit, which needs a

600 kg/hr, or a fertilizer plant, which needs a 300-tones/hr high-pressure

steam generator.

Years ago there was a small company in Mumbai called National SteelEquipment Company (Nat Steel), which made hospital sterilization equipment

and hospital beds. They soon started manufacturing heaters for the hospitals.

Its founder A.S.Bathena (1908-1991) and his son Jamshed decided to go in

for collaboration with a Brussels based company Wansons for manufacturing

of so-called “Baby Boilers”. Wansons was one of the largest manufacturers of

coil type boilers in Europe while Nat. Steel was 5000 Sq. Ft. asbestos go

down in a corner of Mumbai.

Nevertheless, the new venture took off meeting a market need that the

customers not even aware of: while Indian industry in the mid-sixties was

largely familiar with bulky hand fired boilers, the Wansons India “Vaporax”

boilers produced steam within two minutes of cold start.

In two years the new company sold over a hundred boilers, while a

market survey predicted a turnover of RS.3 million in the third year, the

company got in that year a single order for that figure. The order was from

L&T.

Mr. Rohinton D. Aga (1935-1996) soon joined Bathena, a Cambridge

educated economist by training and manager by profession. A visionary, Aga

laid down many of the fundamental principles and value systems that have

5



guided Thermax (as Wansons India was renamed in 1980). One of Aga’s

favorite words was “Synergy” and it was synergy that is at the core of

Thermax’s diversification and growth.

Thermax has been rolling out a company-wide initiative to transform

the way it does business; aimed at significant increase in customer

satisfaction and top line and bottom line growth. The company is investing

substantial resources in attaining operational excellence – focusing on

processes and systems that have a direct impact on cost, quality, and lead-

time and on-time performance at every point of customer engagement. The

following is the detailed description of the whole organization. It includes thefollowing divisions.

1) Boilers & Heaters.

2) Cooling & Heating.

3) Water & Waste Heat Recovery Solutions.

Thermax has been rolling out a company-wide initiative to transform

the way it does business; aimed at significant increase in customer

satisfaction and top line and bottom line growth. The company is investing

substantial resources in attaining operational excellence – focusing on

processes and systems that have a direct impact on cost, quality, and lead-

time and on-time performance at every point of customer engagement. The

following is the detailed description of the whole organization. It includes the

following divisions.

1) Boilers & Heaters. 3) Water & Waste Heat Recovery Solutions

2) Cooling & Heating.

.DEPARTMENTAL PROFILE

ENERGY SYSTEM DIVISION (ESD)

6



INTRODUCTION

Waste heat utilization has become a very important sector of the

industry, owing to which the above division came into being in THERMAX.

This division deals with the Heat Recovery Units (HRU) operating on waste

heat.

The products of this division include:

Exhaust gas waste heat boilers for PG sets, gas turbines and other

industrial application.

Economizers: plain tubes, cast iron, extended surfaces, cast iron

muffled.

Process integrated waste heat boilers.

Waste gas fired heaters & metal recuperates

Special purpose pressure vessels, heat exchangers, towers, columns

radiation coils and reactors for critical applications.

PRODUCTS OF ENERGY SYSTEM DIVISION

7



Basically there is no standard format to divide the product for this

division; this can be divided as per customer, capacity or functions.

Products are:-

1. EGB (exhaust gas boiler). This can also divided as

a. 1DRC (Single Drum Reverse Circulation)

b. 1DNC (Single Drum Natural Circulation)

c. 2DNC (Two Drum Natural Circulation)

2. Bi drum (steam or power generation).This can divided as

a. BD (Without Fluidized Bed)

b. BDF(With Fluidized Bed)

3. PIB (Process Integrated Boiler)

4. WHRB (Waste Heat Recovery Boiler)

Generally it deals with drum shop

DRUM SHOP

8



Drum is part of boiler used for steam separation & is also used as

reservoir. Single or twin drums are required based on type of boiler. Drums for

ESD & TBW are manufactured in drum shop.

Types of design and construction codes for drums:

1. ASME

2. IBR 1950

3. BS

4. AS

Inspection agencies for drum manufacturing:

1. IBR

2. ASME

3. LRIS

4. EIL

5. Customer appointed third party inspection agency.

Types of materials used for drums:

A) Shell plates, dished end, and manhole

Carbon steel - SA516 GR 70

Low alloy steel SA302 GR b

B) Nozzles, flanges, forgings, fittings

Carbon steel - SA106, SA105, SA234wpb

PARTS OF DRUM

9



1. Shell: Plate - Rolling - Welding

2. Dished end: Plates – Pressing – Hot or Cold

3. Manhole: Plates – Press – Weld

4. Manhole cover: Plates – Cut – Machine

5. Nozzles: Pipes, Flanges, Forgings – Cut – Machine - Weld

6. Attachments: Plates, Flats, Angles, Channels

7. Saddles: Plates

8. Lifting hooks: Plates

9. Steam purifier assembly

MANUFACTURING PROCESSES FOR DRUM SHOP

10



Sr. No Processes Skill Required Machine used

1 Marking Fitting Hand Tools

2 Gas cutting Welding

Oxy-Acetylene

torch pug cutting

machine

3 Grinding Fitting

Electrical and

pneumatic

grinders

3 Plate BendingMachine

Operation

Himalaya plate

bending machine

4 Fitting Fitting Hand tools

5

Welding

SMAW, SAW,

GTAW

Welding

Rectifier,

generators, saw

boom

6 Machining Machining Lathe

7 Drilling MachiningKollmann and

radial drilling

8 Boring Machining Union drilling

9 Painting Painting

STEPS FOR DRUM MANUFACTURING

1. Plate Marking and Cutting

11



2. Shell Rolling, Pre-Pinch Cutting, Closing

3. Shell L Seam Setup

4. Shell Welding - Inside SMAW + SAW, Back Grinding, Outside Saw

5. Shell Re-rolling & Radiography

6. Shell C Seam Setup

7. C Seam Weld & Radiography

8. Internal Attachments Set & Weld

9. D/E Setup

10.D/E to Shell Weld & Radiography

11.Nozzle Opening

12.Nozzle Setup & Weld

13.External Attachment Set & Weld

14.Full Welding Clearance

15.Stress Reliving

16.Hydraulic Blank Welding

17.Hydro Testing

18.Tube Hole Drilling Marking

19.Tube Hole Rough Drilling

20.Tube Hole Finish Drilling

21. Tube Hole De-burring

22.Hydro Blank Cut & Nozzle Trimming

23.Drum Internal Assembly

24.Drum Painting & Handing Over

D/E FABRICATION

1. D/E Marking

2. M/H Opening Cutting

12



3. M/H to D/E Setup & Weld

4. Nozzle Opening Drilling

5. Nozzle Setup & Weld

NOZZLE FABRICATION

1. Pipe Cutting & Machining

2. Pipe to Flange Set, Weld, Radiography

SHOP LAYOUT:

