Internship Training Report

Internship Training Report at Jindal Steel & Power Machinery Division

1. INDUSTRIAL TRAINING REPORT
AT
JINDAL STEEL & POWER LIMITED

SUBMITTED BY
AVINASH JURIANI
14MT000354
OF
M.TECH
IN
MANUFACTURING TECHNOLOGY

MAY-JUNE 2015
PLACE OF TRAINING: MACHINERY DIVISION
PERIOD: 13/5/2015 TO 13/6/2015
DURATION: TWO MONTHS

2. ACKNOWLEDGEMENT


I would like to express my deep sense of respect and gratitude toward my Guide
Er. Shyam Sundar Mishra who not only guided the Industrial Training but also stood as a
teacher and philosopher in realizing the imagination in pragmatic way, I want to thank him for
introducing me to the field of Optimization and giving the opportunity to work under him.
His optimism has provided an invaluable influence on my career and outlook for the future. I
consider it my good fortune to have got an opportunity to work with such a wonderful person.



I express my gratitude to Shri Suryodaya Dubey HR & ES, JSPL, Machinery Division,
and staff of Machinery Division, JSPL, for extending all possible help in carrying out the
Training directly or indirectly. They have been great source of inspiration to me and I thank
them from bottom of my heart.




I like to express my gratitude to Shri Debashish Dhar, Senior Engineer, Machinery
Division, JSPL, Raipur and Shri Amresh Kumar, AM, Fabrication for his valuable advice
and permission for carrying out mini project work inside the plant premises. I am especially
indebted to my parents for their love, sacrifices and support. They are my teachers after I came to
this world and have set great example for me about how to live, study and work.













AVINASH JURIANI
14MT000354

3. CONTENTS

TITLE PAGE No.
ACKNOWLEDGEMENT
LIST OF FIGURES

1 Introduction 1
2 Vision & Mission 3
3 Policies 4
4 Education 8
5 Planning & Scheduling 10
6 Sheds 11
7 Fabrication Shop 15
8 Steel Yard 17
9 Machining shop 18
10 Insert 27
11 Cutter 28
12 Ferrous Foundry Shop 29
13 Pressure Vessels 30
14 Shot Blasting & Heat Treatment 34
14 Quality Assurance 35
15
16
Assembly
Products
39
40
17 Certifications 41
18 Customers 42

4. List of Figures




Figure S.1 Sheds 12
Figure S.2 Foundry 14
Figure F.1 CNC & SAW Plate Cutter 15
Figure F.2 Plate Bending Machines 16
Figure F.3 Raw Plates 17
Figure F.4 MIG-CO2 Wires 17
Figure M.1 Machining Bay 19
Figure M.2 Milling & Turning 25
Figure M.3 Varieties 26
Figure FS.1 Foundry 29
Figure FS.2 Casting Products 30
Figure PV.1 Pressure Vessels 31
Figure PV.2 Pressure Vessels - SA516 Gr. 70N 32
Figure PV.3 Vessel Products 34
Figure HT.1 SR & SB process 35
Figure QA.1 Quality Measuring Equipments 36
Figure AP.1 Assembling Process 39
Figure MP.1 Manufactured Products 40
Figure AC.1 Authorization Certificates 41

5. Well connected with Air from New-Delhi, Mumbai,
Chennai, Bengaluru, Kolkata and other major cities
Well connected with Rail Route on Mumbai- Howrah line.
Distance from Raipur Railway Station is 15 kms and
Raipur Airport is 8 kms



RAIPUR JSPL PLANT IS ON THE N.H.-06
PLANT LAYOUT
Railway Track
N.H. - 06

6. INTRODUCTION
Jindal Steel & Power Limited (JSPL) with an annual turnover of over US $ 2.9 Billion is a part
of the over US$15 billion diversified O.P.Jindal Group. The Machinery Division of JSPL is
spread over an area of more than 1,62,000 sq. Meters of land at Mandir Hasaud,13 kms from
Raipur on the NH-06,towards Kolkata.

JSPL Machinery Division Raipur was established in the year 1992.

The Machinery Division has 10 covered bays covering an area of 52,000 sq. meters.
The key
Strength of the Division is our dedicated approach towards the manufacture and supply of
Critical Equipments, Pressure Vessels and Steel Castings for industries such as:

Steel
Power
Cement
Petrochemicals
Mines etc.

The facilities available at the Machinery Division are Steel Foundry, Centrifugal Casting,
Machine Shop with latest CNC Machines, Fabrication & Assembly Shops, Shot Blasting, Paint
Booth & Heat Treatment Furnaces etc..

Manufacture of Pressure Vessels has also started. The unit has been certified with ASME-U, U2,
S, R, NB stamps & IBR. It is a moment of pride that Jindal Steel & Power Limited
Machinery Division is enlisted with Engineers India Ltd. for the manufacturing of Pressure
Vessels.
The material handling capacity in our Pressure Vessel Bay is 250mt at present.

7. The Product Range includes equipment of Steel Plant(Blast Furnace, DRI, Sinter Plant,
Continuous Casters, Rolling Mill, etc.), Power Plant(Rotor, Casing etc.), Cement Plant
(Housings, Kiln etc.), Petrochemicals(Ammonia Storage Tank, Air Receiver, Depitched Tar
Acid Receiver of stainless steel)etc.

The highly skilled and dedicated people and stringent quality controls help us in delivering world
class equipment and spares.

JSPL has been partners in growth of all customers and its customer mantra is
“Partner in your Growth”.

