30

About Kolkata Port Trust

Geographical Location: - Kolkata Port trust is situated at 8824 E and 22.34 N at the bank
of Hooghly River near Bay of Bengal which is in the deltaic plane of the Ganges.
History; - Kolkata Port was set up by the British East India Company after the company
received trading rights from the Mughal emperor Aurangzeb.
Following the shift of power from the company to
the British crown, a port commission was set up in
1870. Though the port was conceived to be a
commercial port and gateway of eastern India, the
port played a very important role in the Second
World War. It was bombed
twice by the Japanese
forces. After the independence, the Commissioner
for the Port of Kolkata was in
View of the
Calcutta Port in 1852 responsibility of the port till January 1975 when Major Port Trusts
Act, 1963, came into force.
In the 19th century Kolkata Port was the premier port in British India. After independence its
importance decreased because of factors including the Partition of Bengal (1947), reduction
in size of the port hinterland and economic stagnation in eastern India. In the 21st century due
to the East Indian economic recovery and infrastructure improvements, the port grew swiftly
to become the nation's second largest container port. It was one of India's fastest growing
ports in 2004-05.
Dock System: - Kolkata Dock System (KDS)
It is situated on the left bank of the Hooghly River at 22 32' 53" N, 88 18' 5" E about
203 km (126 miles) upstream from the sea. The pilotage station is at Gasper/ Saugor roads,
145 Kilometers to the south of the KDS (around 58 km from the sea). The system consists of:

Kidderpore Docks (K.P. Docks) : 18 Berths, 6 Buoys / Moorings and 3 Dry Docks

Netaji Subhas Docks (N.S. Docks): 10 Berths, 2 Buoys / Moorings and 2 Dry Docks

Budge Budge River Moorings : 6 Petroleum Wharves

Anchorages: Diamond Harbour 1. Saugor Road 2. Sand heads

Apart from this, there are around 80 major riverine jetties, and many minor jetties, and a large
number of ship breaking berths.

30

Reasons Behind Growth:KoPT have got a very large hinterland including to metropolitans of India named Kolkata
and Delhi. It includes all the major deltaic cultivation land of northern India, the mines of
ores in Chhotanagpur Plato and the Dears and Himalayan Hills.
Besides it the historical background of Kolkata also provides it a readymade infrastructure for
its both economical and technical growth.
Difficulties of Port:Since it is deltaic planes of Ganges continuous drazzing of the river is required which costs a
lot.
Since its docks are man made frequent maintenance is required.
The swallow depth of Bay of Bengal does not allow the large vessel to enter.
The downfall of heavy industries of north India is weakening its economic back bone.
Solutions:Due to the constraints of the river (like silting, sandbars etc) no sea-going vessel above 200
GRT is allowed to navigate without a qualified pilot of the Kolkata Port Trust. The total
pilotage distance to KDS is 221 km (comprising 148 km in river and 75 km in sea).
Another sister dock complex is established nearer to sea named HDC (Haldia Dock
Complex).
i.

30

Section - I
Section: -Marine
Duration: - 21st June 2010 3rd July 2010

Introduction:The section contains the findings during Summer Training at the Marine
section of Kolkata Port Trust. This section basically contains The Following
Contents.
Deck Layout Of A Ship Kanho
Deck Layout Of A Ship Lava
Engine Room Layout Of Ship Lava
Introduction to the design and functions of major structures of an
ideal ship

30

Main parts of ship.

1: Smokestack or Funnel; 2: Stern; 3: Propeller and Rudder; 4: Portside (the right side is
known as starboard); 5: Anchor; 6: Bulbous bow; 7: Bow; 8: Deck; 9: Superstructure

Deck Layout ofKanho

30

1. Forward side.

3. Port side

2. Drivers Desk

4. Star board Side

30

5. Cabin

10. Bathroom

6. Engine Room.

11. Bathroom

7. Chimney

12. After side

8. Engine Rooms Rear Part

9. Exhaust Fan for Cooling Engines

Kanho on the dry deck of KoPT

30

General View of Kanho

30

Deck Layout Of M.Lava

30

1.
2.
3.
4.
5.
6.
7.

