PREFACE

Training in an industry is a dynamic tool to get feeling of practical aspect of whatever has been learnt by us in the books. It greatly enhances knowledge with the practical experience. Training in such (great) and well-managed company is a great opportunity for the trainer as apart from the basic training. Also we get a change to be familiar with certain other aspects of industry relations etc. Our main objective of undergoing industrial training is to acquire practical knowledge. Training enables us to get a clear-cut view of the subject that we have read. Both theory and practical are essential .Hence we can say The theory is blind without practical and practical without theory . Infact, both are complementary to each other. As a part of our four years of B.Tech with specialization in Welding Technology, I have undergone for Semester. 6 week Industrial Training in the 3 rd I am proud of receiving my 3rd Semester Industrial Training in

department of WELDING TECHNOLOGY at ISGEC Yamunanagar, Haryana which is one of the top most heavy engineering industries of the country.

ACKNOWLEDGEMENT
The saying holds true for that-hard work leads to success. This report named Welding Procedures for Heavy Fabrication is a result of that. To start with, I wish to express my sincere gratitude to Dr. V SANHI (Principal of SLIET) and Dr. Pardeep Gupta (T&P), for providing me an opportunity to undergo 6 week Industrial Training at ISGEC, Yamuna Nagar, Haryana. I am extremely thankful to Mr. Arindam Sen (GM) of Welding Technology Dept & Mr. Harvir Singh (Head of welding Productivity), as They are my Industrial Training guide in ISGEC & Mr. H.C. Ojha (Dep. Mgr.), Mr. Ravinder Sharma (Asst. Manager),Mr. Jaspal singh & Mr. Divesh Tiwari, Mr.Kuldeep kumar in Welding Technology for their valuable support. I convey my heartiest thanks to all those officers and employees of ISGEC who have given me their full co-operation and devoted their valuable time, for rendering me their needy services, guidelines during the course of imparting me practical training and with whose sincere and precious helps, I have been able to complete my practical training successfully

CORPORATE PROFILE
The Saraswati Industrial Syndicate Limited grew from the sugar mill and the general Engineering group. The engineering group was launched in 1946 with the establishment of the Indian Sugar And General Engineering Corporation now it is only called as ISGEC. Today, ISGEC is ISO 9001:2000. Company concentrates its production activities at Yamuna Nagar, Haryana about 200 km. North of Delhi, manufacture a variety of heavy Engineering equipments such as chlorine containers, boilers, sugar machineries, cement machinery, pressure vessels, mechanical and hydraulic presses, plate bending rolls and iron castings. This flagship unit of group also maintains the process division at New Delhi; responsible for the design, sales, contracting, and erection and commissioning of turn key plants besides equipment for sugar and cement industries. In 1960 ISGEC collaborated with John Thompson, UK (now known as NEI International Combustion Limited, UK). Located at New Delhi, ISGEC John Thompson (IJT) designs, sales, erects a range of boilers and associated equipments. UP Steels was acquired in 1981 and latter merged with the parent company. Established as a foundry in 1966 with the technical know how from Japans Kobe steels, UP Steels, an ISO 9002 company at Muzaffar Nagar, UP about 100 km. North of Delhi, manufactures sophisticated alloy steels and steel casting, both hand and machine moulded as well as alloy iron castings steel ingots. Saraswati sugar mill (SSM) located at Yamuna Nagar, Haryana is having crushing capacity of 9600 tones per day and has recorded best overall recovering in India.

Organization Chart ISGEC -Yamuna Nagar, Haryana

Joint Managing Director

Chief executive

Head Quality (Works) Annexure-IV

Head MBD And Foundry

* Head Accounts

Head PVD And Administration

Head Commercial

Head Materials

Head Foundry Annexure-III

Head MBD Annexure-II

* Head Personal Administration

Head PVD Annexure-I

Head Training And Developments

Head Stores

Head Shipping and Transport

* Head Personal

* Head Security

* Head Labor Welfare

* Head Common Service

Head Library

Not come under ISO 9001:2000

Organization Chart for Pressure Vessel Division

Chief executive

Head PVD

Head Marketing and Sales (Export)

Head Marketing and Sales (Domestic)

