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HEAVY ENGINEERING

CORPORATION LIMITED

SUBMITTED BY:
VIVEK VINEET
MR.PRAKASH
CLASS: XI

SUBMITTED TO
TOPPO
SIR
(COMMERCE)

ROLL NO: 09

ACKNOWLEDGEMENTS
I owe a great many thanks to a great many people who helped and supported
me during this project. My heartiest thanks to Mr.Prakash Sir for providing me
an opportunity to make this project, and for their sincere support.
My deep sense of gratitude to SDGMs of all concerned shops, for lending their
immense support and guidance. Heartiest thanks to all the officers involved in

the training process, who sliced out their valuable time to help me during the
training schedule. A respected thanks to all the operators whose endless toil on
machines forms the backbone for running this organization, without them this
project would not have been fulfilled.
I would also thank my Institution and my faculty members without whom
this project would have been a distant reality. I also extend my heartfelt thanks
to my family and well wishers.

CONTENTS
1. Introduction
2. Heavy Machine Building Plant

Shop 010
Shop 020
Shop 030
Maintenance

3. Project Division
4. Foundry and Forge Plant

Shop 04
Shop 03
Shop 02

Shop 08
Gas plant

5. Heavy Machine Tool Plant

Shop 13
Shop 17

INTRODUCTION
Heavy Engineering Corporation or "HEC" is a Public Sector Undertaking ("PSU")
in India. It is one of India's oldest and largest engineering companies. It is the
biggest industry of its kind in Asia. HEC is under the Ministry of Heavy
Industries, Govt. of India. Established in the year 1958 as the largest integrated
engineering industrial complex in India with excellent design, engineering, and
manufacturing base. The company is engaged in the manufacture and supply
of capital equipments, machine tools and spares needed for the core sector
industries.

HEC was established in the year 1958 as one of the largest Integrated
Engineering Complex in India. It manufactures and supplies capital
equipments& machineries and renders project execution required for core
sector industries. It has complete manufacturing set up starting from casting &
forging, fabrication, machining, assembly and testing - all at one location
backed by a strong design - engineering and technology team.

UNITS:

Heavy
Machine
Building
Plant
(HMBP) :

The Plant has a fenced area of


5,70,000sq.m and a floor area of nearly
2,00,000 sq.m. It is well equipped with
sophisticated machine tools and handling
equipments to undertake manufacture of
heavy machinery and equipment of top
quality. It is engaged in design and
manufacture of equipments and
components for Steel Plant, Mining,
Mineral Processing, Crushers, Material
Handling, Cranes, Power, Cement,
Aluminium, Space Research, Nuclear
Power etc..

Foundry

Forge Plant
(FFP):

It is the largest foundry and forging


complex in India and one of the largest of
its kind in the world. The area of the Plant
is 13,16,930sq.m accommodating 76,000
tonnes of installed machinery to cope up
with the various operations effectively.
This Plant is the manufacturer of heavy
castings and forgings for various HEC
make equipments and related to Steel
plant, Defence, Power, Nuclear energy
etc.. Manufacturer of Forged Rolls for
Steel Plants, Crank Shafts for Railway
Loco etc.

HEAVY

MACHINE
TOOLS PLANT

Set up in collaboration with M/s


Skodaexport Czechoslovakia, HMTP is the
most modern and sophisticated of its kind

(HMTP):

Projects
Division

in the country which produces machine


tools in heavier ranges. The Plant covers
an area of over 2,13,500sq.m. It designs
and manufactures medium & heavy duty
CNC and conventional Machine Tools for
Railways, Defense, Ordnance factories,
HAL, Space and other strategic sectors.

Design, Engineering and execution


of Turnkey Projects related to Bulk
Material handling, Steel Plant projects,
Cement Plant and other sectors.

Major Achievements

Over 550 thousand tons of equipment manufactured and supplied to Steel Sector.
Significant contribution in setting up of Bokaro and Vizag. Steel plant.
Equipment supplied for expansion of Bhilai Steel Plant.
Supplied to almost all the Steel plants of India.
Supplied over 580 Excavators (of 4.6 /5 /10 CuM capacity)
Supplied 12 numbers of 24 CuM Draglines.
Supplied over 10 numbers of Heavy Duty Gyratory 1500 TPH crushers.
Manufactured over 300 numbers of Cranes.
Supplied over 900 Machine Tools.

