1.

ABSTRACT
This Industrial training report is based on my training at ELECON ENGINEERING,
ANAND. This training is mainly focused on production of material handling equipments
used in coal plant, cement plant, power station. At the start of the report company history
and their vision and mission is given followed by the major clients and their product.
After that plant layout is given and along with that total number of machines along with
their specification is stated. After that some of their product is briefly explained which
are made during my training period.
2. INRODUCTION

Elecon is the leading manufacturer in gear department all over the world. Even in
production of material handling equipments eleocn has a big name. It is situated at
Vallabh Vidhyanagar, Anand.

2.1 History

Originally established in Mumbai in 1951, by a dynamic visionary late Shree Ishwarbhai

B Patel. A small firm indigenously manufacturing conveying equipments started
spreading its wings in the area so far unexplored, resulting in valuable savings in foreign
exchange outflow. With obvious increase in business operations, it was converted into a
Private Limited Company on 11th January 1960.

On formation of a separate Gujarat State in May 1960, with a view to contribute towards
the development of home-land Gujarat, Elecon shifted its base to Vallabh Vidhayanagar,
and became a Public Limited Company soon after.

Elecon has played a pioneering role by way being first in design, manufacturing and
supplying many of the above products in India, and thereby adhering to the motto of
“Always a Step Ahead in Technology”.

After dawn of its Silver Jubilee Year in 1976, Elecon set up a separate Gear Division,
having an area, spread 1, 73,098 sq. meters. Equipped with state of the art manufacturing
infrastructure. The Gear Division today provides a total solution to industries for power
transmission equipments by designing, supplying and servicing products like – Worm
Gears, Helical Gears, Spiral Bevel Helical Gears and different types of Couplings.

During the span of more than 4 decades Elecon has encompassed the entire major core
sector through its supplies of highly sophisticated equipment bearing ample testimony of
the symbolic mark of Elecon’s unbeatable technology. Elecon has thus made its presence
felt through consistent and satisfactory performance of its equipment in core sector as
fertilizer, cement, coal, power generation, chemical, steel plant and port mechanization
etc. across the country.

In 1994 company diversified in the field alternate non-conventional energy source. The
company successfully implemented the alternate energy system. It installed 7 windmills
out of these 5 were sold to outside parties and 2 were retained by the company for its own
consumption. The company has entered into a technical collaboration agreement with
 Belgium Company for manufacture and supply of Wind Turbine Generators - a non –
conventional source of producing energy.

2.2 ELECON Vision

Create Global Presence in power transmission by innovating and developing products to

enhance value and satisfaction of our customers.

We adopt to the changes and meet the challenges by creative entrepreneurship,

empowered teamwork, continuous improvements, environment friendly practices and
optimize profits to delight our stakeholders.

2.3 ELECON Mission

Be present in all the leading & emerging markets of the world by expanding,
collaborating and associating with other partners and consolidating our presence in
already penetrated markets.

Remain “Always A Step Ahead in Technology” by Continuously investing in research

and development to cater to new applications, industries and segments as well as
improvement of our existing product ranges.

Empower human resources to promote entrepreneurship, team spirit leading to value

enhancement for our Customers and Stakeholders.

Follow environment friendly practices to protect environment and continuously review

and improve products and processes throughout the supply chain.

Upliftment of society at large and well being of our employees.

2.4 Group companies

● Eimco Elecon
Eimco Elecon produces a wide range of underground mining machinery in Air
Powered Rocker Shovels, Electro hydraulic Side Dump Loaders and Electro
Hydraulic and Air Powered Load Gaul Dumpers used as loading machines in both the
underground coal mines and metalliferous mines. It also manufactures Air Motors for
captive consumption and other OEM manufacturers, company also manufactures
hydraulic Drilling and Roof bolting jumbos and Auger-cum-Drills and Tugger Hoists.
Side Dump Loaders, Load Haul Dumpers and Auger-cum-Drills forms backbone of
the mechanization system of underground coal mines. Power Build Pvt. Ltd.

● Power Build Elecon Gears Ltd

PBL has the finest infrastructure to design and manufacture Geared Motors,
Gearboxes and Drive assemblies. RADICON POWERBUILD offers the widest range
 of Geared Motors, Gearboxes and Drive Solutions that provide the best value for your
investment.

● Emitci Engineering Limited

EMTICI Engineering Ltd , is the marketing and servicing company appointed for ELECON,
EIMCO-ELECON, POWER BUILD, PRAYAS ENGINEERING LTD and RINGSPANN
products in India.

● Tech Elecon Pvt. Ltd

Tech Elecon Pvt. Ltd. (TEPL) draws on the company’s vast and varied experience
Tech Elecon Pvt. Ltd.of more than 19 years in the field of hardware, software and
networking solutions. The company's mission is to provide comprehensive software
and hardware solutions and satisfy the business and management needs.

● Elecon Information Technology Ltd.

EMTICI Engineering Ltd. is the marketing and servicing company appointed for
ELECON, EIMCO-ELECON, POWER BUILD, PRAYAS ENGINEERING LTD
and RINGSPANN products in India.

 Redicon Benzlers
Benzlers and Radicon have over 60 years of experience and have a reputation for
being markebenzlerst leaders in the design and manufacture of screw jacks, shaft
mounted gearboxes and industrial reducers.
2.5 Major clients

Elecon has vast range of products in material handling equipments. Because of that
Elecon has many clients all over India and out of India.

(a) Power station :-

-Electrical boards of various state boards

(b) Coal plants:-

- Bharat cooking coal limited,

- Southern cooking coal limited,
- Central coal field
- Mahanand coal field
- Neyveli lignite kilns.

(c) Cement plants:-

- Ambuja cements, -chankya cements

- Chottor cements, -century cements
- Rashi cements, -L & T cements
- Zouri cements, -Lakshmi cements
- Satha cements.

(d) Fertilizer plants:-

- GSFC, -WRO Gulf

- IFFCO, - Chambal fertilizers
- Indogulf fertilizers.

(e) Export order:-

- Coal hardening plants in Thailand,

- Fertilizers plants in Bangladesh,
- TICB in Malaysia.

(f) Other companies:-

-GMM -BIRLA CORP.

-NIRMA -GFCL
-SAIL -ANUPAM
-NTPC -TISCO
2.6 Range of products

Elecon manufacture various types of material handling equipments used in coal plant,
cement plant, thermal power station, fertilizer companies etc. Major products are listed
below.

 Reclaimer
 Stacker reclaimer
 Twin boom reclaimer
 Bucket wheel
 Stacker
 Semi/Full portal scrapper reclaimer
 Bridge type scrapper recliamer
 Wagon Tripler
 Feeder
 Apron feeder
 Paddle feeder
 Grizzly feeder
 Reciprocating feeder
 Weigh feeder
 Conveying System
 Pipe conveyor
 Downhill conveyor
 Long distance conveyor
 High speed conveyor
 Shiflable conveyor
 Crusher
 Double roller crusher
 Feeder breaker
 Impact mill
 Ring granulator
 Delumper
 Cable Reeling Drum
2.6.1 Stacker reclaimer:

Fig 2.1 Stacker reclaimer

 Stacker reclaimer is used to handle bulk material like coal, limestone, and scraps.
 Capacity of stacker reclimer is around 300 tph to 2000 tph.
 Main components of stacker reclimer are bucket, bucket wheel body, boom part,
and counter weight, upper and lower carriage.
 This whole machine is working on bogie. By moving these bogies whole stacker
reclaimer can be moved on rails.
 There are different bogies used for this purpose, 10 wheel bogie, 8wheel boogie
and like 2 wheel boogies.