Head Diversification and development

Head Manufacturing

Head Designing and Engineering

Head Contracts

Head Maintenance

Head Production

Head Planning

Head Welding Technology

Head Industrial Engineering and control

Product Range of the Group

Diversity of product range is the stimulus on which Groups Engineers Division thrives. ISGEC, IJT and UP steels or committed to finding new ventures of endeavor. The group already needs the vital need of industries ranging from automobile and ship building to oil and natural gas, defense, aeronautics and nuclear power the groups product range includes: Boilers 1. Thermal power station boiler up to 60 MW capacities. 2. Water tube boilers fired with coal, gas and vegetable waste. 3. Fluidized Bed Boilers. 4. Waste heat recovery units. 5. Stockers- for coal and cellulose fuels. 6. Ash and dust handling plants. 7. Water treatments plants. 8. Detractors. Sugar Machinery 1. Complete plant Turn key. 2. Milling tandems. 3. Centrifugals. 4. Evaporators, vacuum pans and juice Heaters. 5. Cane unloading and preparation equipments. 6. Bagase Handling and baling equipments. 7. Juice and molasses weighing scales. 8. Sulphur Burners. 9. Filtration and clarification equipments. 10.Crystallizes. 11.Dryer and graders.

Pressure vessels 1. Autoclaves. 2. Gas storages and transport vessels. 3. Distillation columns. 4. Tone containers for liquefiable gases like chlorine, ammonia etc. 5. Galvanizing baths. 6. Heat exchangers. Machine Tools 1. Hydraulic process. 2. Mechanical process. 3. Tandems lines. 4. Press brakes. Castings 1. Low allow creep resistant steel for steam turbine. 2. High allow abrasion resistant steel for hydrogen turbine. 3. Manganese steels and austenitic manganese steels for earth moving mining equipments. 4. Corrosion resistant stainless steel for pump and value bodies. 5. Casting and cryogenic applications. 6. Austenitic ductile Iron casting for vertical turbine pumps.

Approvals
ISGEC has been approved by Lloyds Register of quality assurance as an ISO-9001:2000 company. The American Society of Mechanical Engineers approves ISGEC for the use of ASME U, U2, R & S code stamps. Lloyds Register as class-I Manufacturing of Fusion welded pressure vessels approves ISGEC up to 200 mm thickness. Engineers India Ltd. approves ISGEC for Manufacture of vessels and columns in carbon and alloy steels up to 155mm thickness and in clad steel up to 130 thicknesses. Engineers India Ltd. approves ISGEC for Manufacture of Heat Exchangers up to maximum tube sheet thickness of 300mm. China Safety Quality License

Our Mission
To give a unified direction to each and every employee of the company, a quality mission has been framed which is TO BE THE MARKET LEADER THROUGH QUALITY, TECHNOLOGY AND EMPLOYEE INVOLVEMENT

Quality Policy
The Indian sugar and General engineering corporation (works) in accordance with the quality policy direction provided by the managing Director and based on the requirement of ISO 9001-2000Shall endeavor to supply all products and services to its customer us per their specified requirements. Towards achieving this goal all personal of ISGEC (work) shall ensure that the quality system requirements are strictly adhered to in all the activities. Further, it will be ensured that we all work together in a harmonious environment for continual improvement in our working practices, manufactured products and services. The Quality objectives or well as the continuing suitability of this quality policy shall be reviewed and endorsed so in the annual management Review meeting.

House Keeping
Another significant approach to involve all the employees is to adopt house keeping as an important aspect of team. The whole works had taken up

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these tasks on war footing and good housekeeping has now become a way of life. INTRODUCTION TO HEAVY FABRICATION Heavy Fabrication involves a variety of Engineering Materials of different thicknesses. The thickness involved can range from 3mm to 200mm. Although there are many structures which can be included in the category of heavy welded fabrications but the important ones are: 1. Boilers & Pressure Vessels. 2. Ships. 3. Pipelines. 4. Bridges. 5. Offshore structures. Failure of such heavy fabricated products in service not only causes monetary and production losses, but could also constitute a serious health hazard. Designer and Fabricator therefore must follow safety codes, standards and regulations which govern their construction. The joint designs and the welding procedures etc., therefore, must be carefully selected taking into considerations factors like thickness of the material, dia of the job and location of the joint.