13



14



15



Through Put Time reduction by

Visual management

16



Introduction:

The drum shop mainly was divided as Capsule Area, All Weld Area,

Machine Shop and Assembly. The Capsule Area is further divided into Shell

fabrication and Capsule Fabrication. Mainly the Shell Area was a mere pointof concern as it had a higher through put time which finally was leading to

higher through put time of the drum.

So, the data collection in shell area was to be made in order to find out

the causes of higher through put time. Hence as a project we decided to

monitor the shell area on daily basis in order to reduce the problems which led

to lower output.

Problems faced:

1) No streamlining of job.

2) Non Value adding activities.

3) Non traceability of shells.

Need of the project:

4) To reduce the Through Put Time (TPT).

5) To balance Work in Progress (WIP).

6) To increase safety.

7) To ease material handling.

8) To increase the visual management.

Actions taken:

1) Daily station wise data collection in Shell area.

2) Finding out routine problems leading to lower output.

3) Maintaining data of day to day job tracking.

4) Visual management through layout modification.

5) Implementation of KANBAN.

17



Steps taken to complete the project:

Shell area mainly comprised of the processes from Pate marking, Pate

cutting, Pate rolling, Pre-pinching cutting, Shell Closing, L Seam Setup, L

seam Inside SAW, L Seam Back Gauging, L Seam Outside SAW, L SeamFlush, Shell Rerolling, Shell Radiography.

So, as shown above there were total 12 detailed stages in the Shell

area. So it was very important to study each and ever stage on daily basis as

it was not easy to find where exactly the problems are. The target WIP set by

shop was 2 jobs at each station. And total WIP in shell area was to be brought

below 20 so that automatically the TPT is controlled.

The problem found after 2 months of data collection was that the jobs

were not kept properly after each stage. Especially in L Seam Setup area, L

Seam flush area and Pre Pinching area the job searching time was more as

the jobs from previous station were not kept at right place resulting in loss of

time to take the job. So for that purpose we decided to modify the existing

layout so that there is a foolproof type arrangement which will avoid the

misplacing of jobs in wrong position.

18



OLD LAYOUT:

NEW LAYOUT:

PRIPINCHINGCUTTING

SHELL FOR FLUSHGRIND, SHELL FORCLOSING & READYSHELL

L SEAM BG

NEW AND OLD L SEAMOUTSIDE SAW

ROLLINGMACHINE

L SEAM SETUPAREA

D/E

INSIDE

SAW

PRIPINCHINGCUTTING

SHELL FOR FLUSHGRIND, SHELL FORCLOSING & READYSHELL

L SEAM BG

NEW AND OLD L SEAMOUTSIDE SAW

ROLLINGMACHINE

L SEAMSETUPAREA

L SEAM I/SWELDING

SHELLFOR LSEAMSETUP

SHELLFORIBR

19

L SEAM I/SWELDING

SHELLFOR LSEAMO/S



Above figure shows the old and new layout for the shell area, In the old

layout first the job come to rolling then as shown in the arrow it goes for pre-

pinching cutting, then comes in flush area for pre closing flush and MPI then

goes on rolling machine for closing. Now in this whole process the flush area

consists of jobs for L seam flushing, Shell Closing and ready shell (i.e. for

radiography). So, according to the old layout these shells were placed in any

direction irrespective of the type. Also in pre-pinching area as soon as the

rolled shell was brought there was no such specific place for the shell to be

kept.

So, in order to create some streamlining we concentrated on these

areas. Primarily in pre-pinching area with the help of MED we made railings

so that as soon as the job comes from rolling machine it will be placed in

ahead of the area where actual pre-pinching operation is done. Due to this the

searching time or waiting time for handling the job reduced and also mainly

that area was visually managed.

Similarly in the flush area as there were different type of jobs. So,

previously there was a lot of ununiformity in the way the jobs were kept thus

resulting in stagnation. Thus, in the flush area we changed the position of the

rotators. And then separate area was allocated for shells for closing and

radiography. Due to this the space utilization in that area also increased and

the operator could easily lift the job because as compared to the previous

condition the working space had increased.

20



Now considering the L Seam Setup area, the jobs were so variedly

distributed that there was no scope of any discipline in the movement pf job.

In L Seam Setup area the Shells for L Seam Setup, Shells for IBR offering,

Shells for L Seam BG and Shells for L Seam Outside SAW used to lie

anywhere in that area of 13.5 meter by 4 meter.

So, the main task here was how the WIP can be balanced and how can

the jobs be placed to avoid further non value added activities. So, detailed

analysis was made in this area. Firstly we calculated the area which was

utilized at present which came to be 13.5 meter * 4 meter. Then we found that

there was unutilization of space. So, we physically calculated the area which

could be utilized for modifying the L Seam area.

From this we came to know that the Dished End to barrel inside SAW

machine was much into L Seam Setup side and space in between Dished

End to barrel inside SAW machine and C Seam Inside SAW machine was

unutilized. So, we made decision to shift this machine about 1.5 meters from

current position. Thus now we had area of about 15 meter * 4.5 meters for our

use.

Then in order to modify the actual L Seam setup area we prepared a

CAD layout and we mathematically calculated the number of jobs that will be

accumulated in the area. We decided to segregate the L Seam area into three

sections according to the type of shells always occurring in that area. First we

left around 3 meters for L Seam Setup operation, then from that at 1.55

meters the first railing was there then successive railing was at 1.2 meter. And

gangway was at 650 mm. A gangway of 500 mm was left between each

section. Thus successive 2 more stations were there. Of the three sections

the first was of Shells for L Seam Setup, second was of Shells for IBR

offering and third was of Shells for L Seam BG. Thus we made the L Seam

Setup area totally visually managed. 2 gangways of 500mm each were kept in

between for easy access in the area for handling the job, for easy inspection

of the jobs offered for setup.