2.6.2 Twin boom stacker reclaimer:

 Twin boom stacker reclaimer is having same system like stacker reclaimer but
only difference is that it has two boom parts. It can handle the material at both
the side.
 It is suitable for handling limestone, coal etc. and capacity is 300tph to1000tph.
 Fig 2.2 Twin boom stacker reclaimer

2.6.3 Barrel type bucket wheel reclaimer:

 It is used for handling coal, iron ore, limestone etc in stockyard, steel plant,
thermal power station, cement plants.
 The capacity ranges from 300 to 4000tph.
 In this type of reclaimer conveyor belt is passed through the center of the barrel,
buckets are mounted at intermediate distance on circumference of the barrel. This
whole system can be moved on the rails. The barrel is rotated and material is
collected in the bucket and is fall down on belt passing through the center of the
barrel.

2.6.4 Apron feeder:

 Use of apron feeder is to control , maintain and receive the flow of material from
the hopper.
 Apron feeder has two main components: Headstock side shaft and tailstock side
shaft. Conveying belt is mounted on this shaft and belt is rotated by gear box
attached to the head stock side shaft.
 Material from the feeder is than passes to the crusher.
 Fig 2.3 apron feeder

2.6.5 Paddle feeder:

Fig 2.4 paddle feeder

 Rotary plow feeders are most useful for handling materials that are sluggish, tend
to interlock or mat and thereby arch over restricted openings.
 They are usually mounted under the bottom of bins and hoppers.
 In recent times Paddle Feeders have been very successfully used in Coal Handling
Plants and other installations for extraction of loose materials from stockpiles,
Silos and Bottom Discharge Wagon Systems.
2.6.6 Grizzly feeder:

Fig 2.5 Grizzly feeder

 This type of feeder is used to separate coal of different size and then it passes that
coal to the crusher.
 Perforated tray is placed on the feeder so small size coal direct pass to the
destination while big size coal passes to the crusher.
 Two vibrating motors are attached to the feeder so separation takes place because
of vibration motion.

2.6.7 Idlers:

Fig 2.6 Idlers

  Idlers are the main parts which gives support to the conveying belt throughout the
length.
 Capacity of this system varies according to customer requirement.

2.6.8 Pulley:

Fig 2.7 Pulley

 Conveyor pulleys been recognized as a critical component of conveyor, failure of
which could lead to extensive damage and down time. Hence special attention has
been given to design and develop the most dependable pulleys.
 Suitable for conveys of belt width ranging from 400mm to 2400mm.
 Capacity varies with customers.
 Available in rubber lagging and ceramic lagging.

2.6.9 Single roller crusher:

 It is used to crush the material such as limestone, coal, rocks.
 Material is crushed between grinding wall and rotor shaft.
 Fig 2.8 Single roller crusher

2.6.10 Double roller crusher:

 For crushing of coal, coke, clinker, moderately hard rock, ore, chalk etc.
 Slow Speed Crushing machine used with limited ratios for crushing when lesser
fines are desirable.

Fig 2.9 Double roller crusher

2.6.11 Impact mill:

Fig 2.10 Impact mill

 For crushing hard & medium hard rock’s such as limestone, basalt, blast furnace,
slags etc.
 Rigid Blow bars used to give high impact.
 Breaker plate and grinding rails are used as grinding media.

2.6.12 Cable riling drum:

Fig 2.11 Cable riling drum

  Elecon manufacture Motorized Cable Reels for all types of mobiles material
handling equipments.
 Mainly two types: (1) Parallel (2) Single.

2.6.13 Custom products

 Chutes, Two way chutes, Rack and gear gate (RC gate), Magnetic separator, D.S
trolley are other material handling equipments manufactured in MHE devision.
 Other than this some of structural works are also carried out in fabrication shop.
3. PLANT LAYOUT OF MHE DIVISION
3.1 Production cycle

Client

Market

Project and Marketing department

Planning department Design department

Costing department

Subcontracting Purchase

Store
Inspection

Heavy machine building shop

Finish products
Client Inspection

Assembly line

Shipping department

Client site
The client floats tender in the market. The project and marketing department, after going
through substantial amount of research and considering the cost aspect, fill the tender.
After bagging the tender, all the requirements of the clients are given to the contract
department.

The contract department after studying the all the terms and condition of the clients, gives
the details to the design department and issues work under to planning department. The
design department gives all the drawings and bill of material to planning department, also
many details are given through ERP system.

The planning department distributes the work to three different areas. Firstly, they check
the availability of the material in the store. If inadequate, they issues purchase requisition
slip to purchase department. Secondly, based on the capability of the plant, it sub
contracts some components, based on the past record of the jobs on the respective
machine of HMBS by issuing shop order.
In sub-contracting is of two types
1. Labor subcontracting
2. Full subcontracting
In labor subcontracting the raw material required to furnish the components are also
supplied to the subcontractor (For example: plates, paints etc).
In full subcontracting complete component is bought. (for example: motor, switch, gears,
etc).Elecon also helps the vender to increase their capacity so as to make the products.

All the components that the purchase department orders and the components that are
subcontracted are checked at the store for the desired quality and there after entered in the
ERP system. If approved, then it is sent to the respective shops for further processing.

After the product is furnished at the respective shop, the QC department inspects the
product for the quality as desired by the client. QC depart also arranges for the client
inspection if required.

After the client inspection is over the project is shipped to the site by issuing shop
delivery slip. At site, the final assembly is done which is Assisted by the team of
engineers from Elecon.
3.2 Departmental details
Here are some basic department’s details about their work and function in production
cycle and their significance is company.

3.2.1 Project and marketing department

The functions of this departments mentioned follow:

1. It makes the survey about the market and brings the tender.
2. Purchasing tenders by bidders.
3. According to received tender they prepare the design for the project.
4. Identifies auxiliary system or instrumentation required for the project.
5. They come up with the specification and process of the projects.
6. Finally they get the order and receive latter of indent.

3.2.2 Panning department

Planning department is responsible for the planning of day planning of day to day
planning in various department of the company starting from drawing to dispatch
oracle based ERP (Enterprise Resource Planning) is implemented which forms the
back bone of this department

Design department prepares drawing and part list of the assembly of the product
which is to be produced they forward it to the planning department via ERP
system in the form of BOM (Bill Of Material). A copy of detailed drawings are
given to the planning department, The bill of material includes the assemblies and
subassemblies in the form of levels. The component with higher level is
assembled in the component with lower level.

Form this data the planning department determines the raw material requirement
as per the order and makes the purchase requisition slip (PRS). If some important
or costly item is required then they make the import requisition slip.
After getting the work order, planning department makes the pending order list
from that they make monthly schedule for the total requirement of the product and
makes the manufacturing program sheet copies are sent to each division for their
reference.

Stores provide the monthly stock list to the planning department. Planning
department keep themselves updated with the movements of the stores and the
purchase department by maintaining periodic contact with them.

One of the important sub-division of planning department is that subcontracting

department. Planning department knows the capacity of the shop. If the
component required to be manufactured is out of the capacity of the shop then
 they sub-contract that part to the vendors available in local GIDC or nearby
GIDC. Elecon (MHE) maintaining a relation with around 25 companies for sub-
contracting for fabrication and with around 10 companies for sub-contracting for
machining. They either subcontract with raw material so as to contain the Elecon
standards or without raw material.