Anchoring Mechanism
Steering Desk
Port Side
Star Board Side
Forward Side
Cabin
Mustool

8. Chimney
9. Engine room
10.Air Exhaust of Engine Room
11. Bathroom
12.After Side
13.Kitchen

General View of M.Lava

30

Layout Of Engine Room of M.Lava

30

1.
2.
3.
4.
5.
6.
7.

Fuel Tank
Lubricant Tank
Cooling Unit
Main Engine
Gear Box
Propeller Shaft
Cooling Water Pump
13.
14.
15.

We could not had an opportunity to draw the Layout Of Engine Room of

Kanho, as during our training period in Marine Section, Kanho was on dry deck for
repairing purposes and its Engine Room was in a condition of total chaos with each
and every part wide open. But from an over view of the room it was obvious that it
was equipped with two six cylindered engines, each having their own gear boxes,
power transferring and heat exchanging arrangements. It has also got cooling fans over
each engine which draws in the cool air from the opening on the roof of engine room.
Shown as exhaust fan in deck layout of Kanho.

16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.

8. Diesel Engine to drive

Generator
9. Generator for Domestic
Supply
10.Electric Mains
11.Electric Wiring Board
12.Electric Switch board

30

34. the design and functions of

major structures of an ideal ship

Forward Side: - It is the front most part of a ship which is made V-shaped to
minimize the retarding hydraulic factors of the ship during its motion. It basically
consists the following structures-

35.
36. I.
Starboard Side: - Starboard is the nautical term that refers to the right
side of a vessel as perceived by a person on board facing the front. The equivalent
for the left-hand side is port. The starboard side of a vessel is indicated with a
green navigation light at night.
37. The origin of the term comes from early boating practices. Before ships had
rudders on their centrelines, they were steered by use of a specialized steering oar.
This oar was held by an oarsman located in the stern (back) of the ship.

38.

39.
40.

Front view of Kanho

However, like most of the rest of society, there were many more righthanded sailors than left-handed sailors. hence men sailing with the steering oar
(which had been broadened to provide better control) used to be affixed to the right
side of the ship. The word starboard comes from Old English steorbord, literally
meaning the side on which the ship is steered, descendant from the Old Norse
words stri meaning rudder (from the verb stra, literally being at the helm,

30

having a hand in) and bor meaning etymologically board, then the side of a
ship.
41. It is indicated by green light in night which is an indication for an incoming
ship intersecting the way of the first ship, to move ahead according to the traffic
rules of sailing.
42. II.
Port Side: - Similarly, the term for the left side of the vessel, port or
larboard, is derived from the practice of sailors mooring on the left side (i.e., the
larboard or loading side) as to prevent the steering boards from being crushed.
Because the words larboard and starboard sounded too similar to be easily
distinguished, larboard was changed to port.
43. During night sailors used to illuminate this part with red light which means a
ship coming from the left side of first one and intersecting its path will have to
stand and wait until it crosses away according to rules of sailing for avoiding
collision between two vessels intersecting their paths.
44.
Steering: - It is part of a ship which uses to decide the direction of
motion of ship. In old days it was done with a number of oars operated manually by a
number of sailors costing very large expanse of money and labour. But now a days
nothing but a circular wheel handle is used for the purpose which can be rotated right
or left to turn the ship right or left accordingly which is a very much similar method as
we have in cars.

45.
46.

An ideal steering wheel of a ship

47.
The power given to the rotating steering wheel is supplied to the rudder of the
ship fitted at the back of the ship just behind the propellers by ropes or by hydraulic
mechanisms depending on the size of the ship which forces the rudder to rotate right
or left and thus due to the hydraulic forces applied by the propelled fluid on bent
rudder it causes the head of the ship to turn in an reverse order due to the lever action
of the rigid body structure of the ship itself.