Now the overall layout was decided but there were 2 possibilities

1) Layout by keeping job with test plate facing rolling machine

side.

2) Layout by keeping job with test plate facing office side.

21



Layout by keeping job with test plate facing rolling machine

side:

Layout by keeping job with test plate facing office side:

22



Data collection

Date - 20/02/10TIME: 9.30 am

WIP OF SHELL AREA

Plate Marking

Plate CuttingWA 104100SD S1

WA 104100SD S2

LW 245/1BWD S1

Plate RollingWA 104100SD S3

WAO99200SD S3

P/P CuttingWAO99200SD S2

Shell ClosingWAO99200SD S1

L Seam Set upWCO19100SD S4

L Seam I/SWCO19100SD S1

WCO19100SD S1

WCO19100SD S3

WCO19100SD S5

L Seam BG BDF 300/2SD S1

L Seam O/SLW 242 SDS1

LW 242 SDS2

BDF 300/12SD S2

L Seam FlushBDF 350/4SD S1

WA101100SD S3

LW 242 SDS3

Shell ReRolling

X RayBDF 350/4SD S2

Date - 21/02/10TIME: 9.25 am

WIP OF SHELL AREA

Plate MarkingLW 245/1BWD S2

LW 247 SDS2

LW 247 SDS1,S3

Plate Cutting


WA 104100SD S1

WA 104100SD S2

LW 245/1BWD S1

BDF 300/12WD S1, S2


Shell Closing NO LOAD

L Seam Set up WAO99200SD S1

L Seam I/SWAO99100SD S2

WAO99100SD S3

WAO99100SD S1

L Seam BG NO LOAD

L Seam O/S(NEW/OLD)

BDF 300/12SD S1

LW 242 SDS2

L Seam FlushWA101100SD S2

BDF 300/12SD S2

LW 242 SDS1

BDF 350/4SD S1

WA101100SD S3, S1

Shell ReRolling

LW 242 SDS3

X Ray

23



ate - 22/02/10TIME: 9.45 am

WIP OF SHELL AREA

Plate Marking

Plate Cutting LW 247 SDS1 LW 247 SDS3 LW 247 SDS2 LW 245/1BWD S2


LW 245/1BWD S1

BDF 300/12WD S1, S2


WA 104100SD S1

WA 104100SD S3

Shell ClosingWAO99200SD S2

L Seam Set upWAO99200SD S1


WAO99100SD S3

WAO99100SD S1

L Seam BG NO LOADL Seam O/S(NEW/OLD)

BDF 300/12SD S1

L Seam FlushBDF 300/12SD S2

LW 242 SDS2

WA101100SD S1

Shell ReRolling

BDF 350/4SD S1

WA101100SD S3

LW 242 SDS1

X RayWA101100SD S2

LW 242 SDS3

Date - 23/02/10TIME: 9.15 am WIP OF SHELL AREA

Plate MarkingLW 245/2BWD S1 , S2

Plate CuttingLW 247 SDS2

LW 245/1TWD S1,S2

LW 245/1BWD S2

Plate RollingLW 245/1BWD S1

BDF 300/12WD S1, S2

LW 247 SDS3, S1

P/P CuttingWA 104100SD S2

WA 104100SD S1

Shell ClosingWA 104100SD S3

L Seam Set up WAO99200SD S3 , S1 WAO99200SD S2


L Seam BGWAO99100SD S2

L Seam O/S(NEW/OLD)

WAO99100SD S1

L Seam FlushLW 242 SDS2

BDF 300/12SD S1

Shell ReRolling

BDF 300/12SD S2

WA101100SD S1

X Ray WA101100SD S2 LW 242 SDS3 BDF 350/4SD S1 LW 242 SDS1

24



Date - 24/02/10TIME: 9.35 am

WIP OF SHELL AREA

Plate Marking NO PLATE

Plate CuttingLW 245/2BWD S1 , S2

LW 245/1TWD S1,S2

LW 245/1BWD S2

Plate Rolling LW 245/1BWD S1

LW 247 SDS3, S1 , S2

P/P CuttingBDF 300/12WD S1

BDF 300/12WD S2

WA 104100SD S1

Shell ClosingWA 104100SD S3 , S2

L Seam Set upWAO99200SD S3

WAO99200SD S2

L Seam I/SWCO19100SDS2,S3,S4,S5

WAO99200SD S1

L Seam BG

WCO19100

SD S1 L Seam O/S(NEW/OLD)

WAO99100SD S2

WAO99100SD S1

WAO99100SD S3


BDF 300/12SD S1

Shell ReRolling

BDF 300/12SD S2

WA101100SD S1

X RayWA101100SD S2 , S3

BDF 350/4SD S1

25



26



27



Date - 27/02/10TIME: 9.45 am

WIP OF SHELL AREA

Plate MarkingWF113100SD S1,S2,S3

Plate CuttingLW 245/1TWD S1,S2

WF113100WDS1,S2,S3

Plate RollingLW 247 SDS2

LW 245/1BWD S2

LW 247 SDS3, S1 , S2

LW 245/2BWD S1 , S2

P/P CuttingLW 245/1BWD S1

Shell Closing

L Seam Set upBDF 300/12WD S1

BDF 300/12WD S2

WA 104100SD S1,S3 ,S2

WAO99200SD S3


WCO19100SD S3,S5

WAO99200SD S2

L Seam BGWCO19100SD S2

L Seam O/S(NEW/OLD)

WCO19100SD S1

WAO99100SD S3

WCO19100SD S1

L Seam FlushWAO99100SD S1

WAO99100SD S2

LW 242 SDS2

Shell ReRolling

BDF 300/12SD S1

WA101100SD S1,S3

X RayBDF 350/4

SD S2

Date - 26/02/10TIME: 9.30 am

WIP OF SHELL AREA

Plate MarkingWF113100WDS1,S2,S3

Plate CuttingLW 245/2BWD S1 , S2

LW 245/1TWD S1,S2

Plate RollingLW 245/1BWD S1,S2

LW 247 SDS3, S1 , S2

P/P CuttingWA 104100SD S1

Shell ClosingWA 104100SD S3 , S2


BDF 300/12WD S2

WA 104100SD S2


WCO19100SD S3,S4,S5

L Seam BGL Seam O/S(NEW/OLD)

