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IV Report - 12400097
IV Report - 12400097
Submitted towards the partial fulfilment of the requirements for the award of degree
of Bachelor of Technology in Mechanical Engineering
University of Kerala
During the academic year 2015-16
Submitted by
RASHID A S
S8 M2
REG. NO: 12400097
CERTIFICATE
This is certified that Report of Industrial Visits Undergone by Rashid A S ,Eighth
semester student of Department of Mechanical Engineering, College of Engineering
Trivandrum, towards the partial fulfilment of the requirements for the award of the degree of
B.Tech in Mechanical Engineering of the University of Kerala during the academic year
2015-16
1.
Prof. K S SAJIKUMAR
Associate professor
College of Engineering Trivandrum
2.
Dr. HASHIM
Associate professor
College of Engineering Trivandrum
3.
Prof. Ajith R R
Associate professor
College of Engineering Trivandrum
ACKNOWLEDGEMENT
I am very glad to express my deep sense of gratitude to all those concerned and
especially to our principal Dr. P.C.Reguraj, and to all the staff of College of Engineering,
Trivandrum for their encouragement and support in the successful conduct of the industrial
visit and this report.
I am extremely thankful to Prof. G L ASWINI KUMAR, Head of the Department,
Mechanical Engineering, for his kind and inspiring advices given to me. I would like to
express my sincere gratitude to Prof. K S SAJIKUMAR, Prof. AJITH R R and Dr.
HASHIM for their motivation, suggestion and valuable guidance to complete work timely
and successfully. I express my sincere thanks for their cooperation, encouragement and
constant help.
I am also thankful to each of my colleagues who helped and co-operated with me in
conducting the seminar by their active participation.
Rashid A S
SHIP BUILDING
Ship building department consists of 3 sections which are
Hull shop
HE and GA
Out fit
HULL SHOP
The Hull Shop is self-contained with infrastructure required for fabrication of hull
blocks up to 50 T. The shop is provided with EOT cranes (50 T) for along the bay movements
and gantry crane (20 T) and trailers for across the bay transfer of materials.
The four processes that take place in the hull shop are
Preparation
1. Plate preparation
: The mild steel sheets are picked from steel
yard and is fed into the hull shop for further processes
2. Sectional preparation : different sections are prepared such as Isection, T-section, brackets etc
Sub-Assembly
In this stage the sheets are joint by welding etc
Assembly
5
This shop has telescopic sliding roof with gantry cranes of 300 T and
150 T which spans over it and building dock. Hull blocks up to 450 T can be
jumboized here and erected in the building dock using the gantry crane. In
addition, two 20 T capacity EOT cranes are there in the shop.
Grand Assembly
Mechanical shop
MM1 & MM2
Electrical shop
EM1 , EM2 & EM3
Electronic shop
Transport section
Maintenance
Supply of consumables
Power supply
Transportation
Communication
Office facilities
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Statutory testing
Building maintenance
Dock operations
TRANSPORT SECTION
This section is responsible for the testing of the vehicles, crane and other transports
and making the availability for use
This section also provide taxi services for officers
PUMP HOUSE
This section controls the movement of various liquids
The machinery in pump house are
Ballast pump
Main distributer pump
Gate winch
COMPRESSOR HOUSE
Consist of 6 compressors of which 2 are screw compressors and 4 are reciprocating
compressors
1. Reciprocating compressor : uses reciprocating pistons for compressing air
2. Screw / centrifugal compressor : use the opposite principle as in turbines , it is 3 stage
process
SHIP REPAIR
Ship repair section mainly concentrates on the repair and maintenance of the ships. When a
ship comes to the dock for any repair purpose, SR department is taking care of it. Any tests
and repair needs to be done by this section. There are various shops under ship repair section
which are
Engine shop
Machine shop
Electric shop
Quality shop
Survey shop
Rigging and painters shop
Works done in this shop are shaft polishing, rudder fitting and maintenance, small
plate manufacturing, inserting sleeves onto the shafts, engine check up, lathe operations etc
ELECTRIC SHOP
o Winding machine : wires are coiled using this machine
o Scrapping and chipping machine : chalk fast ruing is used preset moulds of
good accuracy are made and molten metal is poured into it
o Electric component assembly
o Fabrication area
PIPE SHOP
Mostly 2 types of pipes and tubes are used in this area which are seam and seamless
pipes
Seam pipes: electric resistance welding
Seamless pipes: billet and mandrel is used
Pipes are known by its nominal bore and then the outer diameter. The wall thickness may
vary.
