CHAPTER 1

INTRODUCTION
Heavy Engineering Corporation Ltd., is one of the leading suppliers of capital equipment in India
for steel, mining, railways, power, defense, space research, nuclear and strategic sectors. It also
executes turn-key projects from concept-to-commissioning. Set-up in the year 1958, HEC has
acquired expertise in its field through its more than half a century's experience.

With the seamless integration of its facilities, HEC is one of the largest integrated engineering
complex. Sprawling in an area of around 2100,000 sq.m, HEC has facilities starting from steel
melting, casting, forging, fabrication, machining, assembly and testing. It has its own in-house
research and product development wing to deliver products suiting customers' specifications.

HEC is headquartered at Ranchi, the capital city of Jharkhand, in eastern part of India, and also
has its manufacturing facilities located here. A well-suited location nearing to customer sites and
proximity to the ports for import items, is an added advantage for its cost-effectiveness.

Founded primarily to facilitate manufacture of steel plant equipment indigenously, HEC has
made immense contribution in setting-up, expansion and modernization of steel plants in India.
In due course, HEC had diversified to different sectors and made commendable contributions
towards manufacture and supply of import-substitute products. Bestowed with the onus of
making the country self-reliant for heavy engineering equipment and services, HEC continues to
contribute in the nation-building endeavor.

fig1.0

 HEAVY MACHINE BUILDING PLANT  HEAVY MACHINE TOOLS PLANT

 FOUNDRY FORGE PLANT  PROJECTS DIVISION

OPERATING UNITS

1
HEAVY MACHINE BUILDING PLANT (HMBP)
The Plant has a fenced area of 5,70,000 sq.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 13,16,930 sq.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 related to Steel plant, Defence,
Power, Nuclear energy etc. It also manufactures Forged Rolls for Steel Plants, Crank Shafts for
Railway Loco etc.

HEAVY MACHINE TOOLS PLANT (HMTP)

HMTP is the most modern and sophisticated of its kind in the country which produces machine
tools in heavier ranges. The Plant covers an area of over 2,13,500 sq.m. It designs and
manufactures medium & heavy duty CNC and conventional Machine Tools for Railways,
Defense, Ordnance factories, HAL, Space and other strategic sectors.

PROJECTS DIVISION
Design, Engineering and execution of Turnkey Projects related to Bulk Material handling, Steel
Plant projects, Cement Plant and other sectors.

Business Areas

Steel & Metallurgical Plant equipment

fig1.1

2
Mining & Mineral processing equipment
Fig 1.2

Machine Tools
Fig 1.3

Defence & Strategic Sector

Fig 1.4

Heavy Castings & Forgings

Fig 1.5

3
STEEL PLANT EQUIPMENTS

 Blast Furnace
 Coke Oven Batteries
 Continuous Casting Machine
 Steel Melting Converters
 Forged Rolls
 Other Equipments to Steel Sectors


 BLAST FURNACE


Blast Furnace (Volume 1719,2000,3200 CuM): Supplied to BSP, BSL ,VSP and exported to
Turkey & Egypt. Supplies include:


 Technical Structure

 Ch. Column & Plants

 Cooling Plates

 Charging Arrangements

 Charging Distributors

 Skip winch

 Belt Control Winch

 Valves

 Rolling Stocks etc.

 Cast House Machines





















Fig 1.6


4
 COKE OVEN BATTERIES

Coal is processed into coke in large batteries of ovens before entering a blast furnace. The
carbon in coke is more concentrated, making it more efficient than coal. Before carbonization,
coal is blended, pulverized and oiled to ensure proper density. The resulting coke is used to
reduce the amount of iron in blast furnaces.

Inside the coke oven battery, coal is heated to 2012 degrees Fahrenheit in order to drive out
volatile compounds. Each oven in the battery shares a common heating flu with the adjacent
oven. The result is coke, which is hard but porous, and has more concentrated carbon than coal.

Coke Oven Battery (4.3 M to 7.0 M high) :Supplied to BSL, BSP VSP, DSP and Exported to
Turkey, Egypt, USSR & Sri Lanka. Supplies include:

 Coke Pusher

 Coal Charging Car 

 Coke Guide Car 

 Coke Quenching Car 

 Red Hot Coke Car

 Travelling hoist

 Charging Hoist

 Charging Device

 Discharging Device

 Door, Frame, Flash plate and Sealing Frames 

 Buckstays, Anchorages and Tie Rods

 Gas Collecting Mains and Cross Over Gas Mains 

 Reversing Winch

 Skip Hoist




Coke Oven Machine for Bhilai Steel Plant

Fig 1.7

5
 Remote Controlled Wagon Pusher Hot Coke Car
Fig 1.8 Fig 1.9

CONTINUOUS CASTING MACHINE

Continuous casting, also called strand casting, is the process whereby molten metal is solidified
into a "semi finished" billet, bloom, or slab for subsequent rolling in the finishing mills.Continu-
ous Casting Machine/Plant : Supplied to RSP, BSL, BSP & VSP for Turnkey Project
execution/equipment.
Molten metal from Steel Melt Shop is to feed material for Continuous Casting Machine of
Billets, Blooms and Rounds. These are then sent to various Rolling Mills for subsequent Remso
offer cu- stom made Continuous Casting Machine according on user’s request & is used for
continuously cast plain carbon steel, low carbon, medium & high carbon, alloy steel and
stainless steels into the square Billet, Bloom, Bar, the cross section of 80×80, 100×100 or
120×120, 150×150 mm with length of 6m/11m operated by automatic control system.