WAO99100SD S2

WAO99100SD S3

WCO19100SD S1


LW 242 SDS2

Shell ReRolling

BDF 300/12SD S1

WA101100SD S1

X RayWA101100SD S2 , S3

BDF 350/4SD S1

28



29



30



Date - 01/03/10TIME: 9.15 am

WIP OF SHELL AREA

Plate Marking LW 243/1 SDS1,S2,S3

LW 245/2TWD S1,S2

Plate Cutting WF113100 SDS1,S2,S3

Plate Rolling LW 245/1BWD S2

LW 245/1TWD S1,S2

WF113100WDS1,S2,S3

P/P Cutting LW 247 SDS3

LW 247 SDS1 , S2

Shell Closing LW 245/2BWD S1 , S2

L Seam Set up WA 104100 SDS2

WA 104100SD S1,S3

LW 245/1BWD S1

WAO99200SD S3

L Seam I/S WAO99200 SDS1

WAO99200SD S2,S3

L Seam BG WCO19100 SD

S4

WCO19100

SD S3

L Seam O/S(NEW/OLD)

WCO19100 SDS5

WCO19100SD S2

L Seam Flush WAO99100 SDS3

WAO99100SD S2

WCO19100SD S1

Shell ReRolling

WAO99100SD S1

X Ray WA101100 SDS1,S2

LW 242 SD S2 BDF 300/12SD S1

Date - 28/02/10TIME: 9.45 am

WIP OF SHELL AREA

Plate Marking

Plate CuttingWF113100WD

S1,S2,S3

WF113100SD S1,S2,S3


LW 245/1BWD S2

LW 247 SDS3, S1 , S2

LW 245/2BWD S1 , S2

LW 245/1TWD S1,S2

P/P CuttingLW 245/1BWD S1

Shell Closing


BDF 300/12WD S2

WA 104100SD S1,S3 ,S2

WAO99200SD S3


WCO19100SD S3,S5

WAO99200SD S2

L Seam BGWCO19100

SD S4

L Seam O/S(NEW/OLD)

WAO99100SD S5

WCO19100SD S2


WAO99100SD S2,S3

WCO19100SD S1

Shell ReRolling

BDF 300/12SD S1

X RayWA101100SD S1,S3

31



32



Date - 03/03/10TIME: 9.20 am

WIP OF SHELL AREA

Plate Marking LW 243/1 SDS2

Plate Cutting WF113100 SDS2

WF113100 SDS2

LW 243/1 SDS1,S3

LW 245/2TWD S1,S2

Plate Rolling WF113100 SDS1

WF113100 SDS3

LW 245/1BWD S2

WF113100WDS1,S2,S3

P/P Cutting LW 245/1TWD S1

Shell Closing LW 247 SDS2,S1

L Seam Set up LW 245/1BWD S1

LW 245/2BWD S1,S2

LW 247 SDS3

L Seam I/S WA 104100SD S2,S3

BDF 300/12WD S1

L Seam BG BDF 300/12WD S2

L Seam O/S(NEW/OLD)

WAO99200 SDS1

WAO99200SD S3

L Seam Flush WCO19100 SDS1,S2,S3,S4,S5

Shell ReRolling

WAO99100SD S1,S2

X Ray WAO99100 SDS3

Date - 05/03/10TIME: 6.15 pm

WIP OF SHELL AREA

Plate Marking

Plate CuttingLW 245/2 TWDS1,S2

LW 243/1 SDS1,S3

LW 243/1 SDS2

WCO19200SD S1,S2


WF113100WDS1,S2,S3

P/P CuttingWF113100 SDS2

WF113100 SDS1

Shell ClosingWF113100 SDS3

L Seam Set upLW 247 SDS3

LW 247 SDS2

LW 245/1BWD S1

LW 245/2BWD S2

LW 245/1TWD S1

L Seam I/SWA 104100 SDS2

WA 104100SD S3

LW 245/2BWD S1

LW 247 SDS1

L Seam BGWA 104100SD S1

L Seam O/S(NEW/OLD)

WAO99200 SDS2

WAO99200SD S3

BDF 300/12WD S1,S2


WAO99200SD S1

Shell ReRolling

X RayWAO99100 SDS1

Date - 06/03/10TIME: pm

WIP OF SHELL AREA

Date - 02/03/10TIME: 9.10 am

WIP OF SHELL AREA

Plate MarkingLW 243/1 SDS2

Plate CuttingWF113100 SD

S3

WF113100 SD

S2

LW 243/1 SD

S1,S3

LW 245/2

TWD S1,S2


LW 245/1TWD S2

WF113100WDS1,S2,S3

WF113100 SDS1

P/P CuttingLW 247 SDS1

LW 247 SDS2

LW 245/1TWD S1

Shell ClosingLW 247 SDS3

L Seam Set upWA 104100 SDS3

LW 245/1BWD S1

LW 245/2BWD S1,S2

L Seam I/SWAO99200SD S2,S3

WA 104100SD S1,S2

BDF 300/12WD S1,S2

L Seam BG WAO99200 SDS3

WAO99200SD S2

L Seam O/S(NEW/OLD)

WCO19100 SDS4

WCO19100SD S3

WAO99200SD S1

L Seam FlushWCO19100 SDS1,S2,S5

Shell ReRolling

WAO99100 SDS3

WAO99100SD S1,S2

X RayWA101100 SDS3

33



Plate Marking new plate

Plate CuttingLW 245/2 TWDS1,S2

LW 243/1 SDS1,S3

LW 243/1 SDS2

WCO19200SD S1,S2

Plate RollingWF113100WD S1,S2,S3

P/P Cutting LW 245/1 BWDS2 WF113100 SDS1

Shell ClosingWF113100 SDS2,S3

L Seam Set upLW 247 SDS2

LW 245/1BWD S1

LW 245/1TWD S1

L Seam I/SLW 245/2 BWDS1

LW 245/2BWD S2

LW 247 SDS1,S2,S3

L Seam BGWA 104100 SDS2

WA 104100SD S3

L Seam O/S(NEW/OLD)

