ORIGINAL Project 8th Sem

LARSEN AND TOUBRO LIMITED
S.B.M.P., MUMBAI
ENROLLMENT NO. 0705068
SUBMISSION CERTIFICATE
I, DAVE HIRENDRA B. Roll No. Y720059, a student of fifth semester of Diploma

course in Mechanical Engineering, hereby submit my report.
The In-plant Training work as described in this report is completed by me with

own skills and study from 1st December 2010 to 30th May 2011 as per guidance of
Mr. Ankush Jadhav..
I certify that I have not copied the report or its any appreciable part from any
other literature in contravention of academic year.
ROLL NO : Y720059
Date: ____________
S.B.M.P., MUMBAI
Signature:
____________
S.B.M.P., MUMBAI
NO OBJECTION CERTIFICATE
This to certify that Mr.DAVE HIRENDRA BHUPATRAI
student of SHRI
BHAGUBHAI MAFATLAL POLYTECHNIC,VILE PARLE has completed his In-plant

training from 01/12/2010 TO 30/05/2011 in our Quality Control Department at M/s.
Larsen & Toubro Ltd . Powai Campus.
He has been allowed to include the documents, data and sketches for which we
have no objection.
S.B.M.P., MUMBAI
ANKUSH R JADHAV
( Asst. Manager,QC FPEX )
M.S.RAJU
( Sr. DGM, QC-FPEX )
ACKNOWLEDGEMENT
The success of my training at LARSEN & TOUBRO LTD., POWAI
CAMPUS is not only due to my work alone, but also due to interest, help & guidance
offered to me by employees of the company.
I would like to express my deepest sense of gratitude to Mr. M.S.Raju
(Sr.DGM - QC-FPEX),
QC-FPEX), Mr.Ankush Jadhav & Mr. Pankaj Sachdeva for their valuable
guidance, their helping hand & fruitful advice during my projects, which gave me
immense confidence and widened my knowledge.
I cant forget, Mr Abhishek Waravadekar , Mr Kiran Pagar, Mr SAGAR
BOGWAD for guiding and encouraging me throughout my work. Last but not the least; I
would like to appreciate the kindness & co-operation extended by all the employees &
the trainees in the department that helped in making my training a grand success.
S.B.M.P., MUMBAI
Above all, I am deeply grateful6 to R.R.Ambade (Training Supervisor) of

S.B.M.POLYTECHNIC for giving me this opportunity to undergo this training
successfully.
This report is an account of my experiences and the knowledge

gained while working at M/s LARSEN AND TOUBRO LTD., during my in plant
training.
Since, I was placed in QC-FPEX,
QC-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 the INSPECTION & QUALITY
CONTROL Department, 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 like HTR, DCR, OPERATION CARD, NCR, QCP, PROCEDURES,
and PROGRESS REPORT. I also have the experience on BAAN.
S.B.M.P., MUMBAI
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
S.B.M.P., MUMBAI
Sr No
Page
No.
Topic
INTRODUCTION TO LARSEN &

TOUBRO.
INTRODUCTION TO HEAVY
ENGINEERING DIVISION.
INTRODUCTION TO INSPECTION
DEPARTMENT.
MY ROLL IN MY DEPARTMENT
5
6
CONCLUSION.
BIBLIOGRAPHY.
CHAPTER 1
INTRODUCTION TO L&T
Larsen & Toubro Limited (L&T) is a technology-driven engineering and
construction organization, and one of the largest companies in Indias private sector. It
has additional interests in manufacturing, services and Information Technology.
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9
Two Danish engineers, Henning Holck-Larsen
and Soren Kristian Toubro
founded L&T, in 1938. Beginning with the import of machinery from Europe, L&T rapidly
took on engineering and construction assignments of increasing sophistication. It now
has a major presence in key sectors of the economy.
A strong, customer-focussed approach and the constant quest for top-class quality
have enabled the Company to attain and sustain leadership in its major lines of
business across seven decades.
With factories and offices located around the country, further supplemented by a
comprehensive marketing and distribution network, L&T enjoys an image and equity in
virtually every district of India.
The Company has an international presence, with a global spread of offices and
joint ventures with world leaders. L&Ts large technology base and pool of experienced
personnel enable it to offer integrated services in world markets.
L&T is Indias largest builder of world-class, custom-made engineering equipment
with logistics capabilities of supplying it to a tight delivery schedule worldwide. It has
globallyBenchmarked workshops at Powai in Mumbai, Hazira and Baroda in Gujarat,
and Kansbahal in Orissa.
L&T are consistently expanding the magnitude, scope and range of its operations
to offer value-addition to client and shareholder alike. With its unique strengths
technological sophistication, quality consciousness, top-class manpower L&T strides
into the future, confident of conquering the challenges ahead.
The Beginning: L&Ts record of outstanding achievements coupled with its European name lead
many to believe that it is the Indian arm of foreign corporation. The truth is that genesis
S.B.M.P., MUMBAI
10 up by two Danish engineers Mr. Henning

was very much on the Indian soil. It was set
Holck Larsen & Mr. Soren Kristian Toubro in 1935 to asses the value of various cement
manufacturing groups on behalf of F.L.Smith & Co. After having completed their task
they stayed in India to open F.L.Smiths local office. During course of their work they
came to know about India and there people & decided to build their own business.
They started a partnership concern on 1
St.
May 1938 in Bombay and started
undertaking the repair jobs on the improved machinery.