8. Vision
“To be globally admired organization that enhances
The quality of life of all stakeholders through Sustainable industrial and business development.”

Mission
Aspire to achieve business excellence through:
• The spirit of entrepreneurship and innovation
• Optimum utilization of resources
• Sustainable environment friendly procedures and practices
• The highest ethics and standards
• Hiring, developing and retaining the best people.
• Maximizing returns to stakeholders
• Positive impact on the communities we touch.

9. POLICIES Quality Policy

Jindal Steel & Power Ltd.,
Machinery Division, Raipur, is
Committed to manufacture quality
Product, to achieve their desired
performance and supply as per
agreed delivery schedule

This will be achieved through
Adherence to the ISO 9001
Quality Management System with
Emphasis on customer focus
The organization vows for
Continual improvement in the
 Competency of Employees
 Product Precision
 Process Performance

10. Environment Policy

 Jindal Steel & Power Ltd.,
Machinery Division, Raipur is
Committed for Protecting the
Environment by:
 Controlling Emission and
Contamination of Land, Water and Air.
 Complying with the
environmental requirement of
regulatory & Other Bodies.
 Implementing Waste
Management Plan.
 Developing Green Belt.
 Involving Employees for Clean
Green Environment.
 Aiming at Continual
Improvement in Environme ntal
Management System

11. Safety and Occupational Health Policy (SOH)
JSPL reaffirms its commitment to provide safe work place environment to its personnel and
other stakeholders as an integral part of its business philosophy and values. It will continually
enhance our Safety and Occupational Health (SOH) performance in our activities, products and
services through a structured SOH management framework.
Towards this commitment, it shall;
 Ensure compliance with applicable SOH legislations and other requirements
 Establish and achieve SOH objectives
 Prevent / minimize SOH risks through continual improvement in process and practices at all
levels and functions for prevention of injury and ill health of the personnel
 Ensure that SOH is integrated in all managerial decision including procurement of materials;
selection of machinery / equipment; selection / placement of personnel and setting up of projects
 Enhance awareness, skill and competence of our personnel so as to enable them to demonstrate
their involvement, responsibility and accountability for sound SOH performance
 Carryout risk assessment associated with operations and take remedial measures proactively and
implement system of health and safety audits
We shall review this SOH Policy periodically and to be communicated to all people working
under the control of the organization and shall be available to the interested parties.
Total Productive Maintenance Policy (TPM)
Jindal Steel and Power Limited will work for implementation of TPM at all spheres of
activities by:
 Aiming zero defects, zero breakdowns, zero losses and zero accident
 Improving Overall Equipment Efficiency (OEE) for safe and efficient operation of the plant
 Creating a clean and pleasant work environment leading to higher employee morale and greater
organizational profitability
Corporate Social Responsibility Policy (CSR)
Jindal Steel & Power Limited (JSPL) strongly believes that sustainable community development
is essential for harmony between the community and the industry. The company endeavors to
make a positive contribution Specially to the underprivileged communities by supporting a wide
range of socio-economic, educational and health initiatives. JSPL is committed to integrate its
business values and operations to meet the expectations of all its stakeholders.
JSPL will serve its communities by:
 Ensuring presence through meaningful community participation and proactive engagement.
 Building and strengthening community institutions and Panchayati Raj Institutions (PRIs )

12.  Working in partnership with Civil Society Organizations (CSOs) and Government bodies to
widen the reach and leverage each partner’s individual experience and expertise.
 Partnering CSR initiatives through Donor Agencies /Project Implementing Agencies / Corporate
Partners / Corporations / bodies.
 Providing maximum assistance during times of disasters.
 Encouraging employee volunteerism.
 Adhering to the CSR activities as required by the Law.
Guiding principles
 Promote economic, social, educational, infrastructural and health development by providing
active support to local initiatives.
 Create significant difference in the lives of stakeholders by aligning initiatives with sustainable
development.
 Optimum use of physical, financial and natural resources by collaborating with Government
Organizations, community based organization, donor agencies, foundations, corporates and other
development/likeminded partners.
 Ensure stakeholders participation in planning and execution of development initiatives to create
ownership and accountability.
 Enhance capacity, skill and competence of employee, development partners, community and
other stakeholders to enable them to involve in sustainable development initiatives.
 Organize local youths to promote Sports, Art and Culture and also create an opportunity for them
so that they can represent their country.
 Ensure People/Community participation during execution of CSR activities.
 Environment conservation though sustainable initiative

Triple Bottom Line

 People
Building Social Capital, Health, Education and Infrastructure
 Planet
Environmental Factors, Energy Management, Environment
Conservation
 Profit
Adding Economic Value, Income Generation

13. EDUCATION
The company runs co-educational schools at Raigarh, Nalwa & Tamnar in Chhattisgarh, Angul
in Odisha and Patratu in Jharkhand, where quality education is being imparted to over 10,000
students.
The company recognizes education as one of the building blocks of any nation and considers it
as a priority area for its CSR activities. The aim is to nurture young minds and educate them, so
that they contribute to the nation’s development. Realizing the importance and relevance of
education, a number of initiatives have been undertaken in this respect like establishing a global
university, specialized institutes and schools. All these initiatives have been undertaken to
benefit the communities the company is operating in, by helping to increase the literacy levels of
these areas.
O.P. Jindal Global University:
A non-profit global university established under the Haryana Private Universities (Second
Amendment) Act, 2009 – equips the students with the knowledge, skills, scholarship and vision
required to meet the challenges and demands of globalization with help of a trained faculty. The
university has established five schools: Jindal Global Law School, Jindal Global Business
School, Jindal School of International Affairs, Jindal School of Government and Public Policy
and Jindal School of Liberal Arts & Humanities.
 Health
 Infrastructure Development
 Education
 Livestock
 Livelihood
 Sports, Arts and Culture
 Environment