Planning department also makes the loading and scheduling chart for each job on
a particular machine according to the capacity and capability of the machine. At
various stages the following slips are used for the communication with other
departments. These slips are generated by the ERP system. The different slips
used are as follow.
1. Purchase order slip
2. Purchase requisition slip
3. Discrete job routing slip
4. Shop delivery memo

3.2.3 Design department

Design department is responsible for the designing and drawing of the various
products.

Design department uses Creo and autocad for drawing purpose. They use creo for
analysis of product. Strand is used for structure drawing. In case of complex job
CNC program is provided by designer. CNC programming for plasma cutting or
oxy flame cutting is also provided by designers.

In most of the cases client doesn’t ask for analysis result but they ask in case of
civil structure.

The client gives a list of all the specification of the product features required
technical 1 then design the equipment keeping all the specification into mind.
This division is further sub divided into group based on the product type electrical
systems and hydraulic system.

They then prepare the BOM for particular product, which in turn given some
code, generated by ERP. The components of detailed drawings are given to
planning department.
3.2.4 Store

There are mainly 3 stores in the MHE division

1) Main store
Fastener store i.e. Countersunk bolts, fitted bolts, screw nuts, L&Key bolts, eye
bolts, stud, plucks, diff types of washers, realief valves etc.

Main material store i.e. Bearings, sleeves, locking assemblies, flate seal, bearing
blocks, diff types of bushes, oil seal, O ring, V ring, locating ring, locknut etlc.

2)Steel store
Here in steel store, metal or steel parts are stored. As this is very big one, a very
big yard is occupied for the storage of steels.

Many types of steel parts like, plates, pipes, rods, strips, wires etc are stored in
this department.

The stores parts are then used for making diff elements, i.e. Pipes are used to
make the rollers, and long and big sheets are them sent to the cutting shop, where
as per the requirement, the sheets are cut..

3) Tool store
Different types of tools are stored in this room. Tools are ranges from milling
tools to single point cutting tools.
Mainly two different company’s tools are used.
(1) ISKA’s tools are best for grooving purpose.
(2) Sandvik’s tools are best for turning and other operations.

3.2.5 Purchase department

Its main function is procurement of the material at the right time so that there is
no hindrance to the production. It will act on the purchase requisition raised by
planning department considers the following factors:
1. Quality to be ordered.
2. Quality of the client demanded
3. Urgency of order
4. Delivery period
5. Lead time
6. Technical specification
7. Inventory specification
8. Availability in store
9. Price in the market
3.2.6 Quality control department

QC is very essential to prevent rejection and thus reduce cost. Quality assurance
plan is done in pre-tender stage. The requirements of the clients are to be achieved
at each and every stage, from design to dispatch. Various test and inspection are
carried out at each stage.

The inspection are of four types:

1. Raw material inspection
2. In-Process inspection
3. Assembly or end product inspection
4. Client inspection
LPT (Liquid Penetration Test), MPT (Magnetic Particle Test) and UT (Ultrasonic
test) are also done in the shop for checking the quality of welding.
One regular checking they mostly check major dimensions of products.
4. HEAVY MACHINE BUILDING SHOP
This shop is equipped to manufacture heavy and large job. The shop is mainly divided in
seven sheds h1 to h9:

1. Spare department H1

2. Cutting shed H2

3. Machining shed H3

4. Machining shed H4

5. Fabrication + Machining shed H5

6. Fabrication + Machining [Paint zone] shed H6

7. Crusher assembly (Crusher testing) + Shot Blasting shed H7

8. Fabrication and assembly H8

9. Assembly and fabrication H9

4.1 Plan layout of HMBS unit:
4.2 Material handling Equipments:

Equipments Quantity
Overhead cranes (5t to 25t capacity) 27
Trucks 3
Crane Trucks 2
Power operated Fork Lifts 3

4.3 Departmental details of HMBS:

4.3.1 Cutting shop H2:

Equipments Quantity
Laser Cutting Machine 2
Oxy-Flame Cutting Machine 2
Plasma Cutting Machine 2

4.3.2 Light machine shop H3:

Equipments Quantity
Vertical Boring 1
CNC Lathe Machine 8
Gear Planner 1
Radial Drilling Machine 2
Slotting Machine 3

4.3.3 Light machine shop H4:

Equipments Quantity
SAW 1
Vertical Boring 5
Heavy Duty Lathe 2
Horizontal Boring Machine 2
Plano Milling Machine 2
Radial Drilling 1
CNC Milling Machine 1
 4.3.4 Fabrication shop H5:

Quantity
Equipments
MMAW Machine 13
MIG Welding Machine 12

4.3.5 Heavy machine shop H6:

Equipments Quantity
Radial Drilling Machine 2
CNC Milling Machine 3
Horizontal Boring Machine 8
Portable Radial Drilling Machine 3
Hydraulic Press Machine 1

4.3.6 Crusher assembly shop H7:

Equipments Quantity
Radial Drilling Machine 1
Hydraulic Press Machine 1

4.4 Machine Specification

4.4.1 Youji CNC vertical boring machine, YV 500 ATC +C (VB 21)
 Make : Indian (2005)
 Controller : Fanuk
 Maximum cutting diameter : 550 mm
 X axis travel : 480 mm
 Z axis travel : 600 mm
 Maximum Swing diameter : 750 mm
 Maximum cutting height : 400 mm
 Total power consumption : 45 KVA
 Machine hour rate : 952 RS/hour
4.4.2 Bush vertical keyway milling machine (KM 08)
 Make : German(1982)
 Table size : 2700x500 mm
 Table vertical traverse : 275 mm
 Longitudinal travel of height : 3250 mm
 Maximum cutter diameter : 63 mm
 Maximum vertical adjustment of spindle: 100 mm
 Machine rate : 407 RS/hour

4.4.3 HMT make high speed precision lathe (NHL 04)

 Make : Indian(1988)
 Height of centre : 220 mm
 Distance between centre : 1000 mm
 Swing over head : 500 mm
 Swing over cross slide : 270 mm
 Main motor capacity : 11KW
 Machine rate : 237 RS/hour

4.4.4 Vertical hydraulic slotting machine (VS 01)

 Make : Russian(1962)
 Length of ram stroke : 120 mm
 Maximum length of ram stroke : 320 mm
 Working table diameter : 630 mm
 Maximum transverses travel : 650 mm
 Maximum cross travel : 500 mm
 Maximum circular travel : 360 degree
 Machine hour rate : 329 RS/hour

4.4.5 Mazak CNC power master lathe with mazatrol control (NCL 27)
 Make : Japan(2005)
 Controller : mazak
 Swing over bed : 600 mm
 Maximum diameter of chuck work : 540 mm
 Centre distance : 4258.8 mm
 Spindle nose : JIS-A1-11
 Spindle speed : 3-1200 rpm
 Travel in X : 610 mm
 Travel in Z : 4120 mm
 Main spindle drive motor : 40 HP
  Machine rate : 3326 RS/hour

4.4.6 HMT make radial drilling machine (RD 21)

 Make : Indian(1980)
 Drilling capacity in CI : 60 mm
 Drilling capacity in MS : 50 mm
 Spindle distance from edge of column : 530 (minimum), 1790 (maximum)
 Spindle taper : MT-5
 Drilling head motor : 1550 rpm at 3.6 KW
3000 rpm at 4.5 KW
 Machine rate : 220 RS/hour