Cyclotron Magnet Poles


HEC successfully manufactured Magnet Poles and associated components for VECC
(Department of Atomic Energy) and supplied in the year 2002.

Exceptionally low carbon steel. Variation in carbon content within 0.07% and other
elements within 0.10%.
Ultra clean steel, free from alloying & tramp elements and gaseous contents.
Very high homogeneity level.
Control of grain size and micro structure to ensure best magnetic permeability.
Free from non-metallic inclusions and other ultrasonic defects.
Precision machining of complex geometry shapes.

Shop 010
Specifications:1.
2.
3.
4.
5.

Area of the workshop- 21,012 sq. M


Storage area(open)- 6180 sq. M
Total ntotal number of machines- 74
Special machines-27
VTB maximum capacity- 14 m (diameter)
4.7m (height)
250 T (weight)
6. Horizontal Boring Machine maximum capacity
Spindle- 320mm
Job- 5m X 9m X 18 m
7. Plano Milling Machine maximum capacity
Length -7m
Breadth -3.5 m
Height- 2.7 m
Weight- 120 T
8. Specifications of crane
Machine workshop
Number of cranes-10
Capacity 150 T
Assembly workshop
Number of cranes 5
Capacity 150 T
9. Assembly area 7060 sq. M
10. CNC machining 3
VBT 1
Plano Milling 1
Horizontal boring 1

SHOP 020
(MEDIUM AND SMALL SCALE MACHINING WORKSHOP)

VERTICAL TURNING AND BORING MACHINE

Table size: 4000 mm


Spindle size: 1500 mm
Maximum height of job: 190 mm
Capacity: 35 T
Maximum speed: 7.8 rpm
Feed rate: 0.42 mm/sec

W200 HORIZONTAL BORING CNC MACHINE

1.
2.
3.
4.
5.
6.
7.
8.

Boring spindle diameter: 200 mm


RAM dimension: 520X520 mm
Taper in spindle: 60 ISO
Spindle travel: 1962 mm
Ram travel: 1600mm
Headstock travel in column y axis: 5000 mm
Column travel on bed x axis: 18000 mm
Working feed: 1-6000 mm/min

030
SPECIFICATIONS OF THE SHOP:
1.
2.
3.
4.
5.
6.

Building area: 87.6 sq. M


Open gantry area: 2880 sq. M
Number of machine tools: 66
Number of unique machine tools: 15
Maximum plano milling capacity: 85 X 2.5 X 2.5
Maximum gear Hobbing capacity:
Diameter: 5800 mm
Module: 30
7. Maximum rack cutting capacity: 2500 X 350 mm
8. Induction hardening facilities:
Length: 5000 mm
Diameter: 4000 mm
9. Stress relieving tempering furnace cap: 7.5 X 2.4 X 4.5
10.
Overhead material handling capacity:
Number of cranes: 8
Maximum capacity: 50 T
11.
Assembly shop area: 2900 sq. M
Number of cranes: 2
Maximum capacity: 75 T

OUTPUT:
Gear boxes for cranes, excavators, draglines etc.

PROJECT DIVISION
The project division of HEC mainly handles projects which are related to material handling.
The process of tendering to execution takes place as per the following procedure:
1.
2.
3.
4.
5.
6.

Tender notification
Discussions
Submission of query
Price opening(L1)
Order
Execution
- Inquiry
- Purchase

Scrutiny
Drawing
Monitoring

SHOP 04
(MACHINE SHOP)
Some machines that were studued:
Lathe machine:
Machine number: 1004
Type: SR 1000 X 5000
Distance between centres: 5000 mm
Swing over bed: 1000 mm
Swing over carriage: 710 mm
Maximum weight of job: 10 MT

Low frequency Induction Hardening Machine:


Machine number: 4026
Barrel diameter: 300-650 mm
Job weight: 15 T (max)
Power output: 1000 KW (max)

FOUNDRY TECHNOLOGY
(SHOP 02)