BDF 300/12WD S1

BDF 300/12WD S2

WA 104100SD S1

L Seam Flush WAO99100SD S2

WAO99200SD S3

Shell ReRolling

WAO99200 SDS1

X RayWAO99100 SDS1

Date - 07/03/10TIME: 11.15am

WIP OF SHELL AREA

Plate Marking

Plate CuttingLW 243/1 SDS2

WCO19200SDS1,S2,S4,S5

Plate RollingLW 245/2 TWDS1

LW 243/1 SDS1,S3

LW 245/2TWD S2

WF113100WDS1,S2,S3

P/P CuttingWF113100 SDS1

LW 245/2TWD S1,S2

Shell ClosingLW 245/1BWD S2

L Seam Set upLW 245/1BWD S1

WF113100SD S2,S3

LW 245/1TWD S1,S2

L Seam I/SLW 247 SDS1,S2,S3

L Seam BGLW 245/2 BWDS1

LW 245/2BWD S2

L Seam O/S(NEW/OLD)

WA 104100 SDS2

WA 104100SD S1

WA 104100SD S3


WAO99200SD S3

BDF 300/12WD S1,S2

Shell ReRolling

X RayWAO99100 SDS1

WAO99100SD S3

Date - 08/03/10TIME: 11.15am WIP OF SHELL AREA

34



Plate MarkingLW 245/1 SDS1,S3

Plate CuttingWCO19200 SDS2

LW 243/1 SDS2

WCO19200SD S1,S4,S5

Plate RollingLW 243/1 SD

S1

LW 245/2

TWD S2

WF113100WDS1,S2,S3

P/P CuttingLW 243/1 SDS3

Shell ClosingWF113100 SDS1

LW 245/2TWD S1

L Seam Set upLW 245/1 BWDS2

LW 245/1BWD S1

WF113100SD S2,S3

LW 245/1TWD S1,S2

L Seam I/SLW 247 SDS2

L Seam BGLW 245/2 BWDS1

LW 245/2BWD S2

LW 247 SDS3

L Seam O/S(NEW/OLD)

WA 104100 SDS3

WA 104100SD S1


BDF 300/12WD S1,S2

WA 104100SD S2

Shell ReRolling

X Ray

Date - 09/03/10TIME: 11.15am

WIP OF SHELL AREA

Plate Marking


WCO19200SD S1,S4,S5

LW 245/1 SDS1,S3

Plate Rolling LW 243/1 SDS1

WCO19200SD S2

LW 243/1 SDS2

WF113100WDS1,S2,S3

P/P CuttingLW 245/2 TWDS2

Shell ClosingLW 243/1 SDS3

L Seam Set upWF113100SD S1,S2,S3

LW 245/1TWD S1,S2

LW 245/2TWD S1

L Seam I/SLW 245/1BWD S1,S2

L Seam BG

L Seam O/S(NEW/OLD)

LW 247 SDS1

LW 245/2BWD S1

LW 247 SDS2,S3

LW 245/2BWD S2

L Seam FlushWAO99200SD S2,S3

BDF 300/12WD S1,S2

WA 104100SD S2,S3

Shell ReRolling

WA 104100SD S1

X Ray

Date - 10/03/10

TIME: 11.15am WIP OF SHELL AREAPlate Marking

35




WCO19200SD S4,S3

LW 245/1 SDS1,S3

Plate RollingLW 243/1 SDS2

WCO19200SD S2

WF113100WDS1,S2,S3

P/P Cutting

LW 243/1 SD

S1

Shell Closing

L Seam Set upWF113100 SDS1,S2,S3

LW 245/2TWD S1,S2

LW 243/1 SDS3

L Seam I/SLW 245/1 TWDS2

LW 245/1BWD S1,S2

L Seam BG

L Seam O/S(NEW/OLD)

LW 247 SDS3

LW 245/2BWD S2

LW 247 SDS2

LW 245/1TWD S1

L Seam FlushWAO99200SD S2,S3

BDF 300/12WD S1,S2

WA 104100SD S1,S2,S3

LW 247 SDS1

Shell ReRolling

X Ray

Date - 12/03/10TIME: 9.40am

WIP OF SHELL AREA

Plate MarkingLW 240/1 BWDS1,S2

LW 240/1TWD S1,S2

Plate CuttingWCO19200 SDS3,S5

LW 245/1 SDS1,S3

Plate RollingWF113100 WDS2

WCO19200SD S1,S2,S4

P/P CuttingWF113100 WD

S1

WF113100

WD S3

Shell ClosingLW 243/1TWD S1,S2

L Seam Set upLW 245/2 TWDS2

WF113100 SDS1,S2,S3

LW 243/1 SDS3

L Seam I/SLW 245/1BWD S1,S2

LW 245/2TWD S1

L Seam BGLW 245/1 TWDS2

L Seam O/S(NEW/OLD)