4.4.7 Csepel radial drilling machine (RD 01)

 Make : Hungarian(1963)
 Drilling capacity in CI : 80 mm
 Drilling capacity in MS : 60 mm
 Spindle distance from edge of column : 440(minimum), 1750(maximum)
 Spindle taper : MT-5
 Drilling head motor : 9.27 KW
 Machine rate : 300 RS/hour

4.4.8 Mazak power master CNC lathe (NCL 09)

 Make : Japan(1981)
 Controller : Fanuk
 Swing over bed : 770 mm
 Swing over cross slide : 450 mm
 Distance between centre : 2000 mm
 Maximum weight of job : 3000 kg
 Main motor capacity : 60 HP
 Machine rate : 625 RS/hour

4.4.9 Mazak stant bed CNC lathe

 Make : Japan(1985)
 Controller : Fanuk
 Swing over bed : 540 mm
 Standard cutting diameter : 340 mm
 Distance between centre : 1500 mm
 Maximum job weight for chuck : 300 kg
  Maximum job weight for shaft : 1.5 T
 Motor capacity : 30 HP
 Machine rate : 526 RS/hour
4.4.10 Youji CNC vertical boring machine YV 1600 ATC+C (VB 22)
 Make : Indian(2009)
 Controller : Fanuk
 Chuck diameter : 1600 mm
 maximum swing diameter : 2000 mm
 maximum cutting height : 1200 mm
 maximum weight of work :8T
 X axis travel : 1575 mm
 Z axis travel : 900 mm
 Spindle motor : 37/45 KW

4.4.11 Gemini’s heavy duty lathe GE-2000 3G (SKL 03)

 Make : Spain(1982)
 Swing over head : 2000 mm
 Distance between centre : 10000 mm
 Swing over cross slide : 1680 mm
 Maximum weight between centre : 20 T
 Main motor capacity : 73.5 KW
 Machine rate : 1054 RS/hour

4.4.12 HMT make horizontal boring machine (HB 13)

 Make : Indian(1977)
 Spindle diameter : 90 mm
 Table size : 900 X 1200 mm
 Cross traverse over bed : 1600 mm
 Longitudinal traverse over bed : 1400 mm
 Axial travel of spindle : 630 mm
 Machine rate : 509 RS/hour

4.4.13 WGW facing lathe (FCL 04)

 Make : German(1984)
 Centre height over found plate : 1120 mm
 Maximum turning diameter : 2200 mm
 Maximum diameter in plate : 6500 mm
 Diameter of face plate : 3150 mm
 Maximum weight between centre : 20 T
  Machine rate : 1023 RS/hour

4.4.14 Cooper make vertical boring machine (VB 11)

 Make : Indian(1987)
 Controller : Fanuk
 Maximum turning diameter : 1500 mm
 Chuck diameter : 1500 mm
 Maximum swing diameter : 1650 mm
 Maximum height of work : 700 mm
 Maximum weight of work : 8T
 Main motor capacity : 60 HP

4.4.15 Cooper make vertical boring machine (VB 9)

 Make : Indian(1982)
 Maximum turning diameter : 1500 mm
 Maximum facing diameter : 1650 mm
 Maximum height of work : 1100 mm
 Maximum weight of work :8T
 Main motor capacity : 40 HP
 Machine rate : 507 RS/hour

4.4.16 Beco extra heavy duty lathe (SKL 04)

 Make : Spain(1983)
 Swing over head : 1600 mm
 Distance between centre : 4000 mm
 Swing over cross slide : 1200 mm
 Maximum weight of work : 10 T
 Main motor capacity : 30 KW
 Machine rate : 397 RS/hour

4.4.17 Elecon 3 roller bending machine ( PB 04)

 Make : Indian(1981)
 Maximum plate thickness : 50 mm
 Maximum plate width : 2500 mm
 Pre bending capacity : 30 mm
 Diameter of top & bottom roller : 620 mm
 Main motor power : 75 KW
 Machine rate : 859 RS/hour
4.4.18 Gemini’s CNC turning machine (NCL 21)
 Make : Spain(2006)
 Controller : Siemens
 Tail stoke quill diameter : 180 mm
 Quill travel : 300 mm
 Maximum weight between centre : 10000 kg
 Distance between two centre : 1000-6000 mm
 Machine rate : 1521 RS/hour

4.4.19 Juaristi horizontal boring machine (HB 09)

 Make : Spain(1995)
 Controller : HeadnHain
 Cross travel in X : 2000 mm
 Longitudinal travel in Y : 1800 mm
 Spindle axis in Z : 800 mm
 Longitudinal table travel : 2200 mm
 Table size : 1250 X 1550 mm
 Spindle taper : 150-50 DIN 2080
 Spindle diameter : 125 mm
 Spindle power : 50 KW

4.4.20 Mazak vertical CNC machining centre (MCC 21)

 Make : Singapore(2008)
 Controller : Fanuk
 X axis travel : 1050 mm
 Y axis travel : 510 mm
 Z axis travel : 560 mm
 Table size : 510 X 1050 mm
 Maximum weight of work : 1200 kg
 Maximum spindle speed : 8000 rpm
 Spindle taper : BT-50
 Number of tool : 24
 Coolant tank capacity : 250 L
 Maximum tool weight : 20 kg
 Maximum tool length : 350 mm
 motor power : 30 KW
  power capacity : 5.7 KVA

4.4.21 Mazak vertical CNC machine (MCC 26)

 Make : Singapore(2010)
 Controller : Fanuk
 X axis travel : 1900 mm
 Y axis travel : 900 mm
 Z axis travel : 800 mm
 Table size : 860 X 2100 mm
 Maximum weight of work : 2200 kg
 Maximum spindle speed : 40-4000 rpm
 Spindle taper : BT-50
 Number of tool : 32
 Coolant tank capacity : 250 L
 Maximum tool weight : 25 kg
 Maximum tool length : 350 mm
 Motor power : 15/18.5 KW
 Power capacity : 35 KVA
 Air source : 6 kg/cm²

4.4.22 Jauristi make CNC horizontal floor type boring machine (HB 30)
 Make : Spain(2008)
 Controller : Siemens
 X axis travel : 16 m
 Y axis travel :6m
 Z axis travel : 1.2 m
 W axis travel :1m
 Tool taper : BT-60
 Ram size : 430 X 520 mm
 Spindle diameter : 205 mm
 Spindle power : 61 KW
 Floor bed size : 16 X 6 m
 Universal head taper : BT-50

4.4.23 Jauristi make CNC horizontal floor type boring machine (HB 31)
 Make : Spain(2011)
 Controller : Siemens
 X axis travel : 14 m
  Y axis travel :4m
 Z axis travel : 1.2 m
 W axis travel :1m
 Tool taper : BT-60
 Ram size : 430 X 460 mm
 Spindle diameter : 150 mm
 Spindle power : 51 KW
 Floor bed size : 16 X 6 m
 Universal head tape : BT-50

4.4.24 Jauristi make CNC horizontal boring machine (HB 23)

 Make : Spain(1985)
 Controller : Sinumeril
 X axis travel : 2300 mm
 Y axis travel : 2000 mm
 Z axis travel : 1800 mm
 W axis travel : 950 mm
 Tool taper : BT-50
 Ram size : 430 X 520 mm
 Spindle diameter : 205 mm
 Spindle power : 40 HP
 Table size : 2000 X 2000 mm
 Maximum weight capacity : 8T
 Universal head taper : BT-50
 Rapid travel : 2000 mm/min in all direction