30

48.
49.

Steering mechanism of a ship

50.
It is also equipped with a mariners compass to have the sense of direction of
the motion of the ship
51.
52.

Speed Control: - The speed of a ship is controlled by varying the speed

of propellers and like any other machine it is also done by a gear box. Generally there
are two methods of speed control in the ships are seen53. a)
Bridge Control: - With this system driver alone can change the
speed the ship with levers he have on the desk itself.
54. b)
Engine Room Control: - It is a very old system to change the
speed. In this case driver sends his desired value of speed to another
engine operator sitting in engine room by various indications of bells or
with two dials provided on the deck and engine room. Now when driver
sets a value of speed in the dial he have it is immediately transferred to
the engine room dial by means of wires and springs or by telegraph and
after receiving this speed signal engine room operator immediately
changes the gears of engine and changes its speed

Cabin: - It is the residential areas of a ship for crew members and the passengers.
Equipped with all possible and adorable luxuries and comforts and if the ship is a
cargo one it also includes its godown. But as both the ship we had seen (i.e. M. Lava
and Kanho) were surveying ships there cabin contains only two small rooms for
resting of crew members.
55.
Mustool: - It is projected top most part of ship on the roof of the cabin. It very
much looks like a pantograph of a tram. It carries multicoloured lights and sirens and
very often the flag of the owner country or organisations.
56.
It is used to allocate the position and condition of the ship during night
57.
and days having poor view. The colour of light on the mustool says that is it
moving in a certain direction or is it anchored to the local traffic control room and
other ships.
58.

30

Engine Room: - It is the most important and indispensible part of a ship.

It also may be called the master control room for all the mechanical processes on the
ship. Although the design and quality of engine rooms varies widely with the function
and sizes of the ships. So here Im going to describe the engine room of the surveying
vessel.
60.
It contains the following parts.
a) Oil Containers: - Generally two large containers are provided in the engine room
one for carrying fuel during voyage and other for the lubricant for the engine.
b) Generator: - It is a simple DC-generator unit coupled with a separate IC-engine
which charges a number of Pb-acid accumulators which are used to supply the
power on the deck of the ship for domestic usage even if when the ship is anchored
and main engine is not running.
61.
59.

62.

63.

Image of generator of M Lava

64.

Specifications of generator of M Lava

65.

Speed

66.

Bhp

30

67.

: 1800 rpm

68.

: 60 kw

69.
c) Electrical Components: - These are generally electrical switches and wirings
necessary to run the ship properly along with the batteries for storing the power.
d) Centrifugal Pumps: - Two centrifugal pumps are provided on the deck of the
ship. One is to pump the water out of the deck if some secretes in from the gaps in
ship body and the second one is to suck in the water in the engine room from sea
to cool the engine.
70. Like any other centrifugal pumps it also contains an impeller to rotate an
convert mechanical energy into pressure head of fluid at outlet, volute casing to
avoid Eddys formation and to diffuse the water stream so that KE of the fluid
changes to pressure head, suction pipe with a foot valve to suck in the water and a
delivery pipe for fluid output.
71. A centrifugal pump works by converting kinetic energy into potential energy
measurable as static fluid pressure at the outlet of the pump. This action is
described by Bernoulli's principle.
72.With the mechanical action of an electric motor or similar, the rotation of the
pump impeller imparts kinetic energy to the fluid through centrifugal force. The
fluid is drawn from the inlet piping into the impeller intake eye and is accelerated
outwards through the impeller vanes to the volute and outlet piping.
73.As the fluid exits the impeller, if the outlet piping is too high to allow flow, the
fluid kinetic energy is converted into static pressure. If the outlet piping is open at
a lower level, the fluid will be released at greater speed
74.
75.

76.

77.

30

78.
79.
Radial Flow
Centrifugal Pump
Principle

80.

Single Stage Radial

Flow Centrifugal
Pump

81.

82.

Specification of Centrifugal Pumps of M Lava

83.