LW 247 SDS3

LW 245/2BWD S2

LW 245/1TWD S1

L Seam Flush

WA 104100 SD

S1

WAO99200

SD S2,S3

BDF 300/12

WD S1,S2

LW 247 SD

S1

Shell ReRolling

WA 104100SD S2,S3

X RayBDF 300/12WD S1,S2

Date -13/03/10 TIME:9.15am

WIP OF SHELL AREA

36



Plate MarkingLW 240 TWDS1,S2

Plate CuttingLW 245/1 SDS1,S3

LW 240 BWDS1,S2

Plate RollingWCO19200 SD

S1,S2,S3,S4,S5

P/P CuttingWF113100WD S2

Shell ClosingLW 243/1 TWDS1,S2

WF113100WD S1,S3

L Seam Set upWF113100 SDS1

WF113100 SDS2

L Seam I/S LW 243/1 SD S3WF113100SD S3

L Seam BGLW 245/1BWD S2

L Seam O/S(NEW/OLD) LW 245/1TWD S2 LW 245/1 TWDS1

L Seam FlushLW 245/2BWD S2

LW 245/2 BWDS1

LW 247 SDS1,S2,S3

Shell ReRolling

WA 104100 SDS1S2,S3

X Ray

Date - 14/03/10TIME: 9.40am

WIP OF SHELL AREA


Plate Cutting

LW 240 TWD

S1,S2

LW 240 BWD

S1,S2

Plate RollingWCO19200 SDS1,S2,S3,S4,S5

LW 245/1 SDS1,S3

P/P Cutting

Shell ClosingLW 243/1 TWDS1,S2

L Seam Set upWF113100 WDS3

WF113100 WDS1,S2


LW 243/1 SDS3

WF113100SD S1,S2,S3

LW 245/2TWD S1

L Seam BG

L Seam O/S(NEW/OLD) LW 245/1BWD S1 LW 245/1 BWDS2


LW 247 SDS1,S3

LW 245/1TWD S1,S2

Shell ReRolling

WA 104100 SDS1S2,S3

LW 245/2BWD S1,S2

X Ray

Date - 15/03/10TIME: 9.20am

WIP OF SHELL AREA


LW 245/2 SDS2

37



Plate CuttingLW 240 BWDS1,S2

Plate RollingWCO19200 SDS2

WCO19200SDS1,S3,S4,S5

LW 245/1 SDS1,S3

LW 240 TWDS1,S2

P/P Cutting

Shell Closing

L Seam Set upLW 243/1 SDS2

WF113100WD S1,S2,S3


LW 243/1 SDS3

WF113100SD S1,S2,S3

LW 245/2TWD S1

L Seam BG

L Seam O/S(NEW/OLD)

NO LOADLW 245/1BWD S2

L Seam FlushLW 247 SDS1,S3

LW 245/1TWD S1,S2

Shell ReRolling

X RayLW 247 SDS2

WA 104100SD S1S2,S3

LW 245/2BWD S1,S2

Date - 17/03/10TIME: 9.30am

WIP OF SHELL AREA

Plate MarkingLW 245/1 SDS1,S3


LW 245/2 SDS2

Plate RollingWCO19200 SDS1

WCO19200SD S3,S4,S5

LW 245/1 SDS1,S3

LW 240 TWDS1,S2

LW 240 BWDS1,S2

P/P CuttingWCO19200 SDS2

Shell Closing

L Seam Set upWF113100 WDS1

WF113100WD S2,S3


LW 243/1 SDS1,S2,S3

WF113100SD S1,S2,S3

L Seam BGLW 245/2 TWDS2

L Seam O/S(NEW/OLD)

NO LOAD NO LOAD

L Seam FlushLW 245/1 BWDS1

LW 247 SDS2

LW 245/1TWD S2

LW 245/1BWD S2

Shell ReRolling

LW 247 SDS1

LW 245/1TWD S1

X RayLW 247 SDS3

LW 245/2BWD S1,S2

Date - 20/03/10 WIP OF SHELL AREA

Plate Marking

Plate CuttingLW 245/2 SD

S1,S3

LW 240 BWD

EV- II S1,S2

LW 240 TWD

EV- II S1,S2

38



Plate RollingLW 240 TWDEV- I S1,S2

LW 240 BWDEV- I S1,S2


LW 245/2 SDS2

LW 245/1 SDS3

Shell ClosingWCO19200

SD S4,S5

L Seam Set upWCO19200SD S3

L Seam I/SWF113100 SDS1

WCO19200SD S1,S2

WF113100SD S1,S2

WF113100WDS1,S2,S3

L Seam BGWF113100 SDS3

L Seam O/S(NEW/OLD)

LW 243/1 SDS1

LW 243/1 SDS3

L Seam FlushLW 245/2 TWDS2

LW 247 SDS2

LW 245/1TWD S2

Shell ReRolling

LW 245/1 BWDS1

LW 245/2TWD S1

LW 245/1BWD S2


Plate MarkingLW 240 BWDEV- III S1,S2

LW 240 TWDEV- III S1,S2


LW 240 BWDEV- II S1,S2

LW 240 TWDEV- II S1,S2

Plate RollingLW 245/2 SDS1

LW 240 TWDEV- I S1,S2

LW 240BWD EV- I

S1,S2


LW 245/2 SDS2

LW 245/1 SDS2


WCO19200SD S4,S5

L Seam Set upWCO19200 SDS1

WCO19200SD S3


WF113100WDS1,S2,S3

L Seam BGWF113100 SDS1

L Seam O/S(NEW/OLD)

LW 243/1 SDS1

WF113100 SDS2

WF113100SD S3

L Seam FlushLW 243/1 SDS2,S3

Shell ReRolling

X Ray


Plate Marking

Plate CuttingLW 240 TWD

EV- II S1,S2

LW 240 BWD

EV- II S1,S2

LW 240BWD EV- III

S1,S2

LW 240 TWD

EV- III S1,S2

Plate Rolling NO LOAD

39






Shell ClosingWCO19200SD S4,S5


LW 245/1 SDS1

WCO19200SD S3

L Seam I/SWCO19200SD S2,S1

L Seam BGWF113100 WDS2

WF113100WD S3

L Seam O/S(NEW/OLD)

WF113100 SDS3

WF113100 SDS2

WF113100SD S1

WF113100WD S1


Shell ReRolling

X RayLW 243/1 SD

S2


Plate MarkingLW 240 BWDEV- IV S1,S2

LW 240 TWDEV- IV S1,S2

Plate CuttingLW 240 BWDEV- II S1,S2

LW 240 BWDEV- III S1,S2


Plate RollingLW 240 TWDEV- II S1,S2





WCO19200SD S5


LW 245/2 SDS2

WCO19200SD S3,S4

L Seam I/SWCO19200SD S2,S1

L Seam BGLW 245/1 SDS1

LW 245/1 SDS3

L Seam O/S(NEW/OLD)

WF113100 SDS3

WF113100 SDS1

WF113100WDS1,S2,S3

L Seam FlushWF113100 SDS2

LW 243/1 SDS1

Shell ReRolling

LW 243/1 SDS3

X Ray


Plate Marking

Plate CuttingLW 240 BWDEV- IV S1,S2

LW 240 BWDEV- III S1,S2



40




LW 240BWD EV- IIS1,S2

P/P CuttingLW 240 TWDEV- I S1

LW 240 TWDEV- I S2

LW 240BWD EV- IS2

Shell ClosingLW 240 BWDEV- I S1


LW 245/2 SDS2,S3

WCO19200SD S3,S4,S5

L Seam I/SLW 245/1 SDS2

WCO19200SD S2,S1


L Seam O/S(NEW/OLD)