4.4.25 Skoda make CNC horizontal floor type boring machine (HB 19)
 Make : Spain(1982)
 Controller : conventional
 X axis travel : 15500 mm
 Y axis travel : 4150 mm
 Z axis travel : 1600 mm
 W axis travel : 2000 mm
 Tool taper : BT-60
 Ram size : 520 X 520 mm
 Spindle diameter : 200 mm
 Spindle power : 77 KW
 Floor bed size : 17000 X 5600 mm
 Universal head taper : 180 60
  Table size : 2000 X 2000 mm
 Maximum weight of work : 20 T
 Centre height of machine : 600 mm
4.4.26 CNC horizontal floor type boring machine (HB 15)
 Make : Poland(1972)
 Controller : Siemens
 X axis travel : 10850 mm
 Y axis travel : 3600 mm
 Z axis travel : 465 mm
 W axis travel : 1160 mm
 Tool taper : 150 50
 Ram size : 380 X 380 mm
 Spindle diameter : 180 mm
 Spindle power : 30 KW
 Floor bed size : 15 X 6 m
 Universal head taper : BT-50
 Table size : 2000 X 2000 mm
 Maximum weight of work : 20 T
 Centre height of machine : 770 mm
 Rapid travel : 5000 mm/min in all direction

4.4.27 EGW make travelling CNC milling machine (RM 01)

 Controller : Siemens
 X axis travel : 2200 mm
 Y axis travel : 500 mm
 Z axis travel : 410 mm
 B axis travel : +/- 22.5°
 C axis travel : (helical) +/- 22.5°
 Maximum cutter diameter : 288 mm
 Tool taper : SKL 45 DIN 69871
 Tool taper ( S.P 02) : SK 40 DIN 69871
 Spindle power : 25 KW
 Milling capacity of teeth : 30 module
 Table size : 3000 X 400 mm
 Maximum work weight : 20 T
 Coolant capacity : 1000 L
 Required air pressure : 4 bar
 Rapid travel : 10000 mm/min ( in X,Y,Z)
 Rapid travel : 120°/min ( in B,C)
4.4.28 Jauristi make CNC horizontal floor type boring machine (HB 24)
 Make : Spain(1986)
 Controller : Siemens
 X axis travel : 2100 mm
 Y axis travel : 2000 mm
 Z axis travel : 1800 mm
 W axis travel : 950 mm
 Tool taper : BT-50
 Ram size : 520 X 520 mm
 Spindle diameter : 205 mm
 Spindle power : 40 HP
 Floor bed size : 17000 X 5600 mm
 Universal head taper : BT-50
 Table size : 2000 X 2000 mm
 Maximum weight of work :8T
 Rapid travel : 3000 X 3000 X 2000 mm/min

4.4.29 Jauristi make CNC horizontal floor type boring machine (HB 24)
 Make : Spain(1983)
 Controller : Fanuk
 X axis travel : 12000 mm
 Y axis travel : 3000 mm
 Z axis travel : 1000 mm
 W axis travel : 400 mm
 Tool taper : BT-50
 Ram size : 520 X 520 mm
 Spindle diameter : 165 mm
 Spindle power : 40 HP
 Floor bed size : 12000 X 3000 mm
 Universal head taper : BT-50
 Table size : 2500 X 2000 mm
 Maximum weight of work : 20 T
 Rapid travel : 1995 X 1995 X 998 mm/min
4.4.30 CNC horizontal rotary table type boring machine (HB 25)
 Make : Spain(1995)
 Controller : Siemens
 X axis travel : 2100 mm
 Y axis travel : 2000 mm
 Z axis travel : 1800 mm
 W axis travel : 950 mm
 Tool taper : BT-50
 Spindle diameter : 250 mm
 Spindle power : 40 HP
 Universal head taper : BT-50
 Table size : 1500 X 1700 mm
 Maximum work weight :8T
 Rapid travel : 3000 X 3000 X 1800 mm/min

4.4.31 Titan make CNC horizontal floor type boring machine (HB 27)
 Make : Romania(1987)
 Controller : Siemens
 X axis travel : 15000 mm
 Y axis travel : 6000 mm
 Z axis travel : 1500 mm
 W axis travel : 1200 mm
 Tool taper : ISO 60
 Ram size : 600 X 530 mm
 Spindle diameter : 205 mm
 Spindle power : 75 KW
 Floor bed size : 18000 X 4000 mm
 Universal head taper : ISO 60
 Table size : 2000 X 2000 mm
 Maximum weight of work :8T
 Rapid travel : 5000 X 3000 X 4500 mm/min

4.4.32 Profile Gas cutting

 Make : MESSER
 Maximum length of work : 10,000 mm
 Maximum width of work : 2500 mm
 Maximum thickness of work : 250 mm
 Maximum speed : 6000 mm/min
 Minimum speed : 180 mm/min
  Distance between work and nozzle : 3 to 5 mm
 Rail length :16000 X 6500 mm
 Kerf : 2.5 mm

4.5 Controllers
In machine shop area most of the CNC machines are powered by mainly three
controllers. (1) Fanuk (2) Siemens (3) Mazak.

CNC worker mostly prefer Mazak controller because in that case program is self
generating. While in other two workers firstly need to make a program and then whole
CNC program is need to fed in the machine by keyboard, that is somewhat tedious work.
In case of Mazak controller just original dimensions and final dimensions are required to
enter in the machine. After that depth of cut and rotary speed of spindle are fed to the
computer. And that’s all controller will automatically generates a program that how many
cycles are required to reach up to final dimensions.

Another difference between these three controllers is safety. In case of Fanuk and
Siemens controller program is not completely checked by the controller. When controller
reaches to that faulty line at that time controller inform worker about that. While in case
of Mazak controller program is fully checked by the controller at the start and if there is
problem in coding then machine won’t start and inform worker about that.
5. QUALITY CONTROL

QC is very essential to prevent rejection and thus reduce cost. Quality assurance plan is
done in pre-tender stage. The requirements of the clients are to be achieved at each and
every stage, from design to dispatch. Various test and inspection are carried out at each
stage.
The inspection are of four types:
1. Raw material inspection
2. In-Process inspection
3. Assembly or end product inspection
4. Client inspection
LPT (Liquid Penetration Test), MPT (Magnetic Particle Test) and UT (Ultrasonic test)
are also done in the shop for checking the quality of welding

5.1 Inspection procedures

Elecon has some standard procedure for inspection of their product like static balancing,
temperature measurement, noise measurement, dynamic balancing etc.

5.1.1 Temperature inspection

 Connect the sensor.

 Record the ambient temperature.
 Insert the sensor rod in greasing hole on bearing blocks and take reading till
DE and NDE reading get stable.
 Difference between ambient temperature and hole temperature should be less
than that of noted in the drawing.

5.1.2 Noise inspection

 Start the machine and increase its speed to maximum.

 Place noise level meter 1 to 1.5 meter away from the machine.
 Take the reading from all four sides and value must be in acceptance.
5.1.3 Vibration inspection

 Machine should be clamped properly.

 Check the bolts and belt alignment.
 Start the machine and attain its maximum speed.
 Connect the table with the vibration machine.
 If vibration is more than balance the motor and again run the test.
 Vibration level as per ISO 1940 G16.