Continuous Casting Machine

Fig 1.10

6
 Machine equipped to cast

TABLE NO. 1.1

Slab thickness 180mm- 210mm

Slab width 800mm-1300mm

Length 600mm-800mm

Cutting length at slab sizing unit 2200mm-2800mm

Specifications of S lab Caster

TABLE NO. 1.2
Machine Radius 10 m
Machine Support Length 21 m
Maximum Casting speed : For 180 mm thick slab 1.5 m/min
For 210 mm thick slab 1.3 m/min
Maximum Machine Speed 2.5 m/min

Parameetrs required
TABLE NO. 1.3
Annual output 1 million tones
Grade of steel cast Low and medium carbon steel
Bit speed 0-150 rpm
Bit rated torque 950kgm at 100 rpm
Crawled Heavy duty individually motor
Air compressor 28 m3/min at 7kg/cm2

Ladle Turret for RSP

Fig 1.11

7
 STEEL MELTING CONVERTERS

Smelting involves more than just melting the metal out of its ore. Most ores are the chemical
compound of the metal and other elements, such as oxygen (as an oxide), sulfur (as a sulfide), or
carbon and oxygen together (as a carbonate). To extract the metal, workers must make these
compounds undergo a chemical reaction. Smelting therefore consists of using suitable reducing
substances that combine with those oxidizing elements to free the metal.

Steel Melting Converters : Supplied to BSL, BSP, VSP, DSP, RSP, Malvika steel plants,
Indomag( Jindal) 5 nos Converters and 10 no. Mixers supplied.

The Bessemer process was the first inexpensive industrial process for the mass
production of steel from molten pig iron before the development of the open hearth furnace. The
key principle is removal of impurities from the iron by oxidation with air being blown through the
molten iron. The oxidation also raises the temperature of the iron mass and keeps it molten.

Using the Bessemer process, it took between 10 and 20 minutes to convert three to five tons of
iron into steel — it used to take at least a full day of heating, stirring and reheating to achieve this.

Basic oxygen steelmaking (BOS, BOP, BOF, or OSM) steelmaking or the oxygen converter
process is a method of primary steelmaking in which carbon-rich molten pig iron is made
into steel. Blowing oxygen through molten pig iron lowers the carbon content of the alloy and
changes it into low-carbon steel. The process is known as basic because fluxes of burnt
lime or dolomite, which are chemical bases, are added to promote the removal of impurities and
protect the lining of the converter.

TABLE NO. 1.4

Parameters
L.D.Convertors 55T, 100T & 130 T
Hot Metal Mixer 600T, 1300T
Self Propelled Transfer Car 130T
Steel Ladle transfer car 50T, 100T, 200T, 250T, 300T
Hot metal transfer car 100T, 140T
Slag Pot transfer car 16M3, 18M3
Ingot Mould car 160T,180T
Laddle and stand 40T to 100 T

8
 120 T Hot Metal Ladle
Fig 1.12

Slag Ladle Car

Fig. 1.13

FORGED ROLLS
Roll forging or roll forming is a forging technique that utilizes opposing rolls to shape a metal part.
Even though roll forging uses rolls in order to accomplish the deformation of the material, it is
classified as a metal forging process and not a rolling process.

Rolls: HEC is pioneer in manufacturing of Forged Rolls in India and is a regular supplier to major
Steel plants of India. Dedicated facilities have been created for Induction hardened CRM rolls.
Stringent quality control ensures High Quality Rolls.

9
 Induction Hardened Forged Rolls
TABLE NO. 1.5
Type Max Hardness (shore)
length(mm)
HRM 1350 6000 35 45
Rolls
CRM Rolls 600 6000 15 upto 100

Around 3800 nos. Rolls (CRM & HRM) supplied to various steel plants like :BSL, BSP, VSP,
DSP, RSP, TISCO, Jindal, Steelco, Balco, Tinplate, Nippon Dendro etc.

120 T Hot Metal Ladle

Fig 1.14

OTHER EQUIPMENTS TO STEEL SECTORS

Sinter Plant

TABLE NO. 1.6

Equipment to BSL,BSP, VSP,Turkey, USSR.
General Purpose & Steel capacity) RSP, TISCO, BHEL,
Plant Cranes
CIL, Malvika steel

Slag Cups Supplied to BSL, BSP, VSP, DSP, RSP, TISCO.