In 1944, the company stepped into the construction business and started the
Construction Company Engineering Construction Company (ECC.) Later the company
became private limited on 7 Th. February 1946. In the early 50s L&T has became public
company limited.
L&T at Present: Within span of four decades L&T has achieved leadership position in designing,
manufacturing & installing plants & equipment for vital industries.
Today it projects many-sided image of an organization involved in over thirty
distinct fields of engineering. It has gradually expanded over the years with its branch
offices at Madras, Ahmadabad, Lucknow, Bhopal, Chandigarh, Durgapur, Rurkela etc. It
employees about 25000 personnel. At present L&Ts turnover ranks third largest
companies in India (Rs.7423 crores for the year ended 1999). In 1994, the ISO 9001
certificate was awarded to group three of L&T. Over the years of its existence, the
company has established a reputation of having a strong customer orientation,
technological sophistication displayed by its products and projects, and an impression
record of achievements.
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11
LARSEN & TOUBRO LIMITED
Company
:Public limited
Founded
:In the year 1938
No. Employees
:25,000
Turnover
:USS 10 Billion
(Rs. 43000 Cr.)

Market Capital
:USS 20 Million
(Rs. 250 Cr.)

No. Of Share Holders
: Approx. one million
Overseen By
:Board of directors
Head office
:India, USA, Oman, Nepal
&
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12
Factories
Malaysia
:26 spread over 20
location
CHAPTER 2
L&T HEAVY ENGINEERING DIVISION
Figure1. Overview of Powai , campus
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13
INTRODUCTION: Heavy Engineering deals with the marketing, designing, engineering and
manufacturing of one off equipment and machinerys required for basic industries
in the core sector, such as Fertilizer, Chemical, Petrol Chemical Power, Cement,
Nuclear, Aerospace, Defense, Oil, etc. The unit is headed by a Vice President and
has manpower of over 3000 personnel, including 1000 at Hazira works near Surat.
L&T's Heavy Engineering Division activities are organized under self-reliant
Strategic Business Units (SBUs) catering to the needs of core sector industries
through supply of equipment to Process Plant Industries and Defense, Nuclear
Power & Aerospace Sectors. 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 six decades. Heavy
Engineering Division has the state of the art manufacturing facilities, which are
capable of meeting the challenges of technology, quality conformance & delivery,
while ensuring cost competitiveness.
HED Fabrication shops have a built-up area of 46,000 sq.m & equipped with
sophisticated facilities for fabrication, machining, handling and quality control. The
Division's advanced technology and high standard of specialization facilitate the
manufacture of high quality heavy equipment of thick nesses up to 250mm in monoblock construction with individual sections weighing over 300t.
Specialized fabrication facilities include:
CNC-controlled gas/plasma profile cutting machine.
Edge planning/milling machine.
S.B.M.P., MUMBAI
14 an area of 400 sq.m.

100,000 class dust-free enclosure with
1000t hydraulic press.
Heavy-duty plate bending rolls of capacity 90mm thickness in cold and 180mm
thickness
in hot condition.
Deep hole drilling capabilities of up to 900mm thickness.
CNC horizontal boring machines with 200mm spindle dia
CNC vertical boring machines of up to 8500mm dia. and 60t load
Facing and turning lathe of 6000mm dia & 100t weight between centers
Welding machines for a variety of processes (SAW, TIG, MIG, automatic pulse
TIG
tube-to-tube sheet welding, strip cladding, FCAW over-lay, internal bore welding,
etc.
STRATEGIC BUSINESS UNITS: Business activities of Heavy Engineering are overseen by three self reliant
Strategic Business Units (SBUs). These three SBUs are formed on the basis of
following sub-divisions:
Apart from marketing teams, SBUs comprise of design and engineering teams
who work on state of art software packages developed in-house on account of our
being member of HTRI, USA & HTFS, UK. The design teams are supported by
specialized thermal engineering teams for carrying out thermal sizing of different
Heat Transfer processes for the customers basic process data, check rating of
already thermally sized designs, flow induced vibration analysis etc. A specialized
design team is available to carry out stress analysis using Finite Element method.
SBU CODE
S.B.M.P., MUMBAI
SBU DESCRIPTION
FPEX
15 Transfer Equipment
Fertilizers, petroleum & Heat
Business
CGPP
Coal Gasifier & Thermal Power Plant Equipment Business
RCOG
Refinery, Cracker Plant an Oil & Gas Equipment Business
TECP
Technology Development Center for Process Plant.
PRCP
VPs Office- SBU Cluster B
SPLP
VPs Office- SBU Cluster C
AERO
Aerospace & Aviation
MARI
Marine Equipment & Systems
NUCL
Nuclear Business
WSAS
Weapon System & Sensors
ARMY
Army Business
TECS
Technology Development Center for Special Projects
IBCU
International Business Coordination Unit
PRODUCTS
L&T fabricate ultra high pressure - high temperature equipment using a wide
variety of materials of thickness ranging from 2 mm to 250 mm for various
applications. The equipment can be manufactured and supplied in monowall or
multiwall construction depending upon design requirements. Our Workshops have
been approved by Snamprogetti, Stamicarbon, Lloyds, TUV, UHDE, Kellogg, TEC,
EIL, BV, ISO, IBR ...
The products manufactured by us is in accordance with major international codes
like ASME, AD Merckblatter, AS, BS, JIS, ISO, IBR ... More than 4000 welding
procedures have been qualified.
S.B.M.P., MUMBAI
16 range of materials including:

The products manufactured covers wide
Carbon and Carbon Manganese steels
Urea Grade/Duplex/Austenitic/Martensitic & Ferrite Stainless Steels
Low Alloy creep resistant and High Temperature Steels
Low Alloy Steels & High Alloy Steels
Ultra high strength Cr-Mo V Steels and Maraging Steels
Non-ferrous metals such as Ni, Ti, Cu-Ni, Zr, Inconel, Monel, Ta, and Hastelloy...
Clad Steels in various configurations & materials indicated above