5.1.4 Static balancing of pulley

 After assembly, it is to kept on the stand having free rollers and confirmed
that pulley should swing freely.
 Rotate with manual force.
 Free rotation by hand is to be carried out for 4 to 5 times and locations are to
be marked.
 If pulley is stopping, suitable unbalanced weight is to be added and again test
is to be carried out.
 Unbalanced weight should be added/ welded and then checked.
 Acceptance: while checking pulley should not rotate forward and backward
of its own when it comes to rest. (At the time of pulley coming to rest slight
recoil up to 5° has to be ignored and accepted.)

5.1.5 Paddle feeder inspection

 All fabricated components are inspected in shop at various stages right from
cutting of material to sub assembly and fitment of components with machine
structure.
 Main components of paddle feeder are paddle blades, paddle drive, travel
drive, main frame and hydraulic system.
 Paddle drive consists of power pack unit, hydraulic motor, gear box with
paddle blades at output shaft.
 Travel drive assembly consists of geared motor, pairs of wheels.
 All assembly, it completeness and dimensions are verified with drawing.
 No load run test during jack up condition.
 It is ensured that hydraulic system is flushed and clean, oil level in gear box
and hydraulics are proper.
 Hydraulic starts and initiated in no load and no speed condition. Speed of
paddle is gradually increase by controlling the hydraulics.
  Variation in speed from minimum to maximum and in reverse direction in
step less condition.
 Paddle speed is checked manually by stopwatch and record.
 Maximum speed, minimum speed, hydraulic pressure, normal pressure,
temperature rise in oil, pipe leakage is checked.
 Travel wheel speed is checked for two rpm (min & max) in forward and
reverse direction and verified.

5.1.6 Acceptance norms for ultrasonic testing for forging

 Probes: normal beam probe. Frequency: 2-4 MHz

 Back wall echo should be adjusted 100% of screen height in defected area.
 At this setting defect echo height is more than 20% of the screen height then
reject.
 Minimum distance between two acceptance indications scanned as above shall
not be less than three times the diameter of probe.

5.1.7 Stacker reclaimer inspection

 All fabricated components are inspected in shop at various stages right from
cutting of material to sub assembly and fitment of components with machine
structure.
 Bogie assembly as per drawing is done with shaft, wheels and body structure.
Idle running of the wheels are tested. Alignment and wheel clearance are
checked as follow.
 Alignment of wheel is check with help of string. For single wheel bogie only
free movement is done manually and confirms that it is running through.
 Clearance is checked by free rotation of wheel and ensured that no fouling
takes place.
 Boom structure assembly i.e. pivot side, intermediate section and boom head
are assembled and level is checked by water tube.
 Under carriage body is assembled with legs and leveled. Level is checked
with water tube ball race seating area (slew deck leveling area) is checked in
various segments. Deviation in water tube within 2 to 3 mm is acceptable.
 Upper carriage body is assembled and level is checked. 2 to 3 mm deviation is
accepted.
 Bucket wheel body is assembled with bucket wheel shaft and bearing blocks.
Sample bucket is attached and checked visually and overall dimensions are
checked.
  Electric platform components are assembled and leveled as per drawing and
checked by water tube.

5.1.8 Wobble feeder assembly inspection

 Assembly is done according to GA drawing.

 Dimensions and fitment is checked for all components.
 Assembly fitment of sprockets, gear box, coupling is checked.
 Spacing between wobbler bars shall be checked at random to ensure final
product size as specified in foot note of GA drawing.
 Welding, finishing and painting are checked.
 No load run test is conducted and during that bearing block temperature rise
shall be checked and ensured that the same is within the limits.

5.1.9 Friction testing for conveyor roller

 Random sample is taken per lot.

 It should be clean thoroughly and. The roller is mounted on the bracket of
friction testing machine and rotates for grease distribution.
 The end brackets are having knife edge. The load is applied on the roller
through one end of the bracket which is connected to balance by means of
lever.
 The roller is rotated by means of rubberized pulley which is mounted on the
drive. The roller can be rotated on either direction and scaled reading will be
observed up to constant reading.
 µ=g * L6
1000*R3*r
 g is scale reading in grams
 R3 is load in kg
 r is radius of roller in mm
 L6 is distance between roller centre and balance.

5.1.10 Dust proofness of conveyor roller

 Random sample is taken per lot.

 After filling the chamber with sand dust to required level, roller is driven by
electric motor through V belt.
 Roller is rotated for half hour in same condition.
  After that dismantle the components such as rain cup, dust cap, circlip seal,
bearing.
 Acceptance: by visual and by hand feeling.

5.1.11 Water test for conveyor roller

 Random sample is taken per lot.

 After filling the chamber with water to required level, roller is driven by
electric motor through V belt.
 It is rotated at around 350 to 400 rpm for 10 minutes.
 There should be no ingress of water on bearing, which is being judged
experience visually and feeling of grease by finger.
 During the test, the moisture contained inside the enclosure may partly
condense. The dew formed should not be taken for water ingress.

5.1.12 Apron feeder assembly inspection

 All fabricated components are inspected in shop at various stages right from
cutting of material to sub assembly and fitment of components with machine
structure.
 Overall dimensions are checked as per GA drawing.
 Free run test of apron feeder assembly is conducted.
 Noise level and vibration level are checked as mentioned in the approved
QAP.

5.1.14 Inspection of Sub assembly of wagon Tripler

1. End frame with rack

2. Pivot shaft with locating pins
3. Rail table with rail
4. Platform support with bottom locating blocks
 Fabricated end frame:
 Level is checked with water tube and 3 mm deviation is accepted.
 Tooth matching is checked with templates.
 Centre distance between tip of the teeth and pivot centre is checked as
per drawing.
 Tightening torque on bolt is measured.
 Pivot shaft and locating pins
  After applying the heat match drilling is carried out on end frame as
per locating ring holes.
 Overall dimensions are checked as per GA drawing.
 Rail table
 Leveling of the rail table with water tube.
 Distance between rails is checked by rail gauge.
 Overall dimensions are verified with drawing.

5.2 Quality assurance planning (QAP)

As tender passes and design department starts making part drawings and assembly
drawings along with that quality assurance planning is also prepared. In which testing is
mentioned which are to be performed during different stages like raw material, In process
inspection, assembly of product etc.

Here are two samples of QAP are composed.

5.2.1 QAP for impact mill

 Client: Beuner India Pvt. Ltd. Balaji cement Nepal

8. PROBLEM AND ITS REMEDIES

8.1 Due to less maintenance or no regular maintenance there is backlash is CNC machine.
Suppose initial diameter of shaft is 200 mm and final diameter of shaft is 180 mm. Even
after proper CNC programming there is some minor changes in final dimension. CNC
machine is displaying us 180 mm but in real that is little bigger than it suppose 182 mm.
than that 2 mm defect is generated by the backlash in the machine.

There is provision in CNC machine to reduce that backlash but that is in little dimension
up to 4-5 mm. But when backlash is more than 4-5 mm than special technician is needed
to call. For remove that backlash laser machine is used. Technical person connect its
laptop to the laser machine and then he travel tool from left most position to right most
position. At that time there is difference in position coordinates of the tool in laptop and
CNC screen. After that he does proper maintenance work and remove backlash. This
procedure is very costly.

8.2 Another problem is time taken in job mounting in four jaw chuck.
Suppose job shown in figure below is need to mount on the four jaw chuck.