Machines Tools to BSL, BSP, VSP, RSP, TISCO, NINL

RollingMills 3600 MW wide plate mill

10
 BULL GEAR Assembly (72T) Mill Stand for RSP
Fig 1.15 Figure no. 1.16
Fig 1.16

MINING EQUIPMENTS

 Electric Rope Shovels (5 CuM)

 Electric Rope Shovel (10 CuM)
 Draglines




ELECTRIC ROPE SHOVELS (5 CUM)

A power shovel (also stripping shovel or front shovel or electric mining shovel or Electric Rope
Shovel) is a bucket-equipped machine, usually electrically powered, used for digging and
loading earth or fragmented rock and for extraction. Power Shovels are a type of rope/cable
excavator, where the digging arm is controlled and powered by winches and steel ropes, rather
than hydraulics like in the more common hydraulic excavators.Rugged design suitable for
mining Coal, Iron ore and other minerals in open cast mines. Easy to maintain and one of the
most reliable shovel in this capacity range.
HEC supplied over 550 shovels for various mining organizations in India and treated as one of
the most reliable mining shovels operating in Indian mining condition.

PARAMETERS
TABLE NO. 1.7
Bucket Size 5 CuM

Boom Length 10.5 M

Max. Digging Radius 14.4 M
Max. Digging Height 10.3 M
Max. Dumping Radius 12.65M
Max. Dumping Height 6.7 M
Hoist Force 45 T

11
 Rope shovel
Fig 1.17

 Individual DC drives for main mechanisms - hoist, crowed and swing / travel system.
 MG set with 250 KW squirrel cage induction motor as prime mover and 3 DC generators,
one each for hoist, crowed and swing / travel system. 

 Magnetic amplifier controlled. 

 Electrical supply 3.3 / 6.6 KV, 50Hz, 3

HEC supplied over 550 shovels for various mining organizations in India and treated as one of
the most reliable mining shovels operating in Indian mining condition.

ELECTRIC ROPE SHOVELS (10 CUM)

PARAMETERS
TABLE NO. 1.8
Bucket Size 10 CuM
Max. Digging Radius 17.12 M
Max. Digging Height 13.03 M
Max. Dumping Radius 14.61 M
Max. Dumping Height 14.27 M
Hoist motor 477 kw
Crowd motor 97 kw
Propel motor 190 kw
Swing motor 2x97 kw
Power supply 3.3/6.6 kv
Av. Cycle 28 SEC

12
 .

Rope shovel
Fig 1.17

DRAGLINES

Dragline excavator is used for civil engineering projects and surface mining. Dragline is the
largest equipment ever built on this planet. It has the ability to excavate very deep down the
earth. Word drag is used because it has the ability to drag material at far distance from the
machine. Dragline consists of drag rope, large bucket, boom, hoist rope and driving motors. As
shown in the figure;
HEC is the first Indian company to manufacture walking Dragline of 24 CuM Bucket
capacity.12 numbers of Draglines of 24 /96 and 3 nos of 20 / 90 Draglines supplied by HEC to
Indian Mining industry.
PARAMETERS
TABLE NO. 1.9

Bucket capacity 24 to 34 CuM

Boom length 74.6 to 95.6 m
Boom angle 300 / 380
Operating radius 64 to 88 m
Dump height 25.5 to 48.1 m
Digging depth 46.2 to 74.5 m
Base diameter 15.25 m
Bearing area 182.65 sq.m
Average bearing pressure 0.95 kg / sq.cm.
Walking shoe bearing area (for2) 95.2 sq.m.

13
A large dragline system used in the open pit mining industry costs approximately US$ 50–100
million. A typical bucket has a volume ranging from 40 to 80 cubic yards (30 to 60 cubic
metres), though extremely large buckets have ranged up to 168 cubic metres (5,900 cu ft). The
length of the boom ranges from 45 to 100 metres (148 to 328 ft). In a single cycle, it can move
up to 450 tonnes of material.

Dragline
Fig 1.18

Capacity: 400 /60 T installed at a height of 46 M to handle GSLV and PSLV at ISRO, shriharikota

In a typical cycle of excavation, the bucket is positioned above the material to be excavated.
The bucket is then lowered and the dragrope is then drawn so that the bucket is dragged along
the surface of the material. The bucket is then lifted by using the hoist rope. A swing operation
is then performed to move the bucket to the place where the material is to be dumped. The
dragrope is then released causing the bucket to tilt and empty. This is called a dump operation.

On crane-type draglines, the bucket can also be 'thrown' by winding up to the jib and then
releasing a clutch on the drag cable. This would then swing the bucket like a pendulum. Once
the bucket had passed the vertical, the hoist cable would be released thus throwing the bucket.
On smaller draglines, a skilled operator could make the bucket land about one-half the length of
the jib further away than if it had just been dropped. On larger draglines, this is not a common
practice.

14
Chapter 2

MACHINE TOOLS

A machine tool is a machine for shaping or machining metal or other rigid materials, usually by
cutting, boring, grinding, shearing, or other forms of deformation. Machine tools employ some
sort of tool that does the cutting or shaping. All machine tools have some means of constraining
the workpiece and provide a guided movement of the parts of the machine. Thus the relative
movement between the work piece and the cutting tool (which is called the toolpath) is
controlled or constrained by the machine to at least some extent, rather than being entirely
"offhand" or "freehand".