WF113100 WDS3

WF113100 SDS1

WF113100WD S1,S2

LW 245/1 SDS3

L Seam Flush WF113100 SDS2

WF113100 SDS3

Shell ReRolling

LW 243/1 SDS1

X Ray


Plate MarkingLW 240 BWDEV- V S1,S2

LW 240 TWDEV- V S1,S2


EV- IV S2

LW 240 BWD

EV- III S1,S2

LW 240 TWD

EV- III S1,S2


LW 240 TWDEV- IV S1

LW 240 BWDEV- IV S1,S2

P/P CuttingLW 240 BWDEV- II S1

LW 240 BWDEV- II S2

LW 240 TWDEV- I S2

Shell ClosingLW 240 BWDEV- I S2

L Seam Set upLW 240 BWDEV- I S1

LW 245/2 SDS3

WCO19200SD S4

L Seam I/SLW 245/2 SDS1

WCO19200SD S2


LW 245/2 SDS2

L Seam O/S(NEW/OLD)

WF113100 WDS1

WF113100WD S2

LW 245/1 SDS1,S3

L Seam FlushWF113100 SDS1,S2

WF113100WD S3

Shell ReRolling

X RayLW 243/1 SDS1,S3


Plate MarkingLW 240 TWDEV- V S1,S2

Plate CuttingLW 240 BWDEV- V S1,S2

41



Plate RollingLW 240 TWDEV- III S1

LW 240BWD EV- IIIS1,S2

P/P CuttingLW 240 BWDEV- IV S2

LW 240 BWDEV- IV S1


Shell ClosingLW 240 BWDEV- II S2

L Seam Set upLW 240 TWDEV- I S2

LW 240 TWDEV- I S1

LW 240BWD EV- IIS1


L Seam I/S NO LOAD

L Seam BG NO LOAD

L Seam O/S(NEW/OLD)

LW 245/2 SDS3

LW 245/2 SDS2

L Seam FlushWF113100 WDS3

LW 245/1 SDS1,S2,S3

LW 245/2 SDS1

Shell Re

Rolling

X RayWF113100 WDS1,S2


Plate Marking

Plate CuttingLW 240 TWDEV- V S1,S2

LW 240BWD EV- VS1,S2

Plate RollingLW 240 BWDEV- III S1


LW 240BWD EV- III

S2

P/P CuttingLW 240 TWDEV- IV S1

LW 240 TWDEV- IV S2

Shell ClosingLW 240 BWDEV- IV S1,S2

L Seam Set upLW 240 BWDEV- II S2

LW 240 BWDEV- II S1


L Seam I/SLW 240 BWDEV- I S2

L Seam BGLW 240 BWDEV- I S1

L Seam O/S

(NEW/OLD)NO LOAD NO LOAD

L Seam FlushLW 245/1 SDS1,S2,S3

LW 245/2 SDS1,S2,S3

Shell ReRolling

X RayWF113100 WDS1,S2,S3


Plate Marking

Plate Cutting

LW 240 TWD

EV- V S1,S2

LW 240 BWD

EV- V S1,S2

43




LW 240 BWDEV- III S2

P/P CuttingLW 240 TWDEV- III S1


Shell ClosingLW 240 BWD

EV- III S2

L Seam Set upWCO19200 SDS3

LW 240 BWDEV- II S1,S2


WCO19200SD S5



L Seam BGWCO19200SD S1

L Seam O/S(NEW/OLD)

LW 240 BWDEV- I S2

LW 240 BWDEV- I S1

WCO19200SD S2

L Seam FlushLW 245/1 SDS1,S2,S3

LW 245/2 SDS2,S3

Shell ReRolling

X RayLW 245/2 SDS1


Plate Marking


EV- V S1,S2

LW 240 BWD

EV- V S1,S2

44




P/P CuttingLW 240 BWDEV- III S2


Shell ClosingLW 240 TWDEV- III S1

L Seam Set upLW 240 TWDEV- I S1,S2


WCO19200SD S5

LW 240BWD EV- IVS1,S2


L Seam I/S

L Seam BGWCO19200 SDS3

L Seam O/S(NEW/OLD)

WCO19200 SDS1

WCO19200SD S2

WCO19200SD S4


LW 245/2 SDS2,S3

LW 240BWD EV- IS1,S2

Shell Re

Rolling

LW 245/1 SD

S2

X RayLW 245/2 SDS1


Plate MarkingBDF 450/6 WDS1,S2

Plate CuttingLW 240 TWDEV- V S1,S2

LW 240 BWDEV- V S1,S2

Plate RollingP/P Cutting

Shell ClosingLW 240 TWDEV- III S2

L Seam Set upLW 240 BWDEV- II S1


LW 240 TWDEV- III S1

LW 240BWD EV- IVS1,S2


L Seam I/SLW 240 TWDEV- I S1

L Seam BGLW 240 TWDEV- I S2

L Seam O/S

(NEW/OLD)

WCO19200 SD

S5

WCO19200

SD S4

WCO19200

SD S3


LW 245/2 SDS2,S3

LW 240BWD EV- IS1,S2

WCO19200SD S1,S2

Shell ReRolling

X RayLW 245/1 SDS2


Plate Marking

Plate Cutting BDF 450/6 WDS1,S2


LW 240 BWDEV- V S1,S2

45



Plate Rolling

P/P Cutting

Shell Closing

L Seam Set upLW 240 BWDEV- III S2





L Seam I/S LW 240 TWDEV- I S1

L Seam BGLW 240 BWDEV- II S2

LW 240 TWDEV- I S2

L Seam O/S(NEW/OLD)

WCO19200 SDS3

WCO19200SD S4

LW 240 BWDEV- II S1

L Seam FlushLW 240 BWDEV- I S1,S2

WCO19200SD S1,S2,S5

Shell Re Rolling

X RayLW 245/2 SDS2,S3


Plate Marking

Plate CuttingBDF 450/6 WDS1,S2

BDF 450/6WD S3



Plate Rolling

P/P Cutting

Shell Closing

L Seam Set up LW 240 BWDEV- IV S1,S2



L Seam O/S(NEW/OLD)