For that firstly they mount job on the chuck. After that they check whether this job is
unbalance or not. In most of the cases job is unbalanced. So that they place a small rod on
the surface of the job and then they rotate the job. After that they loose one of the jaw and
opposite jaw is then tighten. This procedure is continuous until job got balance. For every
job they follow this time consuming procedure. Time taken for mounting the job is
around 10 to 15 minutes.
8.3 During assembly of breaker to the chain conveyor shaft of breaker is to be supported by
the bearing house. But during assembly of upper half and lower half of the bearing house
drilled holes didn’t match completely. When screw is passes through the hole, screw
touched side of the hole and there is no further movement in screw. Ideally equal space
need to remain around the screw which is not in this case. This happened because at time
of drilling operation dowel pin is tightened too much. At time of drilling operation grease
is not filled inside the housing while at time assembly grease is filled and because of that
holes on upper half and lower half didn’t match.

For that they used upper half of another housing and than that defected housing is again
machine properly.
7. PRODUCT SPECIFICATION

During my internship period heavy material handling eupments are manufactured like
paddle feeder, magnetic separator, chutes, two way chutes, cable riling drum, grizzly
feeder, impact mill, semi portal scraper reclimer, feeder breaker, bearing housing for
idlers, apron feeder.

Here are some technical specifications of those products.

7.1 Vibrating grizzly feeder (floor mounted) 2500x6000

Vibrating grizzle feeder is used to separate coal of different sizes.

Fig Grizzly feeder

As shown in figure two unbalanced motors are attached to the body at the rear end and
four springs are mounted at the front. Perforated tray is attached to the body having two
holes width is around 20 mm. Hopper is placed at the top of the feeder and two conveyor
belt is placed one bottom of the feeder and other is at front of feeder.
At the start both motor are started and because of unbalanced weight feeder starts
vibrating. Coals in hopper are of different size. Bigger size coals are needed to crush
before it goes to the boiler. So when they fall from the hopper because of vibrating
motion and inclination of feeder coals travel at front. Smaller size coal which don’t need
to crushed are fall from tray holes and passes to the boiler or storage. While bigger size
coal don’t fall from that holes and passes to the crusher and then to the storage.

Fig perforated tray for grizzly feeder

Technical specification
 Client: Telangana state power generation limited
Kothagudem Thermal Power plant
 Coal handling system package
 Running time: 24 hours
 Capacity (Rated/ Designed): 1200/1350 TPH
 Feed size: (-) 300 mm, maximum (-) 350 mm
 Coal temperature: maximum 50° C
 Separation size: (-)20 mm max
 Moisture content: 20% maximum
 Inclination: 14°
 Amplitude: 4 mm
 Stock: 8 mm @ 960 rpm
 Motor: 2 nos. x 37 KW x 1000 rpm Squirrel cage
 Arrangement to control capacity: By adjusting the unbalanced weight
 Shaft: Forged steel
 Weight: 16 T
 Lubrication: Manually through grease gun
7.2 Vibrating feeder

Vibrating feeder is more or less similar to the grizzle feeder. This product also separate
particles with help of vibratory motion.

Fig vibrating feeder

Testing of vibrating feeder

 At first vibrating feeder is attached to the vibrating feeder testing machine.

 One unbalanced motor is attached to the feeder.
 Motor than started and its speed is bring to the speed which is mentioned in the
drawing.
 After 15 of test temperature of motor is measured and along with that ambient
temperature is measure.
 Difference between these two must be less than that is mentioned in the drawing.
 Reading is taken at every five minutes.

Technical specification

 Client: Tata chemical limited.

 Type of vibrating feeder: Electro-Mechanical (unbalanced motor)
 Capacity: 130 TPH
 Material: Limestone
 Density: 1.4 T/ m³
 Motor: Unbalanced motor, Quantity: 2 Nos
 Rating of motor: 2 X 1.5 KW X 1500 rpm
 Tray size: 762 mm X 1220 mm
 Stock of vibration: 4-5 mm
 Inclination: 10°
 Tray material: 8 mm thick, MS plate
 Liner material: 8 mm thick, TISCRAL/ SAUARD
7.3 Feeder breaker
 Client: SIngareni colleries company limited
 Technical specification
 Capacity: 500 TPH
 Inherent moisture: 6-8%
 Maximum feed size: 1500 X 1500 X 1200 mm
 Output size: (-) 200 mm 90%
 Bulk density of coal: 900-1100 kg/m³
 Ambient temperature: 45 to 50° C
 Breaker assembly (rotor)
 Rotor diameter: 1320 mm
 Rotor width: 1485 mm
 Rotor picks: 90 nos on drum
 Rotor rpm: 128 rpm
 Rotor bearing: Spherical roller bearing SKF/FAG/NTN
 Weight: 7500 kg
 Rotor motor: 160 KW X 1500 rpm squirrel cage
Consumed power: 125 KW
 Gear box: Solid shaft gear box. K2-22-NH ratio 22:1
 Fluid coupling: XR-CRD-584 with flexible coupling FCF-13
 Chain conveyor
 Inclination: 0°
 Type of chain: Link chain with breaking load 85 T
 Flight bar: Solid section
 Conveyor speed: Variable speed (0.033 to 0.33 m/s)
 Width of scraper: 1300 mm
 Sprocket cross section: 8800 mm
 Motor: 90 KW X 1500 rpm by WVF frequency panel
 Gear box: KH:26:HN ratio: 112:1 rating 145 KW
 Lubrication type: Centralized grease lubrication by hand operated system
 Dust suppression system: Plain water dust suppression system near the crusher rolls
 Hopper: Suitable for 60 T dumper having capacity 60 cu.m made of steel frame
 Rock breaker attachment
 Type: Swing rotating type
 Control: In operating cabin
 Array: Hydraulic power pack
 Motor: 22 KW X 1500 rpm squirrel cage
7.4 Impact mill

 Client: Aditya birla chemical limited, Renukool Dist.: Sonbhadra (UP)

 Crusher: Non reversible impact mill
 Crusher diameter: 1200 mm
 Crusher width: 1200 mm
 Capacity: 120 TPH
 Material to be crushed: Coal
 Moisture: Maximum 14%
 Feed size: (-) 200 mm
 Product size: (-) 8 mm
 Rotor speed: 38-40 m/s
 Motor: 132 KW X 1500 rpm squirrel cage
 Rotor rpm: 640 rpm
 Rotor pulley: 1020 PCD
 Motot pulley: 400 PCS
 Rotor material: Forged steel
 Hammer material: Chrome Molly alloy steel