 Vertical Turning & Milling Machine

 Lathe
 Roll Grinding Machine
 Deep Hole Boring Machine
 Horizontal Boring Machine
 Radial Drilling Machine
 Planning Machine
 Plano Milling Machine
 Special Purpose Railway Macine Tools

Fig 2.0

15
 VERTICAL TURNING & MILLING MACHINE


The increasing demand for enhanced productivity and reduced process time from industries
like automotive sector is prompting manufacturers to introduce machine centers that carry
out various operations like milling, drilling, facing, and turning. The launch of new
technology like 5-axis and 6-axis CNC machines allows end-users to carry out all
operations on a single machine. The machine centers need to modify or change the
corresponding tool or the software control system during each operation. The multi-function
machines are provided with one or more turrets which allow the consumers to use the same
turning tools for various functions. The ability to move the spindle in and around the B-axis
and to change tools automatically is increasing the demand for turning tools.

6-axis CNC machine is an innovation that converts a raw metal bar into the final product by
turning from both the ends of the fixture without multiple fixtures and defects in the final
machine. The use of the 6-axis CNC machines enables complex work like drilling holes of
different diameters, shapes and have variable cutting speed and patterns. It has a smoother
application process, and the quality of the final product is superior to 5-axis CNC machine.
































Fig 2.1 

6 Axis CNC Double Column Vertical Turning & Milling Machine






16
 2 Axis CNC Single Column Vertical Turning & Milling Machine (BVS 55 / 70 NM)
Fig 2.2

2 Axis CNC Vertical Turning Machine

(Mono-block type BV 5 - 16 NS)
Fig 2.3

CNC Double Column Machine Specification:

 Table Diameter : 3 to 5 meter


 Max turning diameter: 4 to 6 meter

 Max turning height ; 3.1 to 4.2 meter

:  Max wt. of work piece :30 to 80 MT

17
 CNC Single Column Machine Specification:

 Table Diameter : 2 to 5.5 meter


 Max turning diameter :4 to 7 meter

 Max turning height :1.6 to 2.85 meter

 Max wt. of work piece: 20 to 50 MT

LATHE
A lathe machine is a machine tool which is used to remove metals from a work piece to give a
desired shape and size. In other words it is a machine that is used to hold the work piece to
perform various metal removing operations such as turning, grooving, chamfering, knurling,
facing, forming etc with the help of tools. It is also called as mother of machine.

A lathe may or may not have legs, which sit on the floor and elevate the lathe bed to a working
height. A lathe may be small and sit on a workbench or table, not requiring a stand.
Almost all lathes have a bed, which is (almost always) a horizontal beam (although CNC lathes
commonly have an inclined or vertical beam for a bed to ensure that swarf, or chips, falls free of
the bed). Woodturning lathes specialized for turning large bowls often have no bed or tail stock,
merely a free-standing headstock and a cantilevered tool rest.

Fig 2.4
CNC Centre Lathe (LC 100 N)

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.

18
Conventional lathe machine specifications

 Swing over Carriage: 650 - 1600 mm

 Distance between centres :3 - 10 metre
 Max. wt of work piece :8 - 50 MT
(2 axes) 

Conventional Lathe Fig 2.5 Conventional Lathes

ROLL GRINDING MACHINE

Roll Grinders have heavy aged cast iron construction, that has been precision machined and
hand scraped. With a Hydro-Dynamic spindle on the wheel head and the Hydro-Static
lubrication system on the table, these machines will give you many years of trouble-free
operation and high accuracies.
Roll Grinding Machine specification:
 Max. dia to be ground : 575 - 1600 mm
 Distance between centers :2 / 3 to 6 / 7 M
 Max. weight of roll :3 to 6 T
 Rigid design for better efficiency & accuracy
 Accurate concave & convex grinding
 Electronic / mechanical feed counter for pre-selection of cross feed
 Built in dynamic balancing device
 Automatic feed at reversing points
 Automatic cut off device for grinding wheel
 Automatic wheel wear compensation

Fig 2.6

19
 DEEP HOLE BORING MACHINE

CNC Deep Hole Boring Machine specification:

 Max. Solid drilling diameter :200 mm


 Max. Trepanning diameter: 350 mm

 Max. Counter boring diameter :350 mm

 Max. Boring depth :12000 mm

 Swing over bed :1400 mm

 Mx. Wt. Job: 15 MT

CNC Deep Hole Boring Machine BDH 140 N

Fig 2.7

HORIZONTAL BORING MACHINE

A horizontal boring machine or horizontal boring mill is a machine tools which bores holes in
a horizontal direction. There are three main types — table, planer and floor. The table type is
the most common and, as it is the most versatile, it is also known as the universal type.

CNC Horizontal Boring Machine specification:

 Boring spindle diameter :100 mm


 Max spindle travel :900mm

 Head stock vertical travel (Y-axis) :1120 mm

 Moving column type design

 Highly rigid construction
 Automatic clamping/unclamping of ISO-60 tooling facility
 Circulating lubrication system for H/S & Feed gear box. 

20
 Horizontal Boring Machine (BH-100 N)

Fig 2.8

RADIAL DRILLING MACHINE

This type of drilling machines is designed for medium to large and heavy work pieces. The
machine is having a vertical column mounted on the large base. The column is supported by
radial arm which can be raised or lowered to accommodate work pieces of different heights.
The arm can swing horizontally to any position around the column over the work. The drill
head mechanism for rotating the spindle and feeding the drill is mounted on the radial arm
can be moved horizontally to and fro from the column then it is clamped at any desired
position.