EQUIPMENTS
Reactors & Pressure Vessels: Columns & Towers: Heat Exchangers: SITE WORK & AFTER SALES SERVICE
Site work
After sale service
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17
CHAPTER 3
INTRODUCTION TO MY (INSPECTION)
DEPARTMENT
INTRODUCTION
Quality control is one of the most important aspects of engineering today.
Because of the requirement of higher quality standards & fierce competition in the
engineering field, the importance of inspection department has been very much
emphasized. The quality requirements of a particular job are mentioned in the
specifications & the inspection has to work according to those specifications to maintain
the quality. For this, individual member of the department, who is called as inspector,
may be required to carry out different tests & inspection activities.
First of all, all the inspector should be a qualified quality control engineer in order
to carry out those tests & inspection activities, which also should be as per the customer
and the job requirements. Inspection is the department, which releases the job for
S.B.M.P., MUMBAI
further work; thus it is the last department in18the sequence of manufacturing process. So
the role of inspection department is to find out or point out or detect the flaws in the job
at any stage in the manufacturing cycle & get it rectified from them. Thus a major chunk
of the quality standard requirements rests on the inspection department.
Depending upon the stages of inspection department is divided into few groups
such as:
Powai central stores (PCS) inspection.
Plate preparation shop (PPS) inspection.
Fabrication shop inspection.
POWAI CENTRAL STORES (PCS) INSPECTION

PCS inspection, also known as Receipt Stores inspection, is responsible for
inspection of incoming raw materials which are in the product from & which are being
sub-contracted to the vendors. e.g. forging hardwares, external attachments etc
The inspector in this department reviews the test certificate (TC) of the product &
confirms that the material supplied by the vendor is as per TC. After ensuring this, the
inspector makes Material Clearance Record (MCR) & releases the material for further
inspection.
PLATE PREPARATION SHOP (PPS) INSPECTION

PPS inspection is concerned with the inspection of raw material, which is in the
plate form. The company keeps the plates in spare & uses it for the job as & when
required. The inspector in PPS inspection ensures that the plate being taken in use for a
job confirms to the requirement of that job. Once this is ensured, the inspector makes
MCR & releases the plate for further inspection.
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19
FABRICATION SHOP INSPECTION

The two major activities of this department are:
In-process inspection.
Final 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 job is over & the
inspection work mainly consists of the overall final dimension check of various
components of the job.
FUNCTIONS OF INSPECTION DEPARTMENT

Raw material inspection.
Quality & standard of the product.
As the part In-process inspection.
Final inspection.
Maintain of management.
Implementation of ideas.
Documentation.
RAW MATERIAL INSPECTION

Inspection department identifies the required raw material; it should be as per the
required:
Size
Shape
Quality
Quantity.
IN PROCESS INSPECTION
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Inspection department inspect20the product, when it is under production, by

applying various inspection techniques (destructive & non destructive). If any
problem is there, it is rectified at the instant of detection. So, in future it will not
create any cause of concern & reduce the work & there is time saving.
FINAL INSPECTION
Inspection department inspects the product prier to the time of dispatch.
Inspection department has to inspect:
Final dimension of the product.
Appearance of the product.
Packing & loading of the product etc.
MAINTAIN QUALITY & STANDARD OF THE PRODUCT

There is a very important function of inspection department as far as
quality of the product is concerned. As the inspection is done at every stage,
such as:
Raw material inspection
In-process inspection
Final inspection
All these activities lead to the following production parameters:
Reduce the work
Shorten the production cycle.
Increase the production rate.
Increase the quality 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
maximum quality conformation.
IMPLEMENTATION OF IDEAS
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21 Design Change Requirements (DCR), if

It plays an important role in issuing
any alteration to be made in the original blue print. If a particular dimension or

part is not according to the drawing or specification & if a design change is not
feasible then, it stands out as an non-conformity in the project.
DOCUMENTATION
This department prepares all the documents related to:
Raw material of product.
Tests carried out & result obtained.
Final product.
In short inspection department has to perform the following activities.
Preparing inspection checklist
Witnessing different tests such as Hydro-test & other NDTs.
Co-ordination with QA (Quality Assurance) Dept. For different gauges to

be used for inspection tests.
Co-ordination with third party or inspection agencies for clearing

inspection stages.
Reporting non-conformities for deviations, if any.
Preparing a list of balance work on job.
In-process inspection of set-up, dimensions, seam finish etc.
Preparing final document such as:
L&T compliance certificate.
Reports of various tests.
PTC, PT& MT reports.
Seam wise welders record.
Obtaining release note from third party / inspection agencies.
INSPECTION REQUIREMENTS
Material identification.
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Material cutting.
22
Forming of pressure equipment components.

Dimensional tolerances on formed components and pressure equipments.
Assembly of joints prior to welding.
Welding procedure qualifications.
Welding consumables.
Welding equipment.
Condition prior to welding.
Condition during welding.
Weld non-destructive examination.
Repair of welds.
Production test plates.
Heat treatment.
Final cleaning, surface treatment.
Protection for transport.
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23O N I A C O N V E R T E R
STUDY PROJECT ON AMM
GENERAL
1.1 INTRODUCTION
More than 99 % of the world nitrogen fertilizer production is based on the

production of ammonia. Ammonia is basically produced from air, water & energy.
The source of energy is normally from coal or hydrocarbons that are reacted with
water at high temperature and electricity to drive the compressor.
A modern ammonia plant has a typical capacity of 1000/2000 t/d per stream.
About 85% of ammonia production is based on steam reforming concepts. A
typical ammonia plant is shown in Figure 1.
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24
For synthesis of Ammonia the converter may be of two types:

1. Axial Flow
2. Radial Flow
In both the processes, the reaction is in the basket, and the converter shell is
the vessel for holding the pressure. The special advantage of the radial converter is
to allow the use of the catalyst small particles without a prohibited pressure drop.
The average lifetime of the catalyst is around 10 years but at high temperature the
reaction is fast and hence the deterioration of catalyst too. Lower temperature
decreases catalyst activity & hence provide high lifetime. Ammonia concentration
at the converter inlet should be minimum as it gives high reaction rate & thus a
high production capacity. Inert gas (Ar) dissolved in the liquid ammonia product is
flashed off in the let down vessel where the pressure is decreased to 25 kg/cm 2 g.
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25
Process condensate used like CO2, Methanol,
ammonia separated at different
pressure with the help of steam.
Before the material comes to shop floor for fabrication process, it has to
go through following cycle:
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26
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27
ACTIVITIES OF QUALITY CONTROL
Inspection Planning
In-Process Inspection
Final Inspection
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1.
2.
3.
4.
Quality Control Plan

Inspection Checklist
Inspection Procedures
Inspection Formats
Material Inspection : At Supplier &

after receipt
2.
Visual Inspection
3.
Dimensional Checks
4.
Welding Inspection
5.
Heat Treatment
6.
NDT (RT/UT/PT/MT, Hardness,
Ferrite etc)
Final Dimensional Check

Pressure Test ( Hydro/Pneumatic )
Leak Test
Surface Preparation & Painting
Final Stamping
Documentation
Packing & Despatch Check
28
CALIBERATION:
Instruments Calibrated to National / Manufacturers /

International Standards.
Written Procedures for Calibration.
Unique Identification of Instruments with display.

of Calibration Status.
Positive Recall System with reference to.

Calibration Programme.
Calibration Records maintained.
MAIN PARTS REQUIRED IN THE MANUFACTURING PROCESS OF

AMMONIA CONVERTER ARE AS FOLLOWS:
Plates
Dish Ends
Nozzle Forgings
Flanges
Gaskets
Fasteners
Pipes
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30
FASTENERS
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31
MATERIAL INSPECTION
1. Material Identification & Marking
2. Dimensional Check :
L x W x thickness
3. Visual Inspection :
Pitting , Damage, Lamination
4. Material Test certificate

Transfer of Markings :
Item, Project, Material Spec.,Heat No. / Plate No.
Check test (PMI) :
PLATES
FORGINGS
If required by customer specification .
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PIPES
32
FORGINGS
TRANSFER OFTUBESHEET
MARKING:
Transfer of marking is basically done for identification of the same material
whenever it will be come in use again in future.
e.g. suppose if the one long plate is taken then it must be having its own
identification as heat no., supplier punching, third party punching etc. now if this
plate is to be cut in two different parts then this all information is transferred to the
other part as it is so that both the part is having their own identification marks
which will be useful to identify the parts.
70
Gr 0004
6
76
67
51
SA t no. 4000
.
a
He e no
t
Pla
v
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33
70
G r 0004
6
76
67
51
SA t no. 4000
.
a
He e no
t
Pla
TRANSFER OF MARKING
TO ENSURE TRACEABILITY TO THE DRAWING PART & MTC
GENERAL ASSEMBLY DRAWING

AMMONIA (NH3) CONVERTER.
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34
PLATE CUTTING & WEP PREPARATION:
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35
L
ROLLING DIR.
No Hard Punching on
SHELL PLATE
1) FM Below 6 mm thick
2) NFM Below 12 mm thick
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36 innermost point.
Mark a reference line 100mm from
The reference line should be only at one location as indicated above.

Minimum 3mm machining allowances taking on either side of the plate.
The difference in diagonal /d1-d2/ = 1mm (max.)
For making the plate a perfect square, reference line is taking from the
machined face at all sides.
Round-off edges of plate to 3R minimum.
WEP (weld edge preparation) is dose on edge planning machine.
Both edges of shell plates longitudinal seam edge to be machined as per
drawing given.
Then the plate is sending for inside surface shot blasting.
EDGE BREAKING :
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37
PLATE EDGE BREAKING

Plate edge breaking is carried out on press machine with the help of lode
edge breaking die.
Edge breaking is done in cold condition.
Bow in the plate edge is corrected within 1mm if present.
Shape is checked with template.
The same is corrected on the other side of the plate.
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ROLLING OF SHELL:
38
ROLLING OF SHELL
After shot blasting & edge breaking rolling is done at room temperature.
No. Of rolling passes as per thickness of plate & pressure applied
CHECKING OF SHELL PROFILE, OVALITY & CIRCUMFERENCE:

Checking shape with d/4 template during rolling from inside and outside
with 2D ply (1/2 thk) template of D length.
Maximum gap with template is allowed to 1mm.
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39
D/4 TAMPLET
PEAK OUT
PEAK IN
ID max - ID min = 0.5 % (1% of Nominal ID as per ASME )
ACTUAL THK.
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I/D CHECK IN HORIZONTAL P
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41
D/4 Template
D/4 Template
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42
Peak Out
LONGITUDINAL SET-UP OF SEAM

Position the shell on fixture saddle with long seam at 6o clock.
Insert offset correction box beam at vertical section into the shell, rest it on
vertical support column.
Correct offset in shell long seam with the tightening or loosening of bolt of
box beam.
Provide jack support from bottom wherever required & correct the skew in
the shell.
Then tacking is done in the long seam.
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43
INSPECTION OF LONG-SEAM SETUP

Check for material identification, item no., and shell course no.
Check weld groove geometry i.e., land angle root gap etc.
Check offset.
Check circumference at both ends and at center.
Check ovality & shape with (d/4) template.
Check tacking on the longitudinal seam as also tacking of supports etc.
Tacking should be free from defects like undercut, cracks, porosity
improper fusion etc.
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44 coupons / production coupons plates if

Check tacking of the run-in/run-out
required.
Check longitudinal as well as circumferential edges for lamination etc.
PREHEATING OF LONG SEAM:

Preheating involves heating the base metal, either in the entirely or just the
region surrounding the joint to specific desired temperature called the pre-heat
temperature.
Heating may be continued during the welding process, but frequently the
heat from the welding is sufficient to maintain the desired temperature without
continuation of the external heat source.
In determining whether or not to preheat, the following should be
considered: code requirement, section thickness, base metal chemistry, restraint,
ambient temperature, filler metal hydrogen content & previous cracking
problems.
In general preheat is usually not required on low carbon steel less than
1in (25mm) thick. However as the chemistry, diffusible hydrogen level in weld
metal, restraint or section thickness increases, the need for preheat is also
increases.
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45
WHY PREHEATING:
It slows the cooling rate in the weld metal & base metal, producing a more
ductile metallurgical structure with greater resistance to cracking.
Slower cooling rate provides an opportunity for hydrogen that may be
present to diffuse out harmlessly reducing the potential of cracking.
It reduces the shrinkage stress in the weld and adjacent base metal , which is
especially important in higher restrained joints.
It raises same steel above the temperature above the temperature at which
brittle fracture would occur in fabrication.
INTERPASS:
The interpass temperature is the base metal temperature at the time of
welding is to be performed between the first & last welding process,
cannot be permitted to fall below the preheat temperature.
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46
LONGITUDINAL SEAM WELDING:

Longitudinal seam welding directly start from inside by SAW welding &
the equipment used is SAW boom.
Strictly maintain the interpass temperature of ~250C.
Weld up to 2/3rd of depth from inside & kept balance 1/3rd
Then immediately check with the metallic template & decide change in
depth of welding based on intermediate shape check
Carryout post heating after completion of partial of partial I/S welding by
putting glasswool covering from inside.
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Then take out the welding boom 47

and remove the offset correction beams by
EOT crane.
Then check the shape & ovality after completion of partial longitudinal
seam welding by the metallic template & fill in the parameter-monitoring
chart.
Provide low velocity candle burners with hood from inside without starting
the burner.
Lower the jack & rotate the shell so that long seam will come at topmost
position
Move trolley along with shell to chip-back grinding station (handling of
shell with crane in half-welded condition strictly prohibited).
Then carry out the long-seam chip-back grinding & check chip-back
configuration with the template, ensure sufficient quantity of templates &
record the chip-back depth.
Clear hot magnetic particle test
Then move the trolley to chip-back welding station, put the hose
connection & start the burners, position & tack the dischargeable
thermocouples at required locations at 100mm on either side of the long
seam on outside surface.
S.B.M.P., MUMBAI
48 welding by SAW boom & record

Carryout long seam chip-back
temperature during welding.

Weld temper beads from outside, refer WE procedure.
Carry out post-heating by putting glasswool from out-side &burner from
inside.
Check the shape and ovality at the end of the chip-back welding by the
metallic template & fill the parameter-monitoring chart.
Rotate the trolley so that long seam will come at bottommost position &
move the trolley to the balance longitudinal seam welding station.
Put-on outside burner, position & tack the outside the thermocouples at the
required locations.
Weld balance long seam from inside by SAW boom & record the
temperature
Weld tempers beads from inside by referring WE procedure.
Put glasswool blanket from inside over the seam & complete the postheating of shell long seam.
Gas cut the run-in & run-out plates, ensure min. 200C while gas cutting.
S.B.M.P., MUMBAI
49allow seam to cool down still in still air ,

Put -off burner, remove blanket &
temperature should be recorded continuously from start of preheating to

the completion of post-heating.
Check the shape, ovality, & bow at the end of the complete welding & fill
the parameter-monitoring chart completely.
Then move the trolley to seam flush grinding station & grind the weld
seam flush/underflush from inside & outside
Ensure that the thickness of the shell-course dose not fall below the
thickness mentioned in the drawing.
Carryout the long seam PT (penetration test) & UT (ultrasonic test) & then
position shell into furnace.
Carryout ISR as per HTR & shape correction by rolling machine & fill the
parameter monitoring chart completely.
Clear shape, ovality, circumference, NDT (RT), touch up by inspection
department & then release the shell for shrink fitting.
INSPECTION OF SEAM FINISH

Inspect the root run for penetration.
S.B.M.P., MUMBAI
50
Check the dressing of weld from
inside / outside for adequacy for
radiography / ultrasonic testing.

Check for presence of any undercuts or excess reinforcement and offsets.
Check the inter-bead valley and undercuts.
Check for weld Finnish requirement as per drawing. Welds shall be ground
flush (or) Welds shall be ground smooth concave contour etc.
Check 1 2 width on either side of seam for ripping / arcing.
Check whether welding process used on seam is same as required by weldplan.
PRODUCTION TEST COUPON (PTC):
Welded production test plates representative of the complete vessel shall be

prepared & tested to check the quality of weld.
All conditions for the welding of production test plates shall be similar to
the production welding of the vessel.
Test plate shall be made from the same standard, grade & manufacturing
process as that of the material used in the construction of the vessel.
It is recommended that the test plate shall be taken from the same plate
used in vessel or from a different plate of the same batch.
S.B.M.P., MUMBAI
51 size required is : The minimum production test plate
1. 150mm wide for steel <= 6mm thick

2. 225mm wide for steel > 6mm thick & for nonferrous metal <= 6mm
thick
3. 300mm wide for nonferrous metal >6mm thick.
The ammonia converter required shell of thickness around 235 mm. so as per
the drawing five different sub shell of concentric diameter are rolled and then
after finishing of all the five sub shell, they are put in to one other one by one
to form a shell of required thickness. This is done by the process of SHRINK
FITTING the diameter of the final shell is maintained.
SHRINK FITTING
S.B.M.P., MUMBAI
52
PROCEDURE FOR SHRINK FITTING

The outer layer of the shell is taken in to the furnace and attaches all the
thermocouples at the specified position.
Then outer layer is heated in the furnace, so that it sufficiently expands for
shrinking the cold shell into it.
The heating rate, temperature and hold time are specified and do not exceed
the limits of the material in relation to its properties.
Cooling from the shrink stress in either in still air or in the furnace.
The shrink fitting of the shell is done in such a way that long seams of
the each sub shell should come in the orientation as shown in the
drawing.after completion of shrink fitting the shell is subjected to reference
line marking and DEGREE MARKING (0, 90, 180 & 270) TOP &
BOTTOM side of the shell is also marked with the help of punching on the
shell. & then the shell is again offered for inspection.
VISUAL CHECK & GAP CHECK:
S.B.M.P., MUMBAI
53
There should be no dust particles
or burrs (observed during gap check)
in the interlayer gaps. Insist of cleaning the same before start of gap checking
Check and note the orientation of seams. (This is required at every gap check
stage subsequent to shrink fitting) Confirm the top / bottom side or left / right
side of shell and note the same.
Each of the sub shell is with its own identification, so before gap check first
the identification punching of the shell near the long seam of the shell &
long seam no. (LW115, LW110 etc.) is checked.
The gap check is done with calibrated feeler gauge.
Gap check is done after every shrink fitting and after final machining. At
every stage (after every shrink fitting or final machining) of gap check,
carry out gap check in between all the layers.
Gap between the layers is noted & if the gap is within acceptable range then
the shell is released for machining.
MACHINING OF SHELL:
After receiving the operation card from the designer the shell is then
released for machining where the W.E.P. (Weld Edge Preparation) on both
the side of the shell is done according to operation card or drawing. After
S.B.M.P., MUMBAI
54 is again offered to inspection for gap

completion of machining the shell
check after machining to ensure that there is no considerable gap.

Then vent hole marking & drilling is done according to drawing.
CIRCUMFERENTIAL SEAM SET-UP & WELDING:
Take the required size & thickness of CS plate & place the plate at welding
station on floor.
Keep the required no. of rollers on this plate at particular locations (one
motorized & rest is idler rollers & lock the rollers with plate, after leveling.
Complete the circ-seam set-up, by strong tack tack welding inside the seam
groove with proper pre-heating temperature.
Carry out post heating of the tack weld up to the required temperature.
Correct job screws motion and lock the rollers & provide anti-drift at
required side of shell.
Provide required no. of low velocity curved burners from inside & provide
glasswool blanket on both side of circ. Seam.
Provide 2/3 D baffle hoods at 500mm on either side of the cir- seam
Start rotation, start circ-seam welding & simultaneously record the
temperature. Ensure pre-heating as per the specified temperature & refer
WPS for welding parameters / consumables.
S.B.M.P., MUMBAI
55 at regular intervals by infra-red non Interpass temperature to be checked
contact sensor.
Final weld run should overlap only up to the specified limit on either side of
the shell & then weld temper beads.
Then carry out post heating up to the specified temperature.

Carryout chip-back grinding as per specified & checks the chip-back
configuration with the template.
Put low velocity curved burner & hood from outside & weld from inside
along with temper beads & then pre-heating is carried out.
POSTWELD HEAT-TREATMENT (PWHT):

Post weld heat treatment (PWHT), defined as any heat treatment after
welding, is often used to improve the properties of weldment. In concept,
PWHT can encompass many different potential treatments; however in steel
S.B.M.P., MUMBAI
56
fabrication the two most common procedures
used are post heating and stress
relieving.
STRESS RELIEVING:
Stress relief heat treatment is used to reduce the stresses that remain
locked in a structure as a consequence of manufacturing processes. There are many
sources of residual stresses, and & those due to welding are of a magnitude roughly
equal to the yield strength of the base material. Uniformly heating a structure to a
sufficiently high temperature, but below the lower transformation temperature
range, & then uniformly cooling it, can relax these residual stresses. Carbon steels
are typically held at 1,100 to 1250F (600 to 675C) for 1 hour per inch (25mm) of
thickness
After all the process, These all long seams & circ seams are subjected to
NDT (Non-Destructive Test) to ensure that the seams are free from any defect
& with the assembly of externals like SUPPORT BRACKET, CLEAT etc. the
shell assembly of the equipment is completed.
INSPECTION OF DISHED ENDS
S.B.M.P., MUMBAI
57
TYPE OF DISHED ENDS
Hemispherical
Ellipsoidal
Torispherical
The D Ends which are used in the ammonia converter equipment are of
hemispherical type. This D Ends are in the form of raw material & which are
being subcontracted to vendor.
IDENTIFICATION OF MARKING:
D/E No.
Project No.
Material Specification
Heat No. & Plate No
S.B.M.P., MUMBAI
58
CUT EDGE GROUND SMOOTH

CORNERS ROUNDED OFF
D/E BLANK
MARKING
CENTRE
LUG INTEGRAL PART OF BLANK
S.B.M.P., MUMBAI
59
PROCEDURE FOR NOZZLE TO D END SET UP:

Study of Drawings & Tolerance Sheet
Development of Cutout
Marking on Shell
Make Cutout
Do Nozzle Set Up
Dimensional Checkup
STUDY OF DRAWING:
Nozzle Mark
Nozzle Size, pipe Schedule, Pipe Thickness
Elevation From Bottom Tan / Ref Line
Height from Centre Line
Orientation of Nozzle
Tolerance Sheet
Details of Pair Nozzle if any
Released or under Hold
HYDROTEST OF EQUIPMENT:
S.B.M.P., MUMBAI
60
ENSURE PRIOR TO WATER FILLING:
Completion of welding on pressure part.

Completion of all NDT to the acceptable stage.
Clearance of all NCR/DCR if any.
Final clearance of material cleared provisionally.
Testing of PTC/MTC, if any, to the acceptable test result.
All dimensional check within the acceptable limit.
Vessel is kept on hydrotest saddle in the specified orientation as per drawing
All long-seam & circ-seam are made visible for inspection.
If job is primer coated, all pressure weld joint are cleaned free from paint.
Gaskets & gasket seating are checked for any damage.
Inside surface is cleaned.
Air vending arrangement wherever is required.
All fasteners are tightened to the required torque.
All openings are closed except top one for filling water.
Arrangement of pressurizing shall be through one of the nozzles from the
bottom.
S.B.M.P., MUMBAI
61outlet connection.
Square bar arrangements on inlet &
Arrow for direction of water flow on fittings to be verified & confirmed.

Two pressure gauge or one & one transducer to be made available.
PPM requirement of test water shall be verified & confirmed.
Hydrotest pump, high discharge pumps shall not be used for vessel with
volume 10 cub. Mtr.
WATER FILLING, PRESSURISING & INSPECTION:

Water shall be filled from top nozzle & closed with test blank.
S.B.M.P., MUMBAI
62 bar, pressure gauge & pipe

Test blank shall be with nipple, square
connection for vending.

Inlet valve shall remain closed till water filling.
After blanking the top nozzle with gauge & vend pipe, water shall be
pumped from bottom.
Vend pipe shall be kept open in a bucket full of water to observe air bubbles.
Vending shall be continued till the air bubble in the bucket is disappeared.
Close the outlet valve on top & connect the gauge to line pressure.
Isolate the gauge at the bottom from line pressure & pump the water in.
Raise the pressure till 50% of test pressure.
Open the inlet gauge to pressure line & verify the pressure on both gauges.
Increase the pressure in increments of 10% of test pressure.
Stop pumping for 5 minutes after each increment of 10% of rise in pressure.
Isolate the inlet pressure gauge when pump is operation.
Connect the inlet pressure gauge to line pressure when pump is stopped for
pressure verification
S.B.M.P., MUMBAI
63pumping, connect inlet gauge to

When test pressure is reached, stop
pressure line and hold for 30 min (as specified in spec) and observe the
vessel from distance.
Reduce the test pressure to above design pressure and inspect all
connections for leakage
If any leakage is observed through gasket connection, repeat the test after
depressurize the vessel & tighten the studs / nuts.
If any leakage is observed from weld or parent metal, drain the water, repair
the leak and repeat the test
Time, temperature & pressure chart wherever specified shall be obtained
RECORDER
PRESSURE GAUGE
IMPORTANT SAFETY POINTS IN HYDROTEST:
S.B.M.P., MUMBAI
Drain the vessel only when top out64

let is kept open
Use minimum 2 gauges for any hydrotest
Never use high discharge pumps for testing low volume vessels. (Volume
less than 10 m3). Never pressurize any vessel above test pressure.
SURFACE PREPARATION:
What is surface preparation?
Surface preparation is the process in which the surface of the work-piece is
been cleaned for next process like painting, coating etc.
Why it required?
With proper surface preparation we can make the work-piece corrosion free.
With this process we can provide more efficiency for the next process.
TYPES OF SURFACE PREPARATION:
S.B.M.P., MUMBAI
65
BLASTING is the process which is most commonly used in industry.

Blasting is one kind of surface preparation process in which surface is cleaned
by impacting of abrasive.
Types of BLASTING:
I)
Wheelabrators
II)
Air Blasting
Blasting is most common & applicable method in industry so blasting is most

preferable in a heavy engineering industry, shipping & fabrication industry.
DISPATCH:
After completion of whole assembly. & documentation & getting released note
from third party the job is ready for dispatch.
S.B.M.P., MUMBAI
66
S.B.M.P., MUMBAI
67
CHAPTER
7
WORK IN DEPARTMENT
My role in the Department
1) Ferrite check of SS overlay.

2) Gap check in Multiwall shell
3) Hardness check of weld seams & D End.
4) Thickness check of shells & D End.
5) Gap check of linear& shell.
6) Rub-off of punching on job.
7) Make PT/MT report.
8) Dimension check of Tube-Sheet.
9) Make Inspection checklist.
10) Preparation of ferrite, gap check, thickness hardness report.
11) DCR/ECR updating on drawing.
12) Preparing & forwarding PTR.
13) Checking & maintain record of Heat Treatment Chart.
14) Updating of drawing folder.
15) Preparing Final Documentation for job.
16) Visit to IBR for submission & collection of TC.
17) Visit to R & C for documentation.
18) Follow-up with designer.
S.B.M.P., MUMBAI
68
CHAPTER
8
THE WORK I DID IN 6 MONTHS

ULTRASONIC THICKNESS GAUGE:-
Ultrasonic thickness gauge is to measure thickness of material by ultrasonic method.

Metals, plastics, ceramics, glass or virtually any other material which conducts
ultrasound can be accurately gauged over a wide range of thickness.
Working principal: Very high frequency 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.
At end point of material, the sound energy is reflected back to the transducer
and recorded.
By measuring the time it takes a sound wave to travel from one point to another,
distances can be measured.
S.B.M.P., MUMBAI
Equotip Hardness Tester
69
Features
Equotip 3 is a hand-held metal hardness tester with a rugged shock-resistant

housing and sealed membrane keypad
The metal hardness tester Equotip 3 converts directly to all common hardness
scales (HV, HB, HRC, HRB, HRA, HS, Rm); creates and uses another up to 20
customer-specific conversions for uncommon alloys
Highly accurate 4 HL (0.5% at 800 HL) with automatic correction for impact
direction
The Equotip 3 metal hardness tester offers a wide measurement range
Internal storage of ~100000 measured values in a flexible user-defined file/folder

structure
The metal hardness tester Equotip 3 offers user profiles for a quick change of
test setup (with password protection)
Down-/upload data from/to PC via USB, Ethernet or RS-232
S.B.M.P., MUMBAI
Ferrite meter:-
70
The rugged FERITSCOPE with plug-in type smart probe is suited for fast, nondestructive and accurate measurement of ferrite content on-site or in the lab according
to the magnetic inductive method.
S.B.M.P., MUMBAI
71
Applications 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.)
duplex steel.
Gap check Meter(Coating Thickness Meter):-
S.B.M.P., MUMBAI
72
Principle: Magnetic Induction or Eddy Current
CALIBRATION
Place probe on Base material Sample
Set Zero reading (Stabilize by taking multiple readings)
Calibrate using calibrated known thk. foils [Refer operating Instructions]
Calibrate by applying probe on known lower & higher thickness foil
Recheck calibration using a mock-up block with known Base Metal to Liner gap.
The reading observed should be near to known gap. (Fig -1)
S.B.M.P., MUMBAI
73
CHAPTER 9
CONCLUSION
DURING THE LAST 46 WEEKS OF MY TRAINING IN LARSEN
AND TOUBRO I ACHIEVED A LOT OF PRACTICAL EXPERIENCE IN
THE FIELD OF QUALITY CONTROL.
AT FIRST 46 WEEKS OF MY TRAINING TERM WHICH I REFER
TO AS MOST EXCITING, ENRICHING AND CHALLENGING
EXPERIENCE EVER IN MY ENGINEERING
CURRICULUM.I HAVE LEARNED THE IMPORTANCE OF WORK
CULTURE AND TEAMWORK. DURING THIS, I HAVE LEANED VERY
IMPORTANT ASPECT OF PLANNING AND CO-ORDINATITION.THIS
TRAINING HELPED ME TO BRIDGE GAP BETWEEN THEORY AND
PRACTICAL KNOWLEDGE.IT HAS MADE ME AWARE THAT
VALIDATING A PROJECT IS VERY IMPORTANT AND CRITICAL JOB
FOR THE COMPANY AND ITS OFFICIALS. I HAVE ALSO LEARNT
THAT CUSTOMER SATISFACTION, SAFETY AND QUALITY ARE OF
MOST IMPORTANCE.
LOOKING AT THE TRAINING FROM A BROADER VIEW, I HAVE
FOUND THAT APART FROM THE TECHNICAL KNOWLEDGE
IMPARTED TO US, IT HAS ALSO TAUGHT US TO BUILD AND
MAINTAIN BETTER HUMAN INTERACTIONS, TO UNDERSTAND
HUMAN NATURE AT WORK AND EXECUTE AN ASSIGNED TASK
EFFECTIVELY.
THE CREDIT TO WHAT WE HAVE LEARNT DURING THE
TRAINING PERIOD GOES TO THE COMPANY PERSONNEL AND OUR
COLLEGE AUTHORITIES. AT LAST I
CONCLUDE MY REPORT WITH MOST SATISFACTION AND BY TAKING
A LOT OF MEMORIES AND EXPERIENCES WITH ME, WHICH WILL
LAST FOREVER.
S.B.M.P., MUMBAI
74
CHAPTER
10
BIBLIOGRAPHY
I had visited the following websites for completion of my
Inplant Training report during my Training period.
1) http:// gr2ueintra [L&T Intranet site]
2) www.ltindia.com
3) www.larsentoubo.com
4) www.google.com
Along with this I also referred books on heat exchanger&
pressure vessel. But mainly guidance provided by the shop
supervisors made an invaluable enhancement of my knowledge
at L&T.
S.B.M.P., MUMBAI

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LARSEN AND TOUBRO LIMITED

ENROLLMENT NO. 0705068

LARSEN AND TOUBRO LIMITED

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

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

ENROLLMENT NO. 0705068

LARSEN AND TOUBRO LIMITED

ENROLLMENT NO. 0705068

LARSEN AND TOUBRO LIMITED

This to certify that Mr.DAVE HIRENDRA BHUPATRAI

BHAGUBHAI MAFATLAL POLYTECHNIC,VILE PARLE has completed his In-plant

ENROLLMENT NO. 0705068

LARSEN AND TOUBRO LIMITED

ENROLLMENT NO. 0705068

LARSEN AND TOUBRO LIMITED

Above all, I am deeply grateful6 to R.R.Ambade (Training Supervisor) of

This report is an account of my experiences and the knowledge

ENROLLMENT NO. 0705068

LARSEN AND TOUBRO LIMITED

Finally concluding, I would like to thank my colleagues for

ENROLLMENT NO. 0705068

LARSEN AND TOUBRO LIMITED

INTRODUCTION TO LARSEN &

ENROLLMENT NO. 0705068

LARSEN AND TOUBRO LIMITED

ENROLLMENT NO. 0705068

LARSEN AND TOUBRO LIMITED

10 up by two Danish engineers Mr. Henning

May 1938 in Bombay and started

undertaking the repair jobs on the improved machinery.

ENROLLMENT NO. 0705068

LARSEN AND TOUBRO LIMITED

LARSEN & TOUBRO LIMITED

:In the year 1938

(Rs. 43000 Cr.)

(Rs. 250 Cr.)

: Approx. one million

:India, USA, Oman, Nepal

ENROLLMENT NO. 0705068

LARSEN AND TOUBRO LIMITED

:26 spread over 20

L&T HEAVY ENGINEERING DIVISION

Figure1. Overview of Powai , campus

ENROLLMENT NO. 0705068

LARSEN AND TOUBRO LIMITED

CNC-controlled gas/plasma profile cutting machine.

Edge planning/milling machine.

ENROLLMENT NO. 0705068

LARSEN AND TOUBRO LIMITED

14 an area of 400 sq.m.

1000t hydraulic press.

Deep hole drilling capabilities of up to 900mm thickness.

CNC horizontal boring machines with 200mm spindle dia

CNC vertical boring machines of up to 8500mm dia. and 60t load

ENROLLMENT NO. 0705068

LARSEN AND TOUBRO LIMITED

Coal Gasifier & Thermal Power Plant Equipment Business

Refinery, Cracker Plant an Oil & Gas Equipment Business

Technology Development Center for Process Plant.

VPs Office- SBU Cluster B

VPs Office- SBU Cluster C

Aerospace & Aviation

Marine Equipment & Systems

Weapon System & Sensors