QUALITY CONTROL
Major on tests done by ship repair are
o
o
o
o
o
INTRODUCTION
The Fertilisers and Chemicals Travancore Limited (or FACT Ltd), a fertiliser and
chemical manufacturing company in Kochi, Kerala, India, was incorporated in 1943, by
Maharajah Sree Chithira Thirunal Balarama Varma. In 1947 FACT started production of
ammonium sulphate with an installed capacity of 50,000 MT per annum at Udyogamandal
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near Cochin. It is the first fertiliser manufacturing company in independent India and also the
largest Central public Sector Undertaking (CPSU) in the State of Kerala. The company has 2
production units - Udyogamandal Complex (UC) at Eloor, Udyogamandal, and Cochin
Division (CD )at Ambalamedu. The Caprolactam plant in Udyogamandal was commissioned
in 1990. Main products of the company include Ammonia,Sulphuric Acid, Ammonium
Phosphate-Sulphate (FACTAMFOS), Ammonium Sulphate, Zincated Ammonium Phosphate,
Caprolactam, and also complex fertilizers. Gypsum, Nitric acid, Soda Ash and coloured
Ammonium Sulphate are major by-products.
The factory commenced production of ammonium sulphate in 1947 at the dawn of
Indian independence using wood as the raw material for production of ammonia. With the
effect of time, wood gasification became uneconomic and was replaced with naphtha
reforming process.Through a series of expansion programmes, FACT soon became the
producer of the widest range of fertilizers suited for all crops and all soil types in India.It
became a Kerala State public sector enterprise in 1960 and in 1962,it came under the
Government of India. Diversification to full-fledged engineering services (FEW)in the
fertilizer field and allied areas followed. The next major step forward was the diversification
of petrochemicals,an important milestone in the growth of the company. FACT has formed a
Joint Venture Company with Rashtriya Chemicals & Fertilizers Limited, named FRBL
(FACT RCF Building Products Ltd) for manufacturing load bearing panels and other building
products using phosphogypsum.FRBL PREFAB RAPIDWALL is a revolutionary, low cost,
pre fabricated, load bearing cellular walling product suitable for use in residential,
commercial, and industrial building construction.
FLAGSHIP PRODUCTS
1. CAPROLACTAM: It is the raw material (precursor) for Nylon-6. The product quality of
FACT Caprolactam is claimed to be among the best available in the world.
2. AMMONIUM SULPHATE: Ammonium Sulphate is a nitrogenous fertiliser containing
20.6% nitrogen, entirely in ammonical form. It has excellent physical properties; nonhygroscopic, crystalline and free flowing. It is ideal as a straight nitrogenous fetiliser and also
as an ingredient in fertiliser mixtures. It is the most widely preferred nitrogenous fertiliser for
top dressing on all crops. Another unique advantage is that it contains 24% sulphur, an
important secondary nutrient.
3. FACTAMFOS (AMMONIUM PHOSPHATE SULPHATE): FACTAMFOS 20:20:0:13 is a
chemical blend of 40 parts of ammonium phosphate and 60 parts of ammonium sulphate. It
contains 20% N and 20% P2O5. The entire N is in ammonical form and P is completely water
soluble. In addition, FACTAMFOS contains 13% sulphur, a secondary plant nutrient which is
now attaining great importance in the agricultural scene. FACTAMFOS 20:20:0:13, with the
granular form and non-hydroscopic and free flowing nature, have excellent physical
properties. It is ideal for application on all soils and all crops. FACTAMFOS 20:20:0:13 can
also be used for foliar application
4. FACT GYPSUM: A by product of phosphoric acid, is a rich and cost effective source of 16%
sulphur and 22% calcium. FACT is marketing bagged gypsum in brand name FACT Gypsum
all 4 southern states as a soil conditioner with fertilising properties.
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PROCESS
Cyclohexanone, the main intermediate, is produced from benzene by hydrogenation
to cyclohexane and subsequent oxidation. Hydroxylamine, the second intermediate, is
obtained in the form of its stabler sulphate salt, from ammonia, sulphur-di-oxide and
ammonium nitrite by the proven, easy-to-operate and efficient Raschig route.