Specifications:

 Max. dia Drilled in steel: 80 - 100 mm


 Min. distance of axis of spindle to column :530 mm

 Max. distance of axis of spindle to column: 2520 / 3070 and 3620 / 4470 mm

Radial Drilling Machine (DR 8A)

Fig 2.9

21
 PLANNING MACHINE
A planer is a type of metalworking machine tool that uses linear relative motion between the
workpiece and a single-point cutting tool to cut the work piece. A planer is similar to a
shaper, but larger, and with workpiece moving, whereas in a shaper the cutting tool moves.

Specifications:

 Planing width:1400 - 2000 mm


 Planing length: 3000/ 4000 - 12000 mm

 Planing height : 900 - 2000 mm
 Max. work weight per meter of planning length: 2 MT
 CNC System Fanuc / Siemance (2 Axi

Double Column Planning Machine (PD 16)

Fig 2.10

22
 PLANO MILLING MACHINE

Double Column Plano Milling Machine Specifications:

 Max. Milling width :1250 - 2000 mm


 Max. Milling length : 10000 - 12000 mm

 Max. Job height : 1250 - 2000 mm

Plano Milling Machine

Fig 2.11

SPECIAL PURPOSE RAILWAY MACINE TOOLS

CNC Under Floor Wheel Lathe:

The machine is arranged in a pit. The wheel sets to be re-profiled are brought into the machine
via the supply rails (if still attached to the vehicle) or by crane (if removed from the vehicle). For
re-profiling, the wheel sets are driven by friction rollers pushing on the running surfaces. The
high dynamic stiffness of clamped wheel sets required to produce the highest possible machining
precision is guaranteed by the radial centering of the axle bearing box. Lateral positioning of the
wheel set is executed by the use of axial guide rollers. The machine is operated from a central
control panel, which enables the operator to have constant access to all machine functions.
During machining, the operator is protected from flying chips. The automated machining takes
most of the work from the operator's hands, making the machine easy to operate.

 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

23
 CNC Under Floor Wheel Lathe (LUW 176 N)
Fig 2.12

CNC Surface Wheel Lathe:

CNC Wheel Lathe is a rugged and reliable above-floor wheel lathe for turning solid wheel
or tired wheel treads of worn wheel sets of railway passenger and freight cars, diesel railcars,
and locomotives. The lathe removes flat spots, shelling, and restores the wheel profile to pre-
programmed specifications. Feeding-in, centering, chucking, wheel contour turning, and
feeding-out are automatically controlled by the CNC controller.

 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 MT

CNC Surface Wheel Lathe (LW 200 N)

Fig 2.13

24
 CHAPTER 3

CASTINGS & FORGINGS

 Steel Castings
 Steel Forgings
 Grey Iron Castings
 Non-Ferrous Castings


 STEEL CASTINGS


Steel casting is a specialized form of casting involving various types of steel. Steel castings are
used when cast irons cannot deliver enough strength or shock resistance. Steel is more difficult
to cast than iron. It has a higher melting point and greater shrinkage rate, which requires
consideration during mold design. Risers should be given more capacity to draw from as the
metal cools and shrinks. Attention should be paid to the thickness of mold cavities, as thinner
areas will cool quicker than thicker areas, which can create internal stress points that can lead to
fracture.

Heavy Steel castings of piece weight 65 Ton finished wt. (as cast wt. upto 90 Ton) (facility of
liquid metal upto 120 T)


Typical steel castings products are;

 Slag cups for Steel Plants ( 11/15/16/18 CuM )


 Roll chocks

 Roll mill housings
 Cement plant tyre (upto 45T piece weight and 6m dia )
 Cyclotron Magnet poles

Bottom Housing of Pinion Stand (Steel Casting, 65 T) Spindle Stand

Fig 3.1 Fig 3.2

25
 Mill Housing (Steel Casting) 20 CuM Slag Cup
Fig 3.3 Fig 3.4

STEEL FORGINGS

When steel is heated to forging temperature, it becomes ductile and malleable and be molded
to a shape of our choice by applying pressure. With proper processing methods, steel forging
allows a billet of steel to be shaped permanently without cracking, due to its plasticity.

Forgings of various grades of alloy material up to piece weight of 65 Ton finished wt.
Complete with heat treatment and machining. (click for forging facilities).

 Forged Rings up to diameter : 4.2 M


 Die forgings

75 T Ingot under Forging Spindle for Hot Strip Mill

Fig 3.5 Fig 3.6

26
 Forged Ball (1.35 M diameter) Ring Forging (4.2 M diameter)
Fig 3.7 Fig 3.8

GREY IRON CASTINGS

Grey iron castings, also known as gray iron casting, are iron-carbon alloyed parts produced in
foundries, not to be confused with forges. Inside foundries, gray iron material is cast and formed via
closed mold operations for applications in a wide range of industries.
Grey iron castings lend durability, hardness and strength to any operation for which they are used.
The applications of gray iron castings are many. As non-flammable building components, they
provide superior fire protection to wooden support structures. Also, their graphite/graphite flake
content is useful in energy dissipation of parts like engine blocks and crankshafts, which depend on
the dampening of mechanical vibrations.

