Report on Industrial Visit to HMC-1 Taxila

Introduction:
Heavy Mechanical Complex Texila, situated at 35 KM from capital Islamabad, is a
leading engineering enterprise in the country, under the ministry of Industries & Production,
Government of Pakistan.
Heavy Mechanical Complex (HMC), rightly known as “Mother Engineering Industry” is serving the
nation since more than four decades. HMC was principally entrusted the task of shifting the
Pakistan’s consumer goods industry to the capital & producer goods industry.
It can be proudly said that HMC has made significant contributions in transforming the country into
strong technological base through acquisition, assimilating the design and manufacturing techniques
to produce capital engineering good’s concepts from the world with emphasis on optimum
indigenization, phased deletion & to exploit Pakistan’s tremendous capital engineering goods
potential besides creating socioeconomic activities and saving hard earned foreign exchange.
HMC engineering and manufacturing company comprises of two main production units:

 Mechanical Works
 Foundry & Forge Works

Mechanical works:
It is started commercial production in 1971 and Forge Works started
commercial production in 1977.
The major facilities of this integrated company include Design and Engineering.

 Fabrication
 Machine shops
 Steel Foundry
 Forging
 Heat treatment
 Pattern Shop.
 Galvanizing Shop
 Assembly
 Quality Assurance

Departments
 Sales and Marketing Department
 Design and Engineering Department
 Production Planning and Control Department
 Production Shops (HMC1 & HMC2)
 Quality Assurance Department(QA)
 Project Management Department(PM)
 Human Resources Department(HR)
 Finance and Budgeting Department

Facilities:
 Fabrication (HMC -1 )

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 Machining (HMC – 1)
 Heat Treatment
 Casting
 Forging
 Galvanizing
 Tool Making
 Assembly
 Design
 Quality Assurance Department with ISO 9001 Certification
 ASME U,U2,PP & R Stamps

Products
 Sugar Mills
 Cement Plants
 Boilers
 equipment for Oil & Gas
 Fertilizer
 Chemical Plants
 OHT Cranes
 Road Construction Machinery
 Railway Equipment
 Over Head Traveling Cranes
 General Steel Structure
 Highly Sophisticated Castings and Forgings
 Items for Defence and Strategic Industry

Introduction
Fabrication shop located in mechanical works HMC-1 is setup to create an interracial
fault on materials/workpieces in order to obtain any useful assembly or equipment. In HMC (Heavy
Mechanical Complex] Fabrication shop consists of five bays i.e.

 1 heavy bay
 2 medium bays
 2 small bays
Bays are divided as per the capacity of the cranes.

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The above triangle shows the bays of fabrication shop along with the crane capacity.
However, these bays are further splits up into different sections as per work requirement according to
the following arrangements

 Welding Section
 Hot Forming Section
 Layout Section
 Fabrication Section
 Machining Section

Machinery Installed in Fabrication Shop:

Now it time to explain all the equipment's installed in fabrication along with their exploit task and
specification.

Heavy Bay:
(Crane Capacity 50 tons)

Gas Furnace:

Manufacturer China
Furnace Type Heating
Fuel Used Natural gas
Max Temperature 1200 C
Purpose Heat the workpiece for press forming

Hydraulic Press:

Manufacturer China
Press type Hydraulic
Capacity 1000 tons
Purpose Straightening, bonding.

Rolling Machine-1
Manufacturer China
No. of rollers 3
Roller length and Dia 3.5 meter and 580mm
Max sheet thickness 10-36mm

Radial Drilling Machine

It is a small drilling machine and capable on working on small parts,

SMAW:
Initial parts are made by Shield Metal Arc Welding or Manual Welding which is the most
common type of used worldwide, Each worker used electrode rods that are consumed within 2 to 3
minutes of continuous use. Although it is cheap it does not perform regular fine welding.

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Heating Torch:
Being used by workers to bring the metal back to its original position because when
once cooled the metal pieces that are joined together due to tension solidify to cause an unwanted
deformation.
Now it time to explain all the equipment's installed in fabrication along with their exploit task and
specification

Medium bay:
Shearing Machine-1:
Three segmented blades above and below with clamps to grip the metal part
is used to cut parts that have a thickness of 12mm or less and 2.7meter length.

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350 Tone Press:

Less than 25mm plates are brought here otherwise they are performed on the 1000
tone press. It is currently used to straighten the sheets after welding.

Edge Planer:
It is a 12metre long machine on which facing and beveling are performed. It's limit of
work parts is 80 mm thick.

Welding Area (For boilers and beams working area)

Automatic welding:
The automatic welding uses linear welding electrode called wire having rather
small diameter and wound up tp a spool. A type of the wire is a seamless mild steel pipe with flux
filled internally. The flux has important features affecting a quality of weldment. Thus, the ratio of
weight of flux to the weight of wire per unit length (called flux fill-factor) is controlled strictly in
manufacturing steps. The flux-cored wire is manufactured by the way to fill the flux into a mild steel
pipe having some large diameter and then draw the steel pipe through several steps using a drawing
machine.
A flux fill-factor measurment method has been investigated to detect a low fill-factor portion and
remove it in a drwing process. The authors used an eddy current testing for measuring the flux fill-
factor because eddy current testing can be performed in no contact with wire moving at high speed.
The thickness of a pipe consisting wire is correlated with the flux fill-factor so that the fill-factor of
wrong part can be measured indirectly by measuring the thickness of pipe. In order to measure the
thickness, the wire was made saturated magnetically using DC exciting coil to increase the penetration
depth of eddy current.

Small Bay-I:
(Crane Capacity 5 tons)

Panel Welding Machine:

Multiple tubes of boilers and other tubes are joined together with straps.
Each strap has 9 tubes in it. Electric welding by a 1.6 mm thick electrode is used.

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Shearing Machine-2:
Three segmented blades above and below with clamps to grip the metal part is
used to cut parts that have a thickness of 0.5-6 mm.
Circular Saw:
It is used to cut tubes, pipes with width of 200 mm and 250 mm thick.

Die Press:
It is a 100 tone press that is used to punch dies and holes inside small metal sheets after
being brought from a small furnace just besides it after the work pieces are heated to suitable
temperatures.

Nibbling Machine:
It is used to sew small holes less than 1 mm diameter but is out of order.

Brake Press:
160 tone brake press is capable of working on 4 m long and 1-6 mm thick parts. Most
of time this press is used to bend sheets.

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100 Tone Press:

After contraction/expansion of beams they lose their original shape and to be bent
and straightened back this machine used.

Straightening Machine:
Strips and curved sheets are straightened in it after passing through the small rollers and
in-built presses but both units are out of order.

Pipe Squeezing Machine

Boiler headers and heat exchangers are formed here and the bending limit is 1.5 diameter
with 1-8% oval shape accepted and over 8% oval shapes rejected.

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