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RECENT DEVELOPMENTS
Union Ministry for Chemicals and Fertilizers have agreed to handover a relief
package of Rs. 1000 crore.
Mobilizing assets by leasing out unused land for commercial purposes
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INTRODUCTION
Plastics, the wonderfully mouldable material, seem to have taken over the
world today. The innumerable products made out of it find infinite variety of uses in almost
all walks of life.In a market crowded with brands - some of them good, many of them bad there are a few like us, FAMILY PLASTICS, towering over the rest through the sheer strength
of quality. The timely delivery of quality products such as moulded furniture, household
items, kitchen containers, fancy articles, garden planters and flower pots, at competitive rates
makes it one of the most sought after names in the Plastic Industry. Ever Since its inception,
the relentless quest for quality has made our products a resounding success not only in India
but also in the Export market that spread from the beautiful cities of North America to the
interiors of Middle East and Maldives.The laurels of excellence are many. In recognition of
the spirit fo enterprise and as a celebration of his vision of excellence, our founder, Mr.
Daniel A. Fernandez was conferred the Udyogpatra Award by the Institute of Industrial
Development, New Delhi. He has also won several export awards from the Government of
India.
THE VISIT
Family plastics is a known for products like moulded furniture,household
items, kitchen containers, fancy articles etc. Injection moulding technology is used for the
manufacturing og goods. Extrusion process is also used for manufacturing plastic bags.The
machineries using in industry are numerically controlled and it makes process easier.
The following are machines used in indusry;
1.
Jonwai- JW-150-SD injection moulding machine for making Buckets.
2.
Polosmart-80 injection moulding machine for chairs.
3.
Fedromatic milacron injection moulding machine for making small chairs
4.
Cincinanati milacrone injection moulding machine for making trays.
High Density Poly Ethylene and Low Density Poly Ethylene is used for moulding. Required
colour is added by Masterbatch.
MANUFACTURING SECTION
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There are 3 units for manufacturing different goods.One major unit consists of 23 mchineries
and other two have 5 machineries. First section consists of 140 skilled labours for operation.The
machines used for moulding is of injection moulding type and numerically controlled.
Jonwai-JW-150
It is a horizontal injection moulding machine.Which is used to manufacturing buckets.It
mainly consists of clamping unit, injection unit and microprocessor controller unit. Compact clamping
unit has large inner rod distance and thickened platen can minimize the toggle pressure, lower
deformation, high structural rigidity and reliability. It can accommodate large mold with core
cylinders and sliders. The toggle moves the platen very quick and smoothly. Table shows the
specification of machine.
Screw diameter
50 mm
Shot size
347 mm
Injection pressure
1637 Kg/cm2
Clamping force
150 tonn
Clamp stroke
400 mm
Mold height
150-450 mm
430 * 430
Motor rated
30 HP
Table : specification
PROCESSES
High Density Poly Ethylene (HDPE) and Low Density Poly Ethylene (LDPE) is used
as the raw material.Masterbatch is used to add the colour.
The process for injection molding is very short. It consists of following stages.
1.
Clamping
Prior to injection of the material into the mold, the two halves of the mold first
securely closed by clamping unit. Each half of mold is attached to the injection molding
machine and one is allowed to slide. The hydraulicaly powered clamping unit pushes the
mold halves together and exert sufficient force to keep the mold securely closed while the
material is injected.
2.
Injection
The raw plastic material inform of pellets , is fed into the injection molding machine
and achieved towards the mold by the injection unit. During the process the material is
melted by heat and pressure. The molten plastic is then injected to the mold very quickely and
the buildup of pressure packs and holds the material. The amount of that is to be injected is
termed as shot. The injection time can be estimated by the shot volume, injection pressure,
and injection power.
3.
Cooling
The molten plastic that is inside the mold begins to cool as soon as with the interior
mold surface. As the plastic cools, it will solidify into shapes of desired part. However during
cooling shrinkage of part may occure. The packing of material in the injection stage allows
additional material to flow into the mold and reduce the amount of visible shrinkage. The
mold cannot be opened until the required time can be estimated from several thermodynamic
properties and maximum wall thickness of the part.
4.