 Iron castings of piece weight 70 Ton finished wt.

Typical Iron castings products are

 Coke Oven door bodies, door frames and flash plated for Coke Oven upto 7 m height.
 Base plate for Blast furnace stove

 Grate bars

NON-FERROUS CASTINGS

 Non-Ferrous Castings of piece weight upto 4 Ton (Click for forging facilities)
 Centrifugal Casting

 Copper based castings upto 2 Ton piece weight

 Aluminium based castings up to 300 Kg. piece weight

Typical Iron castings products are;

 Hollow Shaft for Stripper Crane Bushes, machine components etc .







27
 CHAPTER 4

CRUSHING EQUIPMENTS

 Primary Gyratory Crusher

 Cone Crusher
 Four Roll Crusher
 Reversible Hammer Crusher
 Rod Mill
 Other Crushing and Mineral Processing Products


 PRIMARY GYRATORY CRUSHER



A gyratory crusher is an ore processing machine that crushes the ore between an eccentrically
mounted cone and a crushing throat, that is fixed. In mining, the most important criteria for effective
crushing of ores is to choose the type of crusher that suits the rock (ore) material, and to ensure
uniform feed.

Gyratory crushers are known for their high production rates, with a higher capacity than a jaw
crusher. In order to get cubical material out of a gyratory crusher, it should be choke fed. Gyratory
crushers are not suitable for crushing clay, as clay will clog the crusher.


Designed for heavy duty services and stable product size. Supplied over 12 nos for Coal and Iron ore
crushing.
PARAMETERS
TABLE NO. 4.1
Feed opening 1500 mm

Nominal Discharge 160-200 mm

Capacity (CuM/hr) 1450CuM/hr

Main Drive Motor 400 kw

Weight of Crusher 428 T (with out electrics)











28
 PRIMARY GYRATORY CRUSHER

Fig4.1

 Wide range of models with receiving opening ranging from 1350 to 1500 mm
 Adjustment provision for discharge setting to compensate wear & tear of concaves &
mantel.
 Spider suspension of main shaft assembly.
 Optional duel prime movers
 Different models available for various output range.

CONE CRUSHER
A Gyratory Cone Crusher is one of the main types of primary crushers in a mine or ore
processing plant. Gyratory cone crushers are designated in size either by the gape and mantle
diameter or by the size of the receiving opening. Gyratory cone crushers can be used for primary
or secondary crushing. The crushing action is caused by the closing of the gap between the
mantle line (movable) mounted on the central vertical spindle and the concave liners (fixed)
mounted on the main frame of the crusher. The gap is opened and closed by an eccentric on the
bottom of the spindle that causes the central vertical spindle to gyrate. The vertical spindle is free
to rotate around its own axis.
Cone Crushers both for Secondary & Tertiary Crushing suitable for ore dressing for application
in ferrous and non-ferrous metallurgical works, cement plants and construction material plants.

CONE CRUSHER

Fig4.2

29
 FOUR ROLL CRUSHER

Double-Roll-Crushers are used for the crushing or medium-hard rock as well as for sticky and
soft materials, i.e. lignite and mineral coal, clay, marl, limestone and similar raw materials as
well as for overburden and ores.
For fine crushing of coke etc. for Sintering and other applications. Two stage crushing made
possible in one unit. Available in various capacity range.

Important Parameters :
TABLE NO. 4.2
Recommended feed size Upto 40mm

Diameter of rolls 900 mm

Width of rolls 700 mm

Main drive motor 45 kw

Other drive 15/23 kw

Four Roll Crusher

FIig4.3

30
 REVERSIBLE HAMMER CRUSHER
The main advantage of the Williams Reversible Hammer Mill is that the direction of the rotor
that supports the hammers can be reversed by simple direction selection of the drive motor.
Fresh grinding edges are thus brought into action. Production is increased, hammer life is
doubled, and maintenance is reduced.

Important parameters

TABLE NO. 4.3

Diameter of rotor 1500 mm
Width of Rotor 1500mm
Recommended Mx. feed size 120mm
Product size(coal) 0-3 mm
Capacity 350-550 T/hr.
Main Drive Motor 800 kw
Other Drive 15/23 kw
Weight of machine 28 T (with out electrics)

Features:
 Energy efficient
 Longer service life
 Easy to operate
 Robust design

The crusher especially used in coal company , metallurgy , power , mining , building material, to
crush the brittle material with high moisture content.
The type of the crusher are according to the hardness ,moisture, size of the material, and the
required output size distribution. Our company supply the customer the most suitable crusher, to
meet customers’ requirements.

31
 Reversible Hammer Crusher
Fig4.4
Application for secondary and tertiary crushing limestone

TABLE NO. 4.4

155 x 1500

Diameter of Rotor 1500 mm

Width of Rotor 1500 mm

Recommended Mx. feed size 120 mm

Product size(coal) 0-3 mm

ROD MILL

A rod mill uses steel rods as the grinding media in tumbling mills is an efficient means to feed
ball mills a product finer than could be made in a crusher but coarser than could be made in a
ball mill.