85.
86.
87.
88.
89.

84.Speed
Bhp
Shaft Material
Impeller Material
Body Material
Keys Material

: 1500 rpm
: 50 kw
: Steel
: Phosphor-Bronze, Mn, C.I.
: C.I.
: Mild Steel

e) Diesel Engine: - The giant diesel fed machines which converts the chemical
energy of fuel into mechanical energy for propeller rotation and causes the ship to
move. According to load and size of the ship the numbers and capacity of engines
also varies widely.
90.
Layout of Engine of M. Lava
91.

30

92.

1.
2.
3.
4.
5.

Heat Exchanger
Casing Enclosing Cylinders
Air Filter
Air Injection Pipe to Cylinders
Exhaust Pipe

6.
7.
8.
9.

Fuel Filter
Lubricant Filter
Gear Box
Propeller Shaft

10.The engine of a ship contains following major Parts-

A. Filters: - An engine of a ship carries three filters to restrict the entry of dust and
impurities to the cylinders and other critical parts of the engines.
I. Air Filter: - It filters air entering in the engine first with the sieves in the
base of the dome it has. There after the air is supplied to a cylinder below for
electrolytic precipitation of the air and then with a delivery it is sent to
cylinders when needed.
II. Fuel and Lubricant Filters: - These are basically two cylindrical sieves
used to filter the oils in midway of their path from containers to cylinders.
12.
Oil Filters
11.

13.
14.

Air Filter

B. Piston & Cylinders: - Cylinders are the parts of an engine in which combustion of
fuel occurs and temperature of the gas in it excessively increased to have an very
large amount expanding forces all at a sudden and thus the chemical energy of the

30

fuel is transferred to mechanical energy following diesel cycle which further forces
the movable Piston outward and transfers power to crank causing it to rotate with the
help of Slider Crank Mechanisms.
C.

D. Six Pistons of Kanho

E. The entry and ejection of air and
fuel to the cylinders is automatically
controlled by the valves fitted with it
which gets the signals from the cams
rollers fitted with the rotating crank at
a certain angle of rotation. Here the
crank itself acts as the disk of the cam
with sophisticatedly designed profile.

F.

Piston and Cylinders of Kanho

G.

H. Exhaust Pipe: - These are the pipes in which exhaust valves of a cylinder do open.
Later on these pipes unite to form a wider pipe which leads the smoke and burnt hot
air to the chimney. Besides expelling the hot air out from the cylinder it also plays a
role in heat rejection by expelling the heat out of the cylinder with the thrown out
smoke of burnt fuel and air.
I. Crank:- It is rotating part of an engine connected with the shaft of the sliding piston

J.

with a revolute joint. It is

generally shaped like a profile of a
cam disk having rollers fitted at a
fixed angle of rotation which

governs the opening and closing of

the valves of the cylinder.

30

K.
L.
Now for a multicylindered engine the cranks of each cylinders are
sophisticatedly attached to each other in a series with a constant angular offset of their
profile in such way that the always adds each other multiplying the net power output
of the engine as a unit.
M.
Now interestingly the cranks are not connected to each other with a single shaft
have constant axis of rotation but two adjacent disks are individually connected with a
separate shaft so the piston shaft should have no hindrance during its path.
N.
O.

Q.

P.
Crank of Kanho

30

R. Heat Rejection: - There are generally two methods of heat rejection are adapted in
ships.

I.

II.

Radiators: - These are used to transfer thermal energy from one medium to
another for cooling and heating. It always heats the environment. Hence either
it may act as a heater to environment or cooler to the fluid supplied to it. It is
made up of materials having good corrosion resistance and thermal
conductivity.
Cooler Or Heat Exchanger: - Here lubricant supplied to the engine loses
its heat coming in contact of a stream of cool sea water sucked into the engine
room by the pump.
S.