O.P. Jindal Schools:
The company is running co-educational schools at Raigarh, Nalwa and Tamnar in Chhattisgarh,
Angul in Odisha and Patratu in Jharkhand, where quality education is being imparted to over
10,000 students.
O.P. Jindal Institute of Power Technology:
The institute offers various undergraduate and postgraduate courses, which are based on
renovation, research and modernization of power plants by applying the correct methodologies
and techniques. In accordance with the educational policy of the organization, students are also
provided with practical training on handling of power technology equipment. The institute
promotes its long-term vision of tapping the best available talent from the nation and trains them
accordingly in order to meet the heavy demand of the power industry.

14. O.P. Jindal Institute of Technology:
The Institute offers 4-year undergraduate engineering programs in mechanical, electrical,
electronics, civil and metallurgy courses. The curriculum for the courses is diverse and enriching,
which helps students to deliver in new and creative ways. The institute is committed to develop a
pool of high quality, professionally groomed technical and engineering manpower that will be
respected for professional and social values.
O.P. Jindal Community Colleges:
These colleges have been established as an entirely philanthropic, pioneering institution is the
realisation of the vision of Shri O.P. Jindal to educate and train a "skilled workforce who makes
the products and services of industry as per international standards”.
These institutes offer vocational training in trades like electrical, welding, plumbing, fitting,
computer operation, cutting & tailoring, steno Hindi and automotive. These institutes are located
at Angul & Barbil (Odisha), Patratu and Godda (Jharkhand) and Punjipathra (Chhattisgarh).
Besides the above educational initiatives, the company has also adopted four Industrial Training
Institutes (ITIs) in Sarangarh, Kharsia, Gharghoda in Chhattisgarh and Barbil in Odisha. Besides
this, adult literacy programs have also been undertaken where close to 300 community teachers
are teaching.
WORKING WITH US
Employees form the major intellectual capital of Jindal Steel and Power Limited (JSPL). Being
an equal opportunity employer, JSPL encourages leadership and innovation to train its workforce
and keep them abreast with latest industrial trends. As the company looks to expand its business
both at an international and domestic level, it aims to develop a skilled and cohesive workforce.
The company provides an open and dynamic work environment to all its employees.
The human resource policy of the company focuses on an inclusive growth rate of the
organization and retention of suitable workforce for this purpose.
According to its own requirements from time to time, the company has revised and updated its
human resource policies and procedures. Engagement of management consultants to identify the
skill sets of people and prepare them for the competitive market is one of the ideals which JSPL
diligently follows.
Training programs are conducted at various levels to enhance the skill of the workforce. As per
the guidelines of labor laws, safety awareness programs are organized to minimize the chances
of accidents within the work premises. Proper guidelines are also provided to enhance work
efficiency levels. Rotation of employees is also actively undertaken to create job satisfaction and
increase interaction among employees. To keep the employees fresh and energetic, world-class
recreational facilities are also provided to them. Medical and educational facilities are also
offered to all the employees at plant locations. Open house sessions are also arranged with the
top management to increase direct dialogue approach and increase transparency.

15. UNIT SPECIALITIES


 Total built up area -52,000 sq meters
 Total factory area – 1,62,000 sq meters
 Total man power – 1,280
 Employees(staff category)-180
 Employees(Tech. Category)-300
 Outsource -540
 labours(Need basis)- 260
 Machine shop capacity-30,000MT/Year
 Foundry Capacity-200MT/Month
 Max. Capacity of EOT Crane Mfg-450 MT,4 Girders & double trolleys
 Max. capacity Ladle Mfg-250 MT
 Max lifting Capacity of EOT Cranes to handle single piece-250 MT
 Turnover-200 cr/year (approx.)

16. Nature of Business at Raipur Unit

Equipment Manufacturing
Steel Foundry
Pressure Vessel

SHEDS


Description:
Everything starts within Sheds.
The table illustrates the Utility & Sheds available for production

Utility
Sl. No Description Make Specification Qty.
1 SHED NO. 1 : Assembly Shop 22 M X 206 M 01 No.
2 SHED NO. 2 : Fabrication Shop 22 M X 206 M 01 No.
3 SHED NO. 3 : Light Duty Machine Shop 22 M X 275 M 01 No.
4 SHED NO. 4 : Heavy Duty Machine Shop 22 M X 275 M 01 No.
5 SHED NO. 5 : Fabrication Shop (Under Constructions) 22 M X 206 M 01 No.
6 SHED NO.6: Pre-Fab. Beam Welding Line (Under Construction) 22 M X 206 M 01 No.
7 SHED NO.7: Preparation/ Fabrication Shop. 23 M X 214 M 01 No.
8 SHED NO.-8 : Foundry 23 M X 214 M 01 No.
9 SHED NO.-9 Castings 23 M X 214 M 01 No.
10 SHED NO.-10 : Pressure Vessel 30 M X 132 M 01 No.