Rod mills are very similar to ball mills, except they use long rods for grinding media. The rods
grind the ore by tumbling within the the mill, similar to the grinding balls in a ball mill. To
prevent the conditions leading to rod charge tangling, the length to diameter ratio is maintained
at 1.4 to 1.6. Rod mills accept feed up to about 50 mm (2 in.) and produce a product in the size
range of 3000 to 270 mm (–4 to –35 mesh). Grinding action is by line contact between the rods
extending the length of the mill. Rods tumble and spin in roughly parallel alignment simulating a
series of roll crushers. This results in preferential grinding of coarse material and minimizes
production of slimes.

Applicable for secondary and tertiary crushing of medium hard materials such as
gypsum,limestone etc and bituminous coal.Designed for achieving very high reduction
ratio.Available in various models with capacity ranging from 80 to 550T/Hr.(Coal).
Air swept coal pulveriser is primarily of ball mill family and is designed for pulverizing coal to
prepare boiler feed.

32
 Rod mill

rod mill
Fig4.5

OTHER CRUSHING AND MINERAL PROCESSING PRODUCTS

 Jaw Crushers
A Jaw Crusher is one of the main types of primary crushers in a mine or ore processing plant.
The size of a jaw crusher is designated by the rectangular or square opening at the top of the
jaws (feed opening). For instance, a 24 x 36 jaw crusher has a opening of 24" by 36", a 56 x 56
jaw crusher has a opening of 56" square.


 Apron feeders

Apron feeders consist primarily of two (2) strands of endless tractor chain with either cast
manganese or fabricated steel pans (flights) bolted to a common link of each strand.The
chains are driven by sprockets that are mounted to a head shaft. The pans travel with the
chain and articulate over the head sprockets to discharge material.

CRANE
Electric overhead traveling crane or EOT crane is one of the most common types of overhead
crane, or called bridge cranes, which consist of parallel runways with a traveling bridge spanning
the gap. As obvious from the name, EOT crane is operate by electric, generally there is an
operator cabin or a control pendant along with the EOT crane.

33
 HEC designs and manufactures heavy duty Electric Over Head (EOT) cranes for application in
Steel Plant, Engineering sector, Space Research etc. The highest capacity crane designed &
manufactured so far is 450 T Ladle Crane for handling hot liquid metal.

Typical EOT Cranes:

 EOT Cranes for workshops and engineering sector up to 400 t capacity
 Ladle Crane for handling Hot metal Ladles in Steel and metallurgica l plant up to 450 t
 Rotating Trolley Crane

 Tundish Handling Crane

 Magnet Grab Crane

 Slab handling Tong Crane for steel plant application
 
 Four girder double Trolley semi portal Scrap Charging Crane
 Cantilever Roof mounted Tower Crane,

EOT Capacity: 400 /60 T.

Fig4.6

Special Features:

 Digital AC Vector Drive for smooth control and creep speed.

 Regenerative Active Front End (AFE) Converters for energy efficient operation.
 Planetary Gear system for continuous hoisting & lowering at half speed in case of failure
of one drive system.
 Double wire rope, double upper Block and double bottom pulley block system to facilitate
emergency hoist operation without tilting the load in case of failure of one rope system/one
pulley system
 Emergency Braking system on Hoist Rope Drum to prevent free fall of load
 AC operators cabin and electrical panel room. 
 Weighing system with VHF communication to ground station
 Anti collision system
 Radio remote control
 Automatic Track and wire rope lubrication system
 Interface to automation systems eg. Coil Yard management system.


34
 Supplies made to:

 Bharat Heavy Electricals Limited, Hardwar


 Bhilai Steel Plant 

 Tata Iron & Steel Co., Jamshedpur 

 Bokaro Steel Limited, Bokaro Steel City, Bokaro

 Visakhapatnam Steel Project, Visakhapatnam

 Bhilai Steel Plant, Bhilai

 Jayant Coal Handling Plant, Northern Coal Fields Ltd., Jayant

 Durgapur Steel Plant, Durgapur


 Rourkela Steel Plant, Rourkela 

 Isro, Sriharikota

 Konark Met Coke Limited 

 Tamil Nadu Electricity Board

 Neelachal Ispat Nigam Limited 

 Tiazhpromexport Moscow For Bulgaria

 Durgapur Steel Plant, Durgapur

 Tata Iron & Steel Co., Jamshedpur 

Capacity-wise Break up

TABLE NO. 4.5

Capacity Numbers
Up to 50 t 102

50 t to 100 t 113

100 t to 200 t 83

250 t 3

320 t 4

400 t 1

450t 7

35
 TURN-KEY PROJECTS

Turn-key Project Execution:

HEC Executes various projects in the core sectors from concept to commissioning in different
sectors like mining, power, steel plants, cement engineering etc.

Fields of specialization:

 Material Handling Plant 


 Coal Handling Plants

 Coal Washeries

 Low Temperature Carbonisation Plant and Gas Treatment Plants

 Tar distillation Plant & Processing Plants

 Direct Reduction Plants from Iron Ore

 Sinter Plants

 Continuous Casting Plants for Billets, Slabs and Blooms 

 B.O.F. & Gas cleaning Plant

 Lime Calcination Plants

 Rolling Mills

 Cement Plants.