7.5 Apron feeder

 Client: Ramco cement limited, Vishakhapattanam

 Capacity: 200 TPH
 Material handle: Gypsum
 Moisture: Maximum 13%
 Size: 1600 mm pan X 3200 mm C/c
 Motor: 22 KW X 1500 rpm squirrel cage
 Reduction ratio: 4.13
 Helical gear size: KDN-315, ratio: 125:1, rating: 52 KW
 Maximum lump size: (-)6 mm
 Weight: 18-20 T
 Roller material: Alloy steel
 Maximum conveyor speed: 15.78 Ft/min
 Gears
 Head shaft: Teeth: 95 nos and PCD: 950 mm
 Counter shaft: Teeth: 23 nos and PCD: 230 mm
7.6 Paddle feeder
 Client: Telangana state power generation corporation, Hydrabad
Bhadrari thermal power station
 Type: Bottom supported, one side shelf coal reclaiming, rail mounted
 Quantity: 4
 Rated/Designed capacity: 720/800 TPH
 Variation: 20% to 100% of rated capacity
 Material: Uncrushed coal
 Bulk density: 0.8 T/m³ & 1.2 T/m³
 Lump size: (-) 300 mm. (-) 350 mm maximum
 Range of travel: 0.3-3 T/m
 Paddle wheel diameter: 3100 mm
 Belt width: 1400 mm
 Track rail: 52 kg/m
 Capacity variation: By hydro motor speed
 Maximum moisture: 20%
 Hours of operation: Continuous
 Paddle drive unit
 Paddle wheel drive
1. Hydro motor: 30 to 120 rpm
2. Electric motor: 37 KW X 1480 rpm
 Bearing: SKF, minimum 30000 working hours
 Coupling: Geared coupling
 Reduction gear: KLV-355 Ratio: 18:1
 Paddle drive: 2 to 10 rpm
 Paddle mother blade: 6 nos.
 Material: MS plate
 Paddle hub: 1 nos
 Blade liner: 20 nos
 Lubrication: Centralized grease lubrication manually
 Travel drive unit
 PBC make gear: 2 nos X 2.2 KW X helical gear with brake
1.5 HP @ 8 poles (705 rpm)
3 HP @ 4 poles (1420 rpm)
 Travel speed: 1.25-2.5 m/min
 Travel wheel: Two pairs Cast iron wheel
7.7 Cable riling drum (CRD)
Cable riling drum are manly two types. (1) Mono drum (2) Spiral drum.
When length of cable is small around 250 mm or less than mono spiral CRD is used but
when length of cable is more than it than parallel CRD is used.

 Type: Mono spiral

 Client: Ramagundam Fertilizer & Chemical limited. (RFCL)
 Application data
 Machine: Full portal scraper recalimer
 Travel speed: 10 m/min maximum
 Cable details: 3.5 C X 185 mm² + 8 C X 2.5 mm²
12 C (6 pairs) X 1.5 mm² (s) 1.1 KV
 Cable diameter and weight: Ø 80 ± 2%, 12.24 kg/m
 Safe pulling tension: 15 N/mm²
 Length to be wound: 90 m, 2 nos
 CRD specification
 Type: Mono spiral
 Drum: ID- 1800 mm, OD- 4000 mm, L- 85 mm
 Type: ContoQ
 Make: Elecon
 Size of torque regulating unit: CT 80 BHT X dual drive
With 6’’ NUD gear box
 Type of drive: Geared motor
 Make: PBC
 Power rating: 1.1 KW
 Rotor rpm: 110 rpm. 1 nos
 Slipering unit: 3P + E 400 + 8P, 25A(S) + 12P, 25A(S), 1.1 KW
 Control switches
 Over tension limit switch
1. Type: 45-63 (2 nos)
2. Make: Jai Balaji
 Under tension limit switch
1. Type: ZCKJ1 + ZCKE08
2. Make: Telemechanique (1 nos)
 Direction switch
1. Type: 45-63 (2 nos)
2. Make: Jai Balaji
 Geared rotary limit switch
 1. Type: GRLS Ratio- 48:1
2. Make: Elektromag (1 nos)

7.8 Cable riling drum (CRD)

 Type: Mono spiral

 Client: Telangana state power generation corporation, Hydrabad
Bhadrari thermal power station
 Application data
 Machine: Paddle feeder
 Travel speed: 1.25 m/min (OP), 2.5 m/min (Idle)
 Cable details: 3.5 C X 120 mm²
 Cable diameter and weight: Ø 58 ± 2mm, 6.7 kg/m
 Safe pulling tension: 1.5 N/mm²
 Length to be wound: 175 m + 15 m (maintenance) + 15 m
 CRD specification
 Type: Mono spiral
 Drum: ID- 1300 mm, OD- 3600 mm, L- 126 mm
 Type: ContoQ
 Make: Elecon
 Size of torque regulating unit: CT 80 BHT drive
With 6’’ NUD gear box
 Type of drive: Geared motor
 Make: PBC
 Power rating: .75 KW
 Rotor rpm: 81 rpm
 Control switches
 Over tension limit switch
1. Type: ZCKJ2 +ZCKE21 (2 nos)
2. Make: Telemechanique
 Under tension limit switch
1. Type: ZCKJ1 + ZCKE08
2. Make: Telemechanique (1 nos)
 Direction switch
1. Type: ZCKJ2 +ZCKE21 (2 nos)
2. Make: Telemechanique
 Geared rotary limit switch
1. Type: GRLS Ratio- 48:1
2. Make: Elektromag (1 nos)
7.9 Chutes

There are mainly two type of chutes. (1) One-way chutes (2) Two way chutes.

One way chutes are manufactured for IFFCO Kandala. This product is used for
distribution of fertilizer bags. Bags enter from top of the chutes and then pass to the
distinct conveyor for different type of fertilizer. These chutes can be rotated from bottom
so that different bags go only in their specific conveyor.

Two way chutes are shown in below figure. It has one opening on top and two opening in
bottom. As shown in figure there is on hole is provided. Shaft is inserted in that and one
plate is attached to it. Due to movement of shaft only one opening is open at a time and
material passes from that opening.

7.10 Magnetic separator

Fig magnetic separator

As name suggest it uses to separate metallic particles from the coal particles. Magnetic
separators are primarily used for separation of ferrous material from material transported
over a conveyor in different type of application.

 Protection of downstream processing equipments such as crushers, pulverize,

granulators.
 Purification of the product for high quality end products by removing iron piece from
the material in process.
 Reclamation of either ferrous or non ferrous material from open hearth and blast
furnace slag.
7.11 Bearing housing for idlers

Bearing house are made from operation. It starts with the roll of steel and end with
burnishing of the final product.

Here are step vise figure of product.

6.2 Shot blasting

● Abrasive grit blasting, or sand blast cleaning, is a surface treatment process widely used
in a variety of different industries with many diverse purposes.
● Abrasive blasting is the process by which an abrasive media is accelerated through a
blasting nozzle by means of compressed air.
● The abrasive used varies based on the surface treatment required. Common abrasives
used include:
● steel shot
● steel grit
In elecon shot blasting is done manually with hand gun. Steel balls are filled in the
container and then with pressurized air it sticks the fabricated body.

Fig Blasting Booth

● For removing rust.

● For creating finr surface.
● For better strength of paint.
● Material used –steel shot(S330),steel grit(G25 grade)
● Pressure-(3-8)kg/cm2
6.3 Painting

Necessity:

● To reduce rusting
● To reduce Environmental effect
● For Better look

Type:
1. Ready mix-synthetic paint
2. Two pack system-epoxy, PU, PVC

● In two pack system base and hardener is mixed such as ratio is maintained 3:1.
● There are three layers of paints are to be coated.
1. primer-for smoothing the surface
2. intermediate-for better strength of paint
3. top-for better look

● Equipment used in painting

1. Airless gun / Air gun-used in two pack system and given with a piston assembly.
6. FABRICATION COMPONENTS FLOW CHART

Raw material/ mechanical item recd from cutting or machining shop

If required marking of plate/ section material, edge preparation, grinding,

straightening, drilling before fabrication machining and bending

Lay out preparation and leveling of the job and job set up work (teak weld)

Stage inspection of job components

Primer coating in closing member and full welding grinding

and finishing of the job

Final inspection and machining marking of ready components

Job identification and go for machining or shot blasting/ final

painting/ numbering

Fabrication complete