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INTRODUCTION TO PRESSURE VESSEL (PV) AND PRESSURE VESSEL CODE:

A Pressure Vessel is usually cylindrical in shape, and is made from a no. of shell courses and either ellipsoidal and two-radii tori-spherical heads called Dished-ends. Special shapes include cylinder, sphere, ellipsoid, tori and cones in several combinations. Applications of welding to Pressure Vessels and Boilers have permitted design flexibility, significant weight reduction and operation at higher level of strength and pressure. This has resulted in improved quality and safety, longer service life and economy of construction and operation. Pressure vessel technology is developing rapidly. Industrial demand of pressure upto 3500 psi, temperature from 649oC down to -260oC, pressure and temperature cycling, exposure to corrosive agent, hydrogen containing environment and neutron irradiation has thrown up challenges to the designer and the fabricator. Failure of Pressure Vessel and Boiler in service cannot only causes monetary and production losses, but could also constitute a serious health hazard. Designer and Fabricator therefore must follow safety codes, standards and regulations which govern their construction. Examples of such publications are ASME BOILER AND PRESSURE VESSEL CODE, Rules and Regulations of LLOYDS REGISTER OF SHIPPING, Rules for building and classing steel vessels of AMERICAN BUREAU OF SHIPPING, and INDIAN BOILER CODE.

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These publications are quite exhaustive and cover permissible materials, sizes, shapes, design, service limitations, preheat and post-heat treatment, inspection and testing requirements and even specify conditions for the qualification of welding equipment, welding procedures and welders. Since they are revised from time to time, fabricator must use the latest issue including the latest addenda and amendments. In designing Pressure Vessels, one must consider the maximum allowable working pressure, maximum working temperature and the possible use of pressure relief equipment. The maximum working pressure and working temperature governing the design have to be stamped on the vessel. There are also several other design criteria to be considered, such as fluctuating and repeated pressure loading and temperature, effects of platforms, supports and attached equipment, and wind and earthquake loading. Pressure Vessel Codes provide design criteria for each metal based on tensile strength, stress to produce rapture in a specified time and creep strength. So the designer must be aware of various formulae as applicable to shells and spheres, ellipsoidal and dished-ends, flat covers etc. The Code also describes various types of welded nozzles and other connections to Pressure Vessels. Designing of supports is equally important, because they introduce direct, bending or secondary stresses which have to be maintained at a safe level. Code rules provide data on efficiencies of the welded joints. Butt joints welded from both sides must be used in the design as far as possible, as they offer maximum assurance of uniform or complete fusion.

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FABRICATION PROCEDURE:
Plates received from the Steel Mill must conform to the required specifications with respect to chemistry and mechanical properties indicated by tensile and bend tests and in some cases, by impact tests. Before starting fabrication, the edges and surfaces of all plates must be carefully inspected for the presence of defects such as laminations, blow holes, cracks and tears. The plate edges are usually beveled in the flat positions, but in the case of heavy plates more accurate assembly is obtained if planning or burning is done after forming. The plates are usually formed by bending in pinch roll or offset rolls. Sometimes they are press formed with dies. These operations are commonly done in Cold, Hot-forming may be necessary in the case of heavy plates, which have to be press formed. Since offset rolls or pinch rolls cannot properly bend the extreme ends of the plate, the ends are bent to the required curvatures by means of a press brake prior to roll forming. Large hydraulic presses are used for forming very thick plate sections as well as double curvatures sections To assemble the vessels, the mating edges of the cylindrical sections are brought closer and held together with lugs and bars, other tack welded on the weld root side. The automatic submerged arc processes, by electro-slag process in the case of very heavy plates, then weld the joints, preferably. The complete cylinder normally shows depression at the joint due to weld contraction, and in most cases out of round tolerances is exceeded. In light plates, the out of roundness can be corrected by re-rolling. In heavy plates, correct circularity is achieved by judicious selection of edge bevel, making pressing allowances during forming, and by placing supporting struts at the cylinder during assembly and welding. Double-bevel joints in place of single-bevel also help. Dished-ends are prepared for welding by cutting the edges in a boring mill and lathe. Oxy-cutting, gauging and plasma-arc cutting are also used. They are attached to the shell with or without backing strip or ring, depending on the welding processes & procedures. Welding procedure is same as for the circumferential joints of the vessels. Besides the automatic welding processes mentioned above, MMAW and MIG/CO2 welding are used, preferably for welding nozzles and attachments. Heating before and during welding may be necessary depending on the type of metal, plate thickness and rigidity of the joint. Preheating requirements are specified in codes.
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Attachments like nozzles and pads which go on the dished-end are welded to the dished-end before these ends are attached to the shell, because in this case all welding can be completed in approximately in the flat position. Similar external connections to the shell, however, are attached and welded after the dished-end have been welded to the shell and after radiography inspections, in order to avoid the interference of the connections with these two steps. Nozzle welding is very important step, and the relevant code requirements must be closely studied, both at the design and fabrication stage. If radiographic test is specified for nozzle welds, the fitting must be designed to be amenable to radiographic examination. Most boiler codes stipulate that the welded Vessel be subjected to a stress relieving post weld heat treatment (PWHT). The temperature range to which the vessel must be heated is dictated by the type of metal, and the time at maximum temperature depends on the plate thickness. For Carbon Steel, the treatment usually consists of heating the complete vessel at a uniform rate to a temperature of 600-650oC, holding at that temperature for a period of 1 hour per 25mm of thickness and then cooling uniformly. Thick walled Vessels which have to stay in the furnace for long periods and those having a high diameter plate thickness ratio may, during heat treatment, sag and distort through plastic flow induced by the weight of the vessel. This can be prevented by providing properly spaced saddle support capable of providing a large bearing surface, and internal struts across the diameter. The inspection methods commonly used in Pressure Vessel fabrication are visual, sectioning and etching, fluorescent and liquid penetrants, magnetic particles, radiography and ultrasonic. For economic reasons such inspection is carried out before the vessel is PWHT and subjected to pressure tests. Then Hydro Testing is done to confirm safe working of a pressure vessel at certain pressure. Water is filled in the shell and tubes one by one at a pressure normally three times of working pressure. If there is any leakage it is detected either visually or by using some developer and is removed by corrective measures. Shot blasting is used to remove scale from the surface of pressure vessel shell as well as for roughening of the surface, so that primer or paint can easily stick on