17. SHED NO.01-Assembly & Painting SHED NO.02-Assembly

Jib Crane.01- 2 MT-01 EOT crane-25MT/8MT- 02
Semi gantry crane-5MT-01
EOT crane-25MT/8MT- 02
Fig. S.1 Sheds

SHED NO.03-Conventional Machines SHED NO.04-CNC Machines










Jib Crane-0.5MT-01 EOT Crane-80MT/20MT- 01
EOT Crane-25MT/5MT- 01 EOT Crane-25MT/08MT- 01
EOT Crane-10MT/5MT-02

18. SHED NO.4A-Cranes Fabrication SHED NO.05-Fabrication

EOT Crane-25MT/8MT-02 EOT Crane-63MT/10MT-02

SHED NO.06-Fabrication Area SHED NO.07-Fabrication Area

EOT Crane-25MT/8MT-02 EOT Crane-25MT/08MT-01
EOT Crane-63MT/15MT-01

19. SHED NO.08-Foundry




EOT Crane-25MT/8MT-01
EOT Crane-25MT/8MT-01

Fig. S.2 Foundry
SHED NO.10-Pressure Vessel

EOT Crane-100MT/30MT-01
EOT Crane-050MT/15MT-01
EOT Crane-100MT/30MT-01

20. FABRICATION SHOP
CNC Oxyfuel Plasma Cutting Machine Column & Boom Submerged Arc
Welding Machine

300mm thk (MS) & 40mm thk (SS) Capacity – 1200 Amps
Fig. F.1 CNC & SAW Plate Cutter
Description:
Fabrication Includes the Structures & Pressure Vessels. It employs different types of welding
processes which are generally needed to join any metal piece.
The requirements for a typical welding are as follows
 Thickness of plates
 Number of passes
 Type of Destructive/ Non Destructive test to be performed
 Type of plates to be used
Electrodes used are as follows:
 Stainless Steel Mild Steel
304L CN182
308L E7014
316L E7018

21. FACILITIES
 Fabrication & Welding
Sl. No Description Specification Qty.
01 WELDING RECTIFIER 600 AMPS 60
02 WELDING ELECTRODE BAKING OVEN 300
0
C 01
03 WELDING ELECTRODE HOLDING OVEN 300
0
C 02
04 MIG WELDING MACHINE 400 AMPS / 600 AMPS 17
05 TIG WELDING MACHINE WITH HF UNIT 600 AMPS 01
06 SUBMERGED ARC WELDING MACHINE 1200 AMPS SAC-1200 (THYRO) 01
07
CNC OXYFUEL & PLASMA CUTTING
MACHINE
6000mm x 25000mm x 300mm thick 01
08 PLASMA CUTTING MACHINE
150 PLUSE E, MAX. CUTTING
THICKNESS FOR SS - 40 mm
01
09 PLATE BENDING MACHINEÂ Â (3 ROLL)
MAX. THICK - 40 mm, MAX. WIDTH -
3200 mm, MIN. DIA - 700 mm
01
10 PLATE BENDING MACHINE (3 ROLL)
MAX. THICK - 20 mm, MAX. WIDTH -
1200 mm, MIN. DIA - 500 mm
01
11 PLATE BENDING MACHINE (3 ROLL)
MAX. THICK - 70 mm, MAX. WIDTH -
4000 mm,MINDIA - mm
01







45mm thk x 3.2mtr wide 70mm thk x 4mtr wide
Fig. F.2 Plate Bending Machines

22. Steel Yard

Plate Recognition

Grade Colour
E350 Blue
E250 Green
A516GR70 Yellow
Others White

Raw material

Fig. F.3 Raw Plates




Wires for MIG Welding


Cu coated Flux core
Fig. F.4 MIG-CO2 wires

23. MACHINING SHOP


CNC BAY
Description:
Machine Shop Includes wide range of top grade machines.
It is the life line of the plant


Machining of Exciter Rotor Assembly
(For 135MW JSPL Power Plant
Fig. M.1 Machining Bay
CNC Lathe Machine, L&L, Taiwan
Dia - 900 x 7000

24.  Lathe Machines
SL No. Qty. No. M/C No. Make Country Control
Swing Over
Cross Slid (mm)
Cent To
Cent (mm)
Load
Capacity.
(MT)
1 1 L-01 CRAVEN ENGLAND MANUAL 1480 9100 50
2 1 L-05 CRAVEN ENGLAND MANUAL 2000 3000 15
3 1 L-07 ALFA INDIA MANUAL 1200 8500 16
4 1 L-09 HASSE BERUN MANUAL 860 2400 06
5 1 L-11 BATALA INDIA MANUAL 600 2200 03
6 1 L-12 BATALA INDIA MANUAL 600 2200 03
7 1 L-13 BATALA INDIA MANUAL 420 1400 01
8 1 L-14 BATALA INDIA MANUAL 500 1400 01
9 1 L-16 TOS
CZECH
REPUBLIC
MANUAL 460 3000 02
10 1 L-17 TOS
CZECH
REPUBLIC
MANUAL 460 5000 03
11 1 L-18 ASHOKA INDIA MANUAL 420 1400 02
12 1 L-19 ASHOKA INDIA MANUAL 420 1400 02
13 1 L-20 LEHMANN U.S.A. MANUAL 750 6500 05
14 1 L-21 BEECO INDIA MANUAL/DRO 470 4000 02
15 1 L-22 WARD ENGLAND MANUAL 360 3600 01
16 1 L-23 SOUND INDIA MANUAL 550 2100 06
17 1 L-24 SOUND INDIA MANUAL 1000 3500 10
18 1 L-25 SOUND INDIA MANUAL 550 2000 1.5
19 1 L-26 SOUND INDIA MANUAL 550 2000 1.5
20 1 L-27 SOUND INDIA MANUAL 800 8000 10
21 1 L-28 L & L TAIWAN CNC 500 3000 09
22 3 L29,31, 32 L & L TAIWAN MANUAL 840 3000 09