LW 240 BWDEV- II S1

L Seam FlushLW 240 BWD

EV- I S2

WCO19200 SD

S1,S2,S3,S4,S5

LW 240BWD EV- IIS2

Shell ReRolling

X RayLW 240 BWDEV- I S1


Plate Marking

Plate Cutting BDF 450/6 WDS1,S2

BDF 450/6WD S3


LW 240BWD EV- V

46



S1,S2

Plate Rolling

P/P Cutting

Shell Closing

L Seam Set upLW 240 BWDEV- III S2








L Seam O/S(NEW/OLD)

LW 240 BWDEV- II S1

L Seam FlushLW 240 BWDEV- I S2

WCO19200SD S3

LW 240BWD EV- IIS2

Shell ReRolling

WCO19200 SDS2

WCO19200SD S4

WCO19200SD S5

X RayWCO19200 SDS1


Plate Marking

Plate CuttingBDF 450/6

WD S3

LW 240 TWD

EV- V S1,S2


Plate RollingBDF 450/6 WDS2

P/P CuttingBDF 450/6 WDS1

Shell Closing

L Seam Set upLW 240 TWDEV- IV S1


LW 240 TWDEV- IV S2

L Seam I/SLW 240 BWDEV- III S1

LW 240 TWDEV- I S2


LW 240BWD EV- IIIS2

L Seam BGLW 240 TWDEV- II S1

LW 240 TWDEV- I S1

L Seam O/S(NEW/OLD)

LW 240 TWDEV- II S2

L Seam FlushLW 240 BWDEV- I S2

WCO19200SD S3

LW 240BWD EV- IIS1

LW 240 BWDEV- II S2

Shell ReRolling

X RayWCO19200 SDS1,S2,S4,S5

47



Above table shows all station wise day to day data. This data helped to

track the daily position of he job, it helped to calculate the Work in Progress,

and due to this we were also able to calculate the TPT for shells according to

day to day productions of shells.

Following are actual changes in Shell area

L Seam Setup area before

48



49



L Seam Setup area after modification

50



L SEAM FLUSH AREA MODIFICATION

PRE-PINCHING AREA AFTER MODIFICATION

51



CONCLUSION:

52



1) Shell area is visually managed.

2) TPT of shell reduced from 40 up to below 25.

3) Shell WIP maintained due to the separate allocation of areas.

4) Job searching time reduced.

5) Space utilization increased

ASSIGNMENTS:

53



1) Center marking on dished end using template.

2) Cover plate on manhole rim to avoid spatters while edge

cutting.

3) Fixture for supporting test plate during L Seam BG.

4) Work station visual in dished end area

Center marking on dished end using template:

54



Introduction:

Dished End is the part of a drum which is welded on both sides of a

barrel to form it into a capsule. Dished End’s are of 3 different type of shapes

i.e. hemispherical, torrispherical and ellipsoidal. Usually dished end are hot or cold pressed. The dished end blanks are cut in the shop and then sent for

pressing of forging.

Conventional process:

In conventional process the pressed dished are initially brought from

stores. Then, initially hook is welded to the dished end. After that the four

quadrants are been marked manually. Also 100 mm is taken on the either sides of the point. Then the dished end is tilted up side down. Then again both

points taken are used to bisect the quadrant point. Then we get another point

similar on all four sides. Then again curve is drawn from these four points.

Finally the diagonals of this curved rectangle is joined to get center.

Raw Dished End:

55



Dished End with hook welded:

Dished End tilted with quadrants marked:

56



Dished End with center marked

Problems of conventional process:

57



1) Marking time was more

2) More skill was required.

3) The process was lengthy.

Conclusion:

1) Setup time reduced.

2) Less skill required for marking.

3) Time required for center marking is much less compared to

conventional process.

58



Cover plate on manhole to avoid spatters:

Introduction:

After Dished end to manhole inside submerged arc welding the edge

cutting operation is performed on the dished end. During this the spatters are

fallen onto the machined face of the manhole.

So, after edge cutting again to remove the spatters the manhole rim

face had to be ground again. Thus, there was a type of rework which had to

be made on the manhole rim.

Actions taken:

So, To avoid the spatters on the machined face we had to prepare a

cover plate which would help to avoid the spatters to fall on machined surface

of the manhole

59



Conclusion;

Thus due to the lid of manhole type we were able to avoid the spatters

from damaging the surface of machined manhole and thus rework was

eliminated.

60



Fixture for supporting the test plate while L Seam BG:

While doing L Seam back gouging the gouging wheel remains totally

in contact with the job and is the depth is given more force is applied on the

job.When the wheel reaches near the test plate portion of the shell then

as the test plate of the shell is of cantilever type the back gouging wheel

exerts force on the test plate part. So in order to eliminate the vibration at this

section of the job it was very necessary to prepare a fixture which would

support the test plate portion. Hence we designed the fixture of such type.

61



As shown in the above figure there are two bars which are telescopic

type. The two pipes are simultaneously drilled on the drilling machine. The

inner pipe with smaller diameter fits into the outer pipe. The outer pipe and

inner pipe both are welded with 20 mm thick plate. As the inner pipe fits in

outer pipe then 16mm bolt is used to adjust the height of the fixture. Thus this

fixture can be varied from job of 750 mm to 2000 mm.

Thus due to this there was much rigidity obtained on the job and more

stiffness is at the test plate section. Also we can see that there is a jack on the

62



Work station visual in Dished end area:

The Dished end area is that area which is from raw pressed dishedend from the stores to the dished end to man hole completely welded. So it

was necessary to separately visualize these areas in order to easily identify

the areas. So, we decided to create visual display of section with photographs

showing the existing station operation, post operation and pre operation.

So the main stages of dished end area were as follows

1) Raw dished end.

2) Dished end to manhole marking and opening cutting.

3) Dished end to manhole setup.

4) Dished end to manhole inside submerged arc welding and edge

cutting.

5) Dished end to manhole back gouging.

6) Dished end to manhole outside submerged arc welding

63

project prasad

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