T.
U.

Specification of Engine of M. Lava

V.
Type
: Diesel Engine
W. Speed
: 900 rpm
X.
Bhp
: 190 kw
Y.
Temperature
: 318 K
Z.
Pressure
: 760 mm of Hg
f) Gear Box: - It is the mechanism in the engine room used to control the speed of
the rotating propeller with the help of a complex train. Here power input is from
the rotating crank from engine while output is fed to propeller shaft.
g) Propeller Shaft: - It is the shaft coming out of the gear box and running up to the
rear part of the ship and attached with the propeller at its terminal. It is the mean to
transfer the power from gear box to propellers.
AA.
It is well machined in the Lathe m/c prior to being attached to ship and
then fitted at its exact position with help of sufficient number of bearings.
Generally universal joints are used to couple the main shaft with propellers and
shaft out of gear box.
AB.
AC.

Propeller shaft is generally made with Steel so that it can have required degree of strength
and smooth surface finish to minimize friction during rotation
AD.

AE.

Specification of Propeller shaft of Kanho

30

Length
Dia.
Materials
Rotation
Direction of rotation

: 4.22 ft
: 8.25 cm
:Steel with a gun metal covering
: 300-1200 rpm
:Both clockwise and anticlockwise

AF.
AG.

AH. Engine of Kanho

AI.
Chimney :- It is the square or
cylindrical pipe on the top most roof of the
ship just beside the mustool which used to
expel out all the smoke formed in the
engine and generator with the help of the
exhaust pipes from each individual
mechanical prime movers in the engine
room.
AJ.
AK.

AL.

AM.
AN.
AO.
Cooling Fans :- These are the fans provided in cylindrical pipes situated
beside the chimney and draws cool air from the atmosphere to the engine room above the
engines to cool it down.

30

AP.

AQ.
Propeller : - A propeller is a type of fan which transmits power by
converting rotational motion into thrust. A pressure difference is produced between the
forward and rear surfaces of the airfoil-shaped blade, and water is accelerated behind
the blade. Propeller dynamics can be modelled by both Bernoulli's principle and
Newton's third law.
AR.

30

AS.

AT.

AU.

Different types of propellers

AV.
AW.
A propeller is the most common propulsor on ships, imparting momentum to a
fluid which causes a force to act on the ship.
AX.
The ideal efficiency of any size propeller (free-tip) is that of an actuator disc in
an ideal fluid. An actual marine propeller is made up of sections of helicoidal
surfaces which act together 'screwing' through the water (hence the common
reference to marine propellers as "screws"). Three, four, or five blades are most
common in marine propellers, although designs which are intended to operate at
reduced noise will have more blades. The blades are attached to a boss (hub), which
should be as small as the needs of strength allow - with fixed pitch propellers the
blades and boss are usually a single casting.
AY.

AZ.

Marine propeller nomenclature

BA.

BB.

D.

A.

E.

B.
C. 1) Trailing edge

30

F. 6) Leading edge

BC.

2) Face

G. 7) Back

8) Propeller shaft

3) Fillet area
4) Hub or Boss
5) Hub or Boss Cap

BD.

9) Stern tube

ateri

bearing

als

H. 10) Stern Tube

Used

in Propeller Design
For Propellers Body

:Phospho-Bronze

For Shaft

: Steel

For different Bushes

: Gun metal

BE.

Cardan Shafts are also used in marine applications for the transmission of

power between gear box and propeller

BF.
BG.
BH.
Rudder :- A square sheet of metal attached to the rear most part of
ship just behind the Propellers by means of a vertical shaft attached to its one end. It is
made able to rotate right or left around the shaft as axis of rotation. It is used to turn the
ship. It receives power from the steering on deck by hydraulic means which is converted
into the rotation of its axis by means of gears and wires.
BI. Now if rudder is rotated towards right the outward flow of water from right side of
propeller is resisted which causes a force on the sheet of rudder and in reaction sheet also
applies an equal opposite force on right hand side of the rear part of the ship which acts as
a torque to rotate the front part of ship towards left.
BJ.
BK.

