Training report for Industrial Training

in
Prime consultants & engineers

By :

Jay Mavani

Guided by : - Jayant Bharadiya

Praful Bharadiya
 Introduction
As the part of our study in Gujarat Technological University it
is necessary to visit and take an industrial training on our
interest area and get extra knowledge of our interested subject.

Thanks to PRIME CONSLTUNTS & ENGINEERS to

give me an interesting platform for my curiosity and provide
me best knowledge of various type of production of mechanical
equipments.
 DIFFERENT MECHANICAL EQIPMENTS MANUFACTURED BY
COMPANY

 Chemical Reactors
 Pressure Vessel
 Storage Tanks Horizontal , Verticals , Under grounds .
 Heat Exchangers.
 Distillation column .

 AS FOR MY 15 DAYS TRAINING IN PRIME CONSULTANT &

ENGINEERS I KNOW ABOUT HOW TO MAKE DIFFERENT
TYPE OF CHEMICAL REACTORS .

 CHEMICAL REACTORS
 Main purpose of chemical reactors are to prepare
different type of chemicals by reacting two or more
chemicals .
 Design of reactors is depend facilities required to
carry out successful chemical reactions take place
inside vessels and produced desired chemicals .
 CLASSIFICATION OF CHEMICAL REACTORS
 HIGH PRESSURE REACTORS
 LOW PRESSURE REACTORS
 ATMOSPHERIC REACTORS
 VACCUME DISTILLATION REACTORS
 FACILITIES & REQUIRNMENTS FOR CHEMICAL REACTORS
  HEATING & COOLING :- Providing jacket , external
limpate coils ,internal limpate coil etc.
 STRRING & MIXING :- Stirrers agitators provide of
various design .
 CONTROLLING OF REACTIONS :- To control internal
reactions various type of instruments provided .

 MECHANICAL DESIGN & FABRICATION

 Generally chemical reactors are fabricated from
metal plates ,pipes, flanges, metal rods etc..

 MECHANICAL DESIGN IS INCLUDES

 Selection of raw materials like mild steels , alloy
steels , stainless steels etc .
 Selection of minimum thickness of vessels depending
of operating pressure & temperature during reaction.
 Stirring & mixing pattern requirements.

 FABRICATION OF REACTORS
 Selection of quality raw materials like plates/sheets
,round bars , pipes, flanges etc.
 Forming of various parts like shell, dished heads,
cones, pipe coils etc.
 Set up assemblies of formed parts & welding to
construct vessel .
 Fabricate agitator assemblies consist shaft , bearings
, housings , impellers & turbines. Drive assemblies
like gear box & motors.
 Providing nozzles for inlet/outlet of product for
inspection & instrumental requirements.
 INSPECTION OF A RAW MATERIAL

 Raw material identification &testing

 Putting stamps on identified pipes and samples.

 Dimensional & visual checking
 Chemical analysis
 Physical or tensile test

 Give v shape

 Give v shape on an identified sheets by grinding .Grinding

is abrasive machining process which uses grinding wheel
as the cutting tool.
 Some important and basic operation

 Cutting
 Drilling
 Welding

 Cutting
 Cutting is very important operation for manufacturing
process
 There are many type of cutting operation performed on job
.
1. Oxyaccetiline cutting
2. Plasma arc cutting

3. Laser beam cutting

 BENDING OF PLATES

By use of cold rolling process, plates are bended in the range

of 1250mm.

 Welding Process

 Welding is the primary and very important process of any

type of manufacturing process.

1. Gas metal arc welding

More commonly used MIG welding .this welding type is

most commonly used and widely used for mild steel ,
stainless steel as well as alluminium .

 Tig welding

 In this type of welding it is oxy acetylene welding and need

expert welder for it.Superior standard of cleaning needed.
 Arc welding
It is the most basic type of welding .It is used for
manufacturing and repairs and constructions .

Common defects of arc welding

 Cracks
 Distortion
 Poor Penetration
  Undercut
 Porosity
 Overlapping
 Lake of fussion

 Visual Inspection (VT)

Visual inspection is a non-destructive testing (NDT) weld
quality testing process where a weld is examined with the eye
to determine surface discontinuities. It is the most common
method of weld quality testing.
Advantages of nondestructive weld quality testing:

 Inexpensive (usually only labor expense)

 Low cost equipment
 No power requirement
 Quick identification of defects and downstream repair
costs due to issues that weren't caught early

Disadvantages:

 Inspector training necessary

 Good eyesight required or eyesight corrected to 20/40
 Can miss internal defects
 Report must be recorded by inspector
 Open to human error