25. 23 1 L- 30 L & L TAIWAN CNC 900 7000 20
24 1 L-31 DOOSAN KOREA CNC 590 - 09
25 2 L-34, 35 HMT INDIA DRO 850 7000 07
26 1 L-36 PINACHO INDIA DRO 250 750 0.1
Horizontal Boring Machines
S
L.
N
o.
Qt
y.
No
.
M/
C
No
.
Make
Count
ry
Control
Spindl
e
Dia(m
m)
Table
Size(m
m)
Travel In Mm
Load
Capac
ity
(MT)
X-
AX
IS
Y-
AX
IS
Z-
AX
IS
W-
AX
IS
U-
AX
IS
1 1
HB
01
KEARNS U.K.
MANUAL/
DRO
180
2400x190
0
2800 1700 2500 1220 450 25
2 1
HB
02
RICHAR
DS
U.K. MANUAL 125
1500x150
0
2000 1500 2500 960 300 10
3 1
HB
03
WMW U.K.
MANUAL/
DRO
80 1100x900 1000 900 1500 700 125 03
4 1
HB
04
RICHAR
DS
U.K. MANUAL 125
1500x150
0
2000 1500 2500 965 300 10
5 1
HB
05
SCHAR
MA NN
GERMA
NY
MANUAL/
DRO
240/150
2200x200
0
9000 3500 2000 1800 400 25
6 1
HB
08
KARAM INDIA
MANUAL/
DRO
125
1220X15
60
2000 1500 2050 600 150 05
7 1
HB
09
WOTAN
GERMA
NY
MANUAL/
DRO
130
1520X17
20
2500 1800 1270 800 - 10
8 1
HB
10
TOS
CZECH
REPUBL
IC
CNC
SIEMENS
130
1800X22
00
3500 2500 1250 800 - 16
9 1
HB
11
PAMA ITALY
CNC
SIEMENS
160
2500X30
00
10000 3500 1200 1000 280 40
10 1
HB
13
SMTCL CHINA
MANUAL/
DRO
110
1250X11
00
1600 1200 1400 600 180 03
11 2
HB
14
HB
16
JUARIST
I
SPAIN CNC 150
2000X
2000
4000 2500 2400 1000 - 18

26. 12 1
HB
15
SMTCL CHINA
MANUAL/
DRO
130
1600X18
00
2000 1800 2000 900 250 10
13 1
HB
17
TOS
CZECH
REPUBL
IC
CNC 130
1800X18
00
3500 2000 2000 800

12
14 3
HB
18
HB
22
HB
23
HMT INDIA
MANUAL/
DRO
110
1200x120
0
1770 1170 1570 630

04
15 1
HB-
19
PAMA ITALY CNC 160
3500X35
00
10000 4000 1200 1000

65
16 2
HB-
20
HB-
21
PAMA ITALY CNC 160
2000X20
00
6000 3000 1200 1000

25
Vertical Boring Machines
SL
No.
M/C
No.
Make Country Control
Chuck
Dia
(mm)
Travel in mm
Column
Distance
Job
Load
Capacity
(MT) Y-
Axis
Z-
Axis
Max
Dia
Max.
Height
1 VB-01 WMW GERMANY MANUAL 1800 1800 1600 2000 1900 1900 8
2 VB-05 RAFAMET POLAND
MANUAL
/ DRO
3200 3800 2500 3500 3500 3000 16
3 VB-06 QIQIHAR CHINA DRO 2250 2500 2000 2500 2000 16
4 VB-07 WUHAN CHINA DRO 5700 5700 3200 6300 3200 63
Horizontal Machining Centre
SL
No.
M/C
No.
Make Country Control
Table Size
(mm)
Travel In mm
Load
Capacity
(MT)
X-AXIS Y-AXIS Z-AXIS
1 HMC-1 BFWL INDIA CNC 630X630 900 750 700 0.8
2 HMC-2 BFWL INDIA CNC 1000X1000 1600 1250 1100 02

27. Vertical Machining Center
SL
No.
M/C No. Make Country Control
Table Size
(mm)
Travel In mm
Load
Capacity
(MT)
X-AXIS Y-AXIS Z-AXIS
1 VMC-1 VISION TAIWAN CNC 1300 X 3100 3000 1600 1020 10
Universal Tool & Cutter Grinder Machine
SL
No.
Qty.
No.
Make Country Control
Swing Over
Cross Slid (mm)
Table
Size(mm)
Cent. To
Cent (mm)
Load
Capacity
(MT)
01 01 HMT INDIA MANNUAL 280 980x140 760 0.15
Rotary Planner
SL NO. M/C No. Control
Table Size
(mm)
Travel in mm
X-Axis Y-Axis Z-Axis
1 RP 01 MANUAL 1800X1800 296 2500 720
Plano Milling Machines
SL
No.
M/C
No.
Make Country Control
Spindle
Dia
(mm)
Table
Size
(mm)
X-
Axis
Travel In Mm
Load
Capacity
(MT) Y-
Axis
Z-
Axis
W-
Axis
1 PM 01
PUNJ
STEEL
INDIA MANUAL - 6000x1800 6500 2200 - 1700 20
2 PM 02 BATALA INDIA MANUAL - 3000x1200 3500 1700 - 1000 10
3 PM 03 SIMMONS U.S.A MANUAL - 10000x2400
1100
0
3000 - 2200 45
4 PM 04 SOUND INDIA MANUAL - 3500x1200 4000 1250 - 1100
12 T/ sq.
mtr.
5 PM 05
WALDRIC
H SIEGEN
GERMANY CNC 200 8200X2500 8700 3600 1000 2000
15 T/ sq.
mtr.
6 PM 06 SANCO TAIWAN CNC