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the surface. A nozzle from where balls of 0.4 mm diameter at very high velocity come out and strikes the surface of the shell. A fluid called primer is applied to pressure vessel preferably by spraying to increase corrosion resistance is well as to make it good looking. If client demands, painting on shell can also be done. In this way, a heat exchanger / pressure vessels / boiler unit is manufactured.

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The advantages of welding having been well-recognized by designers and fabricators, most of heavy structures which used to be built earlier by employing riveted joints are now most often welded. Welding has made a significant impact on quite a large no. of major industries by: raising the Operational Efficiency, raising the Productivity, and Service life of the plant and equipment involved. It is possible to make high quality welded joints and the consequential greater confidence in the performance of such structures in service. The important aspects in the Fabrication of Pressure Vessels are: 1. Material Selection 2. Welding Procedure 3. Preheat 4. Post Weld Heat Treatment

1. Material Selection: Pressure Vessels consist of mainly the shell, the nozzles, and the tubes. These are main factors which determine the selection of materials for Pressure Vessels Shells.

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i. ii. iii. iv. v.

Corrosion Resistance Resistance to effect of temperature Fabricability Requirements of Code Cost and availability

Acceptable corrosion rates vary greatly according to nature of industrial application and severity of environment. Accordingly the life of vessel and corrosion allowance varies from 10 to 2 years and 3mm for petroleum industries to chemical industries. In food processing industries, the criteria for material selection is governed by metal pickup of the process fluid. Stress corrosion cracking is hazardous form of corrosion as it can result in catastrophic failure of the vessel. The common agents promoting such cracking are chlorides and caustic alkalis in case of austenitic Cr-Ni steels and alkalis, nitrates and H2S in ferritic steels. Hence we use stainless steel cladding instead of solid stainless steel for austenitic Cr-Ni steels. Non-metallic materials like baked/dried resin, rubber or acid resisting bricks may be used for lining. Materials for use at sub-zero temperatures require good notch ductility. Metals with fcc lattice structure i.e. all materials except ferritic steels are not much affected by reduced temperatures. Pressure Vessels Codes do not have mandatory requirements for notch ductility for vessels operating above 0oC. Nevertheless special precautions against brittle failure and hydrostatic testing need to be considered for thick plate vessels. Cracking during welding and stress relieving is important consideration.Two main considerations in selecting a steel for elevated temperature service are strength and metallurgical stability. One of the new materials gaining popularity in Pressure Vessel Technology is Duplex Stainless Steel.
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