Stacker cum reclaimer in operation Conveyor Gallery

Fig4.7 Fig4.8

36
 COAL HANDLING PLANT

The huge amount of coal is usually supplied through railways. A railway siding line is taken
into the power station and the coal is delivered in the storage yard. The coal is unloaded from
the point of delivery by means of wagon tippler. It is rack and pinion type. The coal is taken
from the unloading site to dead storage by belt conveyors. The belt deliver the coal to 0m level
to the pent house and further moves to transfer point 8.

The transfer points are used to transfer coal to the next belt. The belt elevates the coal
to breaker house. It consists of a rotary machine, which rotates the coal and separates the light
dust from it through the action of gravity and transfer this dust to reject bin house through belt.

The belt further elevates the coal to the transfer point 7 and it reaches the crusher through belt.
In the crusher a high-speed 3 phase induction mototr is used to crush the coal to a size of
50mm so as to be suitable for milling system. Coal rises from crusher house and reaches the
dead storage by passing through transfer point 8.

coal handling plant

Fig4.9

Flow chart

Special Focus:
Concept to Commissioning for Bulk material Handling and steel plant projects

 Feasibility studies & Site selection

 Basic Engineering with Process Flow Sheets, Energy and Material Balance 

 Detail Specification of Plant and Process Equipment 

 Manufacturing, Erection, Testing & Commissioning of Plant & Equipment 

37
CHAPTER 5

SERVICES PROVIDED BY THE ORGANIZATION

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. 

Fig 4.15

500th Excavator ready for dispatch (2008)

Fig 4.10

Cyclotron Magnet Poles

A cyclotron accelerates charged particles outwards from the center along a spiral path. The
particles are held to a spiral trajectory by a static magnetic field and accelerated by a rapidly
varying (radio frequency) electric field.
HEC successfully manufactured Magnet Poles and associated components for VECC
(Department of Atomic Energy) and supplied in the year 2002.

38
Cyclotrons can be used in particle therapy to treat cancer. Ion beams from cyclotrons can be
used, as in proton therapy, to penetrate the body and kill tumors by radiation damage, while
minimizing damage to healthy tissue along their path. Cyclotron beams can be used to bombard
other atoms to produce short-lived positron-emitting isotopes suitable for PET imaging.

 exceptionally low carbon steel with variation in carbon content within 0.07% .
 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.

Pole Tip Assembly Cyclotron Magnet Assembly

Fig 4.11 Fig 4.12

High Impact Steel for DMRL

 Two grades of steel 249 A (ABA) and 249 AB2 developed for application in NAVY.
 Excellent Mechanical properties of the material achieved which is the manifestation of its
internal soundness and cleanliness of steel composition.
 Impact test result achieved 170 Joules / cm2

 Commercial production of the established grade of steel started.

 A mile stone achievement in Indian metallurgy

39
 Contribution to Nuclear Energy

 HEC has successfully manufactured special forging of nuclear gradel.

 The ultra clean liquid steel has been developed with close control of chemical composition &
impurities.

 HEC has now established the technological processes and controls needed to make forgings
for nuclear power sector.

 CNC Vertical Turning & Boring machine for Durgapur Wheel and Axle Plant
15 nos. of machines were manufactured with Automatic Wheel Handling System to cater the
production of 1 lakh wheels per year from rough forging to finish stage. These wheels are
being supplied to INDIAN RAILWAYS for direct mounting on axles. The machines were
equipped with FANUC 12 T with Auto Tool Changer.

 CNC Deep Hole Boring machine

The machine was designed & developed with Sinumerik 810 M.GA3. The machine was
commissioned in 1994 at Field GUN Factory, Kanpur for deep hole drilling/trepanning of
large size gun barrels. It's performance was appreciated by the user.
 Heavy Duty CNC Roll Turning Lathe for Rolling Mills 
4 nos. of machines were developed & manufactured for rough & finish machining of Rolls
with very high skin hardness. These machines with a use of FANUC 0-TD CNC System were
supplied & commissioned at Bokaro steel Plant in the year 1997.

 Wheel Lathe for Tramways

 Conversion of Hydromotor to DC Feed Drive for Horizontal Boring machine
 Twin Horizontal Boring machine system for Co-Co Bogie machining for CLW.HEC has
successfully developed High Strength Low Alloy Steel Grade DMR-249A and 249B for
Naval ApplicationHEC has taken up developmental work of large size rings of special
material for ISRO .

40
 CONCLUSION

The two moths industrial training done at Heavy Engineering Corporation

Limited was completed with deep knowledge and understanding of various
process and function of the plant. The different working units had different
function and was contributing towards the finishing of products from initial raw
material to final finished product. I carefully worked and observed the complete
manufacturing set up starting from casting & forging, fabrication, machining,
assembly and testing

During these days I was able to understand and gather as much as knowledge as I
could. This vocational training left a deep insight on me as i could analyze and see
the heaviest machine tool manufacturing processes and their assembly. With this
largest integrated engineering complex in India , I had a great feeling of
satisfaction after completion of my training.

41