2500X6000 6200 3600 750 - 20

28. Universal Milling Machine
SL
No.
M/C No. Make Country Control
Spindle
Dia
(mm)
Table Size
(mm)
Travel in mm
Load
Capacity
(MT)
X-Axis Y-Axis Z-Axis
1 UM 01 H.M.T INDIA
MANUA
L/ DRO
90 1520x310 800 265 400 0.250
Vertical Milling Machine
SL
No.
M/C
No.
Make Country Control
Spindle
Dia (mm)
Table Size
(mm)
Travel in mm
Load
Capacity
(MT)
X-Axis Y-Axis Z-Axis
1 VM 01 BATLIBOI INDIA
MANUAL
/ DRO
128 1200X600 1200 400 365 0.250
2 VM 02 ELGAMILL U.K.
MANUAL
/DRO
- 6900X1500 6000 1219 1016 05
Hob Grinding Machine
SL No. M/C No. Make Country Control Module Max
1 01 WMW GERMANY MANUAL 20
Gear Cutting Machines
SL NO. M/C No. Make Country Control Module Max Max Dia (mm) Face Width (mm)
1 HOB. - 01 PFAUTER GERMANY MANUAL 6 500 250
2 HOB. - 02 LORENZ GERMANY MANUAL 12 1000 450
3 HOB. - 03 LORENZ BARUN MANUAL 16 1500 630
4 HOB. - 04 WEST HOU U.S.A. MANUAL 25 3500 750
5 HOB. - 06 LIEBHERR GERMANY MANUAL 6 500 250
6 HOB. - 07 LORENZ GERMANY MANUAL 12 700 450

29. Surface Grinding Machine
SL NO. Make Model No. Table Size Table Travel Spindle to Table Distance Load Capacity(MT)
1 PERFECT D4080AH 400X800MM 450X860MM 450X860MM 0.5
Shaper Machines
SL No. M/C No. Make Country Control
Stroke Length
(mm)
Load Capacity
(MT)
1 01 CEL INDIA MANUAL 600 0.9
2 02 CEL INDIA MANUAL 600 0.9
3 03 CEL INDIA MANUAL 750 03
Key Setting Machine
SL No. Bore Dia. Table Size Load Capacity(MT)
1 20-260mm 570X570MM 05
Tower Drill
SL
No.
M/C
No.
Make Country Control
Spindle
Dia
(mm)
Table
Dia
(mm)
Travel in mm
Load
Capacity
(MT) W-
Axis
X-
Axis
Y-
Axis
Z-
Axis
1 TD 01 K & W ENGLAND MANUAL 85 2150 950 3000 3500 1200 20
2 TD 02 K & W ENGLAND MANUAL 80 2000 1400 200 3500 3600 10

30. CNC Floor & Ram Type Boring and Milling Machine
PAMA, ITALY.
Spindle Dia – 160 mm
X-Axis 10000 mm, Y-Axis 3500mm, Z-Axis 1200mm











Vertical Boring Machine, WUHAN, China (DRO)
Dia - 6300 x 3200 mm Height
Fig. M.2 Milling & Turning

31. Machining of Turbine Shaft for BHEL Machining of Lower Bracket
(For 120MW Power Plant)




CNC Vertical Machining Centre, Vision Wide , Taiwan
Table Size – 3100 x 1300 mm
Along with vertical and universal Milling Head
X-Axis 3000mm, Y-Axis 1600mm, Z-Axis 1020mm


Fig. M.3 Varieties

32. INSERTS
R390-1806 12 PM 4240
R390-11T308 M-KL 3040
R290- 12T308 M-PM 4240

TPKN 2204 PDR
SDMT 1506 PDR- MH- TN7225
XNEX 080608 TR- M13, T350M
APKT 1305 PER-EM TT9030
SEMT1304 PETER-M TT9030
SNMG120408 HT
LNKT 080508 PPTN-M06
SPMT 120408 D-51
SPMW120408 -A57
LNHU 160812 - F57 T
CPNT 060204 T
TCMT 16T 304 PF 4225

33. CUTTERS
FACE MILL CUTTERS- Ø250, Ø200, Ø160, Ø150, Ø120, Ø100,
Ø80, Ø60,Ø50
END MILL CUTTERS- Ø40, Ø32, Ø30, Ø26, Ø22, Ø18, Ø16,
Ø12, Ø10
FLY CUTTERS- Ø400, Ø315, Ø250, Ø200, Ø150, Ø100, Ø80,
Ø50

34. FERROUS FOUNDRY SHOP















Induction furnace Centrifugal Casting
Fig. FS.1 Foundry
Description:
One of the finest foundry shop at JSPL Raipur Machinery division caters the need of all types of
ferrous castings with a centrifugal casting machine
Casting involves ball valves for BHEL, air tubes chequered plates, pellet cars, etc.

Charge
For IS1030 SS SK-40 Mn Steel Grade3
C 0.35% Si 1.5-2.0% C 1.05-1.35
Mn 1.5% Cr 23-27% Mn 11.5 %
Ni 19-22% Cr 1.5-2.5
Mo 0.5% Si 1%

35.  Casting Equipments
Sl. No Description Specification Qty.
1 INDUCTION FURNACE 6 TONNE (WITH 2 NOS. CRUCIBLES) 01 NO.
2 INDUCTION FURNACE 4 TONNE (WITH 2 NOS. CRUCIBLES) 01 NO.
3 INDUCTION FURNACE 1 TONNE & 0.25 TONNE CRUCIBLES 01 NO.
4
CENTRIFUGAL CASTING
MACHINE
MAX. OUTSIDE DIA 470 mm
MIN. OUTSIDE DIA 100 mm
CAST LENGTH IN SINGLE PIECE 1900-2500 mm
01 NO.
5 STEEL CASTING VARIOUS SIZES UPTO 12 MT CAST WEIGHT (SINGLE PIECE) -
6 GRADES OF CASTING
MILD STEEL/MANGANESE STEEL,CAST IRON,S.G. IRON,
STAINLESS STEEL(IS/DIN/ASTM GRADE) & OTHER AS PER
REQUIRED COMPOSITION BY CUSTOMER
-










Air Tubes Chequered Supporting System

Fig. FS.2 CASTING PRODUCTS

36. FABRICATION BAY FOR PRESSURE VESSEL
MANUFACTURING


Fig. PV.1 Pressure Vessels
Description:
One of the most important bays for manufacturing pressure vessels which are highly critical jobs
as these are widely used in oil & gas Plants, chemical industries, coal gas plants
All the pressure vessels are manufactured using ASME standards of U, U2 & S Grades
The description is given below:
Power Boilers - Section I
S
This section provides requirements for all methods of construction of power, electric, and
miniature boilers; high temperature water boilers, heat recovery steam generators, and certain
fired pressure vessels to be used in stationary service; and power boilers used in locomotive,
portable, and traction service. Rules pertaining to use of the V, A, M, PP, S and E Code symbol
stamps are also included. The rules are applicable to boilers in which steam or other vapor is
generated at a pressures exceeding 15 psig, and high temperature water boilers intended for
operation at pressures exceeding 160 psig and/or temperatures exceeding 250 degree F.
Super heaters, economizers, and other pressure parts connected directly to the boiler without
intervening valves are considered as part of the scope of Section I.

37. Section VIII - Pressure Vessels
U


Division 1 provides requirements applicable to the design, fabrication, inspection, testing, and
certification of pressure vessels operating at either internal or external pressures exceeding 15
psig. Such vessels may be fired or unfired. This pressure may be obtained from an external
source or by the application of heat from a direct or indirect source, or any combination thereof.
Specific requirements apply to several classes of material used in pressure vessel construction,
and also to fabrication methods such as welding, forging and brazing.
Division 1 contains mandatory and non-mandatory appendices detailing supplementary design
criteria, nondestructive examination and inspection acceptance standards. Rules pertaining to the
use of the single ASME certification mark with the U, UM and UV designators are also included
Alternative Rules for Pressure Vessels
U2
Division 2 requirements on materials, design, and nondestructive examination are more rigorous
than in Division 1; however, higher design stress intensify values are permitted. These rules may
also apply to human occupancy pressure vessels typically in the diving industry. Rules pertaining
to the use of the single ASME certification mark with the U2 and UV designators are also
included.



Fig. PV.2 Pressure Vessel - SA516 Gr. 70N

38. The A516 / SA516 standard, its full name is “Standard Specification for Pressure Vessel Plates,
Carbon Steel, for Moderate- and Lower-Temperature Service”, could almost be described as the
default material specification for pressure vessel applications
Chemical Requirements
Element Thickness Composition (%) Note
Carbon (max) 12.5 mm and under 0.27 A, B, C
over 12.5 to 50 mm 0.28 A, B, C
over 50 to 100 mm 0.30 A, B, C
over 100 mm 0.31 A, B, C
Manganese 0.85 - 1.20 A, C
0.79 - 1.30 B, C
Phosphorus (max) 0.025 A, B
Sulphur (max) 0.025 A, B
Silicon 0.15 - 0.40 A
0.13 - 0.45 B
Notes: A - heat analysis, B - product analysis, C - For each reduction of 0.01% below the specified maximum for
Carbon, an increase of 0.06% above the specified maximum for Manganese is permitted, up to a maximum of 1.50%
by heat analysis and 1.60% by product analysis.

Tensile Requirements
Mechanical Property Value
Tensile Strength, MPa (ksi) 485 - 620 (70 - 90)
Yield Strength, min MPa (ksi) 260 (38)
Elongation min, % 200 mm (8 in) 17
Elongation min, % 50 mm (2 in) 21

39. Pressure Vessels material test, it includes the following:
 Welder selection
 Dye penetration test
 Ultrasonic test
 Tensile test
 Radiographic test
 Hydro Testing


 PRODUCTS












Ammonia Bullet wt 500 mt Seam Joint of 28M diameter tank
being welded using SAW in 2G
position

Fig. PV.3 Vessel Products

40. SHOT BLASTING & HEAT TREATMENT


Stress relieving Furnace Shot Blasting Machine
Fig. HT.1 SR & SB process
Description:
Heat treatment is done to improve hardness, ductility, grain refinement. The basic methods
employed are annealing, normalizing, quenching. Sometimes tempering is also done
Shot blasting is used to clean, strengthen (peen) or polish metal.
Here after heat treatment shot blasting is done so that the paint after polishing the work remains
firm
SHOT BLASTING MACHINE: -
ROOM SIZE: 12000mm X 5000mm X 4000mm
(Length under extension from 12000mm to 18000mm)
PAINT SHOP: -
ROOM SIZE: 18000mm X 5000mm X 4000mm
Sl.No. Description Specification Qty.
1 ANNEALING FURNACE 7 m X 5 m X 4.5 m 01 No.
2 HEAT TREATMENT FURNACE (ELECTRICAL) 3 m X 2.8 m X 1.5 m 01 No.
3 PREHEATING FURNACE (ELECTRICAL) Dia 1000 mm X 1200 mm 02 Nos.
4 PREHEATING FURNACE (ELECTRICAL) Dia 800 mm X 1200 mm 01 No.
5 MODULAR FURNACE Single panel 7mx3.5 01 No.
6 WATER QUENCHING TANK 85000 Liters 01 No.
7 OIL QUENCHING TANK 4000 Liters 01 No.