A foundry is a factory that produces metal castings. Metals are cast into shapes by melting
them into a liquid, pouring the metal in a mold, and removing the mold material or casting
after the metal has solidified as it cools. The most common metals processed
are aluminum and cast iron. However, other metals, such
as bronze, steel, magnesium, copper, tin, and zinc, are also used to produce castings in
foundries.
Melting:
Melting is performed in a furnace. Virgin material, external scrap, internal scrap, and alloying
elements are used to charge the furnace. Virgin material refers to commercially pure forms
of the primary metal used to form a particular alloy. Alloying elements are either pure forms
of an alloying element, like electrolytic nickel, or alloys of limited composition, such as
ferroalloys or master alloys. External scrap is material from other forming processes such as
punching, forging, or machining. Internal scrap consists of the gates, risers, or defective
castings.
The process includes melting the charge, refining the melt, adjusting the melt chemistry and
tapping into a transport vessel. Refining is done to remove deleterious gases and elements
from the molten metal to avoid casting defects. Material is added during the melting process
to bring the final chemistry within a specific range specified by industry and/or internal
standards. During the tap, final chemistry adjustments are made.

MOULD MAKING:
In the casting process a pattern is made in the shape of the desired part. This pattern is
made out of wax, wood, plastic or metal. Simple designs can be made in a single piece or
solid pattern. More complex designs are made in two parts, called split patterns. A split

pattern has a top or upper section, called a cope, and a bottom or lower section called a
drag. Both solid and split patterns can have cores inserted to complete the final part shape.
Where the cope and drag separates is called the parting line.
When making a pattern it is best to taper the edges so that the pattern can be removed
without breaking the mold. This is called draft. The opposite of draft is an undercut where
there is part of the pattern under the sand making it impossible to remove the pattern
without damaging the mould. The molds are constructed by several different processes
dependent upon the type of foundry, metal to be poured, quantity of parts to be produced,
size of the casting and complexity of the casting. These mold processes include:

Sand casting Green or resin bonded sand mold.

Lost-foam casting Polystyrene pattern with a mixture of ceramic and sand mold.

Investment casting Wax or similar sacrificial pattern with a ceramic mold.

Ceramic mold casting Plaster mold.

V-process casting Vacuum is used in conjunction with thermoformed plastic to form


sand molds. No moisture, clay or resin is needed for sand to retain shape.

Die casting Metalmold.

Billet (ingot) casting Simple mold for producing ingots of metal normally for use in
other foundries.

Pouring
In a foundry, molten metal is poured into molds. Pouring can be accomplished with gravity,
or it may be assisted with a vacuum or pressurized gas. Many modern foundries use robots
or automatic pouring machines for pouring molten metal. Traditionally, molds were poured
by hand using ladles.

Shakeout
The solidified metal component is then removed from its mold. Where the mold is sand
based, this can be done by shaking or tumbling. This frees the casting from the sand, which

is still attached to the metal runners and gates - which are the channels through which the
molten metal traveled to reach the component itself.

Degating
Degating is the removal of the heads, runners, gates, and risers from the casting. Runners,
gates, and risers may be removed using cutting torches,bandsaws or ceramic cutoff blades.
For some metal types, and with some gating system designs, the sprue, runners and gates
can be removed by breaking them away from the casting with a hammer or specially
designed knockout machinery. Risers must usually be removed using a cutting method (see
above) but some newer methods of riser removal use knockoff machinery with special
designs incorporated into the riser neck geometry that allow the riser to break off at the right
place.

Lathe
CNC Centre Lathe specification

Swing over Carriage 650 1000 mm


Distance between centres 3 6 metre
Max. wt of work piece 8 15 MT
CNC System - Fanuc / Siemens (2 axes)
Centralised lubrication
8 station programmable turret
2 Stage high efficiency transmission head stock
Spring clamped - Hydraulic unclamped tail stock

CNC Roll Turning Lathe specification

Swing over Carriage 650 1600 mm


Distance between centres 3 10 metre
Max. wt of work piece 8 50 MT
CNC System - Fanuc / Siemens (2 axes)

Special Purpose Railway Macine Tools


CNC Under Floor Wheel Lathe

Gauge 1676 mm
Max./Min. tread dia 1250 / 700 mm
Uncoupled axle distance 1600 mm
Coupled axle distance 1500 2650 mm
Max. Axle load 25 MT
Max. Axle load 1889 2750 mm

CNC Surface Wheel Lathe

Gauge 1676 mm
Max./Min. tread dia 1250 / 700 mm
Max. axle distance 2750 mm
Min. axle distance 1850 mm
Max. weight of wheel set 3.5