BL.

30

BM.

Turning of a Ship Towards Right

BN.
After Side :- The Rear part of the deck of a ship is called after side.

BO.
It is generally the part of a ship which is equipped with all the gear and wire mechanisms
to steer the rudder of the ship
BP.
BQ.

Section - II

BR.

Section : - New Machining and Fitting Shop

BS.

Duration: - 5th July 2010 13th July 2010

BT.
BU.

Materials generally Used:

Gun Metal
Monal Metal
Mild Steel
Phospho-Bronze
Copper
Platinum( in gasket sheets for leak proof)

BV.
BW.

BX.

Job Seen At Machine Shop:

Lathe Operations
i. Machining of Propeller Shafts
ii. Making a part of square bar cylindrical by turning
iii. Thread Cutting on a part of studs
iv. Making Nuts with a hexagonal parallelepiped
BY.
Fitting Shop
i. Vice Operation
ii. Study of Main Parts of a Centrifugal Pump
BZ.
CA.
CB.
CC.

30

CD.
CE.
CF. Layout Of New machining & Fitting
Shop
CG.

1. Marine Workshop & Planning

Office
2. Area Of Keeping Spare Parts
3. Staff Table
4. Vice Table
5. Wooden Block
6. Wooden Block
7. Wooden Block
8. Vice Table
9. Lathe M/C
10. Lathe M/C
11. Lathe M/C
12. Vice Table
13. Vice Table
14. Vice Table
15. Vice Table
16. Marking Table
17. Pipe Thread Cutting Table

18. Shaping M/C

19. Drilling M/C
20. Drilling M/C
21. Vertical Boring M/C
22. Milling M/C
23. Lathe M/C
24. Lathe M/C
25. Lathe M/C
26. Lathe M/C
27. Lathe M/C
28. Lathe M/C
29. Lathe M/C
30. Lathe M/C
31. Slotting M/C
32. Shaping M/C
33. Horizontal Boring M/C
34. Grinding M/C
35. Grinding M/C

30

36. Staff Room

37. Lathe M/C
39.
40.
41.
42.
43.
44.

38. Lathe M/C

Lathe M/C
Lathe M/C
Lathe M/C
Lathe M/C
Lathe M/C
Lathe M/C

45.

46.

Job Seen At Machine Shop

i. Machining of Propeller Shafts

47.
48.
49.
50.
51.

Name Of M/C
Specifications
Position
Procedure
I.

: Lathe M/C
: 6 Jaws Manually Centred Chuck 22 ft Bed Length
: 30th M/C of New Machining & Fitting Shop
: Machining of propeller shaft consists following steps
The propeller shaft is cantered in between the Head stock and
Tailstock of the lathe m/c with help of the chuck and live centre
fitted with the tail stock with the sufficient numbers of well

II.

centred support in between.

An appropriate machining tool is fitted at the tool post with a

III.

very small cutting depth.

Auto feed is engaged in the m/c with the appropriate gear
settings with the help of the gear setting manual printed at the

IV.

body of head stock.

Now when one complete horizontal displacement of the tool is
complete the direction of feed is immediately reversed with the

V.

help of a lever provided below the tool post.

Now the desired level of surface finish is obtained by changing
the width of tool tip, feed speed and cutting speed. Lesser will
be the feed rate higher will be the degree of the smoothness
52.
53.

ii.
55.
56.
57.
58.

Making a part of square bar cylindrical by turning

54.
Name Of M/C
Specifications
Position
Procedure

: Lathe M/C
: 4 Jaws Manually Cantering Chuck 12 ft Bed Length
: 27th M/C of New Machining & Fitting Shop
: Process includes the following steps

30

I.

The job is carefully cantered in between the chucks jaws so

that the centre of the biggest in circle of the square base
remains aligned with the tip of the live centre attached with the

II.
III.

tail stock.
Now the job is rotated freely to mark that centre.
The turning length on the job is measured using a steel rule and

IV.

marked with a file.