Visual Weld Quality Testing Steps

1. Practice and develop procedures for consistent application

of approach
2. Inspect materials before welding
3. Weld quality testing when welding
4. Inspection when weld is complete
5. Mark problems and repair the weld

Visual Weld Equipment

Fillet Weld Gauge

F ILLET W ELD GAUGE IS AN ESSENTIAL WELD QUALITY TESTING TOOL . I T IS

USED TO CHECK FILLET LEG SIZE , CHECKING FILLET THROAT SIZE W ELD
M ATERIAL I NSPECTION

 Do the materials purchased match the specification for

base metal size and type? Check electrode size, gas
selection and grade.
 Check materials for defects. Look for contaminants such as
rust, scale, mill, lamination etc.
 Are materials prepared for correct angles

Assembly Inspection
Follow these weld quality testing steps for assembly inspection:

 Check for fit

 Alignment of fixtures and jigs. Check cleanliness (look for
spatter from previous jobs)
 Check quality if tack welds are used. The tack weld must be
made with the same electrode as the main weld (s).
 Check use of pre heat to slow the cooling rate and to
minimize distortion
Equipment Inspection
 Check for damage (cables, ground clamps, electrode
holder).
 Check arc voltage
 Check amperage meter for range against specification

Visual Inspection During Welding

 Check electrodes for size, type and storage (low hydrogen
electrodes are kept in a stabilizing oven)
 Watch root pass for susceptibility to cracking
 Inspect each weld pass. Look for undercut and required
contour. Ensure the weld is cleaned properly between each
pass.
 Check for craters that need to be filled
 Check weld sequence and size. Gauges are used to check
size.

Inspection After Welding

 Check weld against code and standards
 Check size with gauges and prints
 Check finish and contour
 Check for cracks against standards
 Look for overlap
 Check undercut
 Determine if spatter is at acceptable levels

Gas Weld Testing

Inspection weld quality testing criteria for gas welds:

 The weld should be of consistent width throughout. The

two edges should form straight parallel lines.
 The face of the weld should be slightly convex with a
reinforcement of not more than 1/16 in. (1.6 mm) above the
plate surface. The convexity should be even along the
entire length of the weld. It should not be high in one place
and low in another.
  The face of the weld should have fine, evenly spaced
ripples. It should be free of excessive spatter, scale, and
pitting.
 The edges of the weld should be free of undercut or
overlap.
 Starts and stops should blend together so that it is difficult
where they have taken place.
 The crater at the end of the weld should be filled and show
no holes, or cracks.

For Butt Joints:

If the joint is a butt joint, check the back side for complete
penetration through the root of the joint. A slight bead should
form on the back side.

For Fusion of Lap and T-joint Testing:

The root penetration and fusion of lap and T-joints can be
checked by putting pressure on the upper plate until it is bent
double. If the weld has not penetrated through the root, the
plate will crack open at the joint as it is being bent. If it breaks,
observe the extent of the penetration and fusion at the root. It
will probably be lacking in fusion and penetration.

 INSPECTION
We have used three types of inspection to sure about the
product dimension, proper welding, crack on the plate.
Dimension faults are mainly solved by measuring with a proper
scale by a well-educated inspector. There are generally to types
of inspection on welding are made. They are destructive test
and non destructive test. UT and DP are non destructive test.
  DYE PENETRATION

This module is intended to provide an introduction to the

NDT method of penetrant testing. Penetrant Testing, or PT, is a
nondestructive testing method that builds on the principle of
Visual Inspection. PT increases the “seeability” of small
discontinuities that the human eye might not be able to detect
alone.
 BASIC REQUIREMENTS OF SAFETY
 Job should be handle safely while using crane.
 Hammering never be done on the oxy-acetylene cylinder, it
may cause accidents.
 Workshop should be cleaned properly.
 Chain and belts are to be checked before use.
 Sharp corner can cut chain. so lower sheet or rubber can
be used to save chain from damage.
 Factory inspection to be done.
 Electric safety should be taken properly.
 Every worker should be trained about safety.
 You are responsible for your own safety and for safety to
others.
 All accidents are preventable.
 Do not take short-cuts, follow the rules.
 If you are not trained don’t do it.
 Use the right tools and equipment and use them in the
right way.
 Access the risk before you approach the work.
 Never wear loose clothes and slippery footwear.
 Always wear safety shoes and wear goggles while
grinding and welding.

 Inspection
 Hydro test
 Positive Material Identification test
 Pnumetic test
 Final running trial with test media like water .