41. QUALITY ASSURANCE
Description:
Quality Assurance is must for any manufacturing unit to maintain customer satisfaction, attain
profitable output
Different types of tests are done before finalizing the product for final production.
These include

 Composition examining, ,
 Weight check,
 Impact test
 Tensile test
 Imaging
 Calibration


Fig. QA.1 Quality Measuring Equipments

42.  Inspection and Testing
Sl. No. Description Specification
1 Chemical Lab Weight process
2 Spectrometer Q8MAGELLAN-57Channel(Make:Bruker Element)
3 Empower Image Analyzer System SDM-210 with camera & its software
4 Universal Testing Machine Model : UTE-40
5 IMPACT Testing Machine Model : IT-30
6 ROCKWELL Cum Brinell Hardness Tester Model : RAB-250
7 Ultrasonic Flaw Detector Model : Microscan Ex-100
8 Digital Ultrasonic Flaw-Detector Model : DIGISCAN DS-322
9 Ultrasonic Thickness Gauge Model : ETM-2
10 Magnetic Particle Inspection Unit (Prod System) Model : EF-1500
11 Radiography Testing Outsourced
12 Portable Digital Surface Finish Tester Make : Mitutoyo ( Surftest 178-923E )
13 Coating Thickness Gauge
Make : Elektro Physic German
Model : Exacto F with external probe range 0-3000 um
14 Sound Level Meter (DB Meter) Make : Lupron ( Range - 35-130 db )
15 Integrated Hardness Tester (Digital) TH-170
16 Poldi Impact Hardness Tester Model : PHM for all metal
17 Outside Micrometer up to 1200 mm
18 Inside Micrometer 50 mm to 2100 mm
19 Flange Micrometer Upto 225 mm
20 Vernier Calipers Upto 2050 mm
21 Vernier Height Gauge Upto 1000 mm
22 Vernier Depth Gauge Upto 300 mm
23 Combination Set 600 mm
24 Bore Dial Indicator 18.0 mm - 400 mm

43. 25 Slip Gauge 87 pcs. (1 set)
26 Granite Surface Plate 1000 mm x 1500 mm
27 Granite square 1000mmx1000mm
28 Granite cube 300mmx300mmx300mm
29 Precision straight edge 3000mm
30 Tool scan Max.Dia-300mm, Length-400mm
31 Dial Gauge 0-10 mm,  0-1mm,  0-5mm
32 Radius Gauge 0.5 to 13mm
33 Feeler Gauge 0.03 to 1mm
34 Thread Pitch Gauge 4-60 TPI
35 Spirit Level

36 PI Tape ( Make: USA ) 1200-1500MM
37 PI Tape ( Make: USA ) 3000-3300MM
38 Tip Type Pyrometer (Make: V-Smart Thermotech Pvt. Ltd.) Temp. Range upto 1700 Deg.C
39 Non Contact Pyrometer( Make: RAYTEK-RAYNGER 3i) Temp. 500 Deg. C- 1800 Deg. C

44. ASSEMBLY SHOP
Description:
After Final touch of quality followed by heat treatment & shot blasting. The components
produced are assembled as per the requirement. A brief study of assembly drawing is done for
assembling of components
The table below depicts the utilities for assembly shop:
ASSEMBLY:
Sl. No Description Specification Qty.
01 VERTICAL HYD. PRESS. 1500 MT 01
02 HORIZONTAL HYD PRESS 500t 01
03 BEARING HEATER ID 50-250mm(150KG MAX) 01
04 UNIVERSAL DRILLING MACHINE BRP-50 (BATLIBOI) 01
05 RADIAL DRILLING MACHINE MAX. DIA-50mm 01
06 SURFACE GRINDING MACHINE TABLE SIZE 400mm X 800mm 01


Mould Housing for Slab Caster
Fig. A.1 Assembling Process

45. PRODUCTS


Centrifugal Casting (SS/Mn/MS ) Control assembly of 4 Girder Hot Metal Crane
450 mt capacity



Raffinate after Settler capacity 134 m3 – CGP Steel Ladle 250 mt capacity-Domestic & Export
Fig. P.1 Manufactured Products

46. CERTIFICATIONS

Boilers Pressure Vessels


ASME S ASME U ASME U2


NB Stamp R Stamp
Fig. C.1 Authorization

47. Major Customers
 Enercon (India) Limited
 BHEL Hyderabad
 METSO Minerals
 Namco Industries
 Metalock
 ANDRITZ HYDRO Private Ltd.
 L&T MHI – Hazira
 Balco
 Danieli India Limited
 Tenova Hypertherm
 Bhushan Steel & Power Limited
 JSW Steel Ltd.
 Monnet Ispat & Energy Ltd.
 Jindal Stainless Ltd.
 Jindal Saw Ltd.