Ejection
After sufficient time has passed, the cooled part may be ejected from the mold by the
ejection system, which is attached to rear side mold. When the mold is opened , a mechanism
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is used to push the part of mold. Force must be applid to eject the part because during cooling
part shrinks and adheres to mold. Inorder to facilitate the ejection of the part, a mold release
agent can be sprayed onto surface of the mold cavity prior to ejection of material. Once the
part is ejected, the mold can be clamped shut for next shot to be injected.
After the injection molding cycle, some postprocessing is typically required. During
cooling, the material in the channels of the mold will solidify attached to the part. This excess
material, along with any flash that has occurred, must be trimmed from the part, typically by
using cutters. For some types of material, such as thermoplastics, the scrap material that
results from this trimming can be recycled by being placed into a plastic grinder, also called
regrind machines or granulators, which regrinds the scrap material into pellets. Due to some
degradation of the material properties, the regrind must be mixed with raw material in the
proper regrind ratio to be reused in the injection molding process.
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Nano-ceramics
Energy Materials
Polymeric Materials
Electronic Materials
Magnetic Materials
He shared his experiences in the field of research related to these topics and brought
out the latest developments in the field. With the topic energy materials, he covered various
coatings that could be adopted so as to protect a building from adverse climatic conditions
and ensure safety and comfort of humans.
He gave a brief description about the application of Nano Ceramics in the field of
aerospace. These included aluminium oxide, metalized Aluminium oxide PZT ceramics etc.
The properties of each type were explained and suitable selection criteria were identified.
Further details on various polymeric materials were imparted to us. Overall, the talk
provided students with a general outline on the role of Functional ceramics in the present day
technologies that affect human life.
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necessary todesign alloys with good soldering characteristics and also having ductility atcryo
temperatures.
2. Development of Process Technology to coat SiC chopped fibres with BN and Carbon:SiC
fibre reinforced composites are suitable candidates for thermo-structuralcomponents of
reusable launch vehicles and air breathingengines. In order to maintain the integrity of the
composite for a longerduration under loading these fibres need to have suitable coating
beforeincorporating intro the matrix. In addition reinforcing the coated fibre leadsto proper
adhesion aids in stress release.
3. Sub microstructure characterization of Al-Li alloys:Al Li alloys are being
developed as a potential candidate for the futurepropellant tankages and structural material
for the launch vehicles andsatellites.
4. Development of Processing Maps for High Temperature Aerospacealloys:High
temperature materials are being developed or the futuristic launchvehicles like RLV, TSTO,
SSTO, HSP missions of ISRO. High temperaturedeformation processing of these materials is
complex and poses manychallenges to manufacturers.
5. Evaluation of Ceramic matrix composites based on SiC and ZrB2 forbehaviour
under water vapour containing environments at hightemperatures and development of
suitable coatings.
6. Oxidation behaviour of advanced high temperature coatings for superalloys and Tibased intermetallic alloys:Inter-metallics such as Gamma Ti-Al and super alloys are
considered
asgood
candidate
alloys
for
high
temperature
applications
due
to
severaladvantages. However, these alloys can be used at high temperature withgood coatings
covering bond coat along with TBC ceramic coatings.
7. Development of nano composite coatings for corrosion protection oflight alloys
such as Aluminium and Magnesium:Aluminium and magnesium alloys are widely used in the
aerospaceindustries due to light weight and other properties. However, they areprone to
corrosion in the environment containing chlorides. Hence thesealloys are mostly used in
coated conditions covering single and multiplelayered coatings of epoxy and polyurethane.
Currently nano compositecoatings are reported to show good barrier corrosion properties and
henceshow more advantages than the traditional coatings.
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Thepolymer
should
have
high
tear
strength,
toughness
and
water
vapourtransmission.
9. Development of Addition Curing Silicone Binder Resin Systems Along with Its
Catalyst:These polymers are used for thermal paints for satellite components. Theproposal
involves indigenous development of silicone polymers withpendant hydrosilyl (-SiH) and
vinyl groups and suitable platinum catalystsoluble in these silicone polymers.
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22
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SUMMARY
Sl.
Name Of Company
No.
Date Of
Visit
1.
2.
3.
4.
(FACT), Kochi
Family Plastics And Thermoware (P) Ltd
26/8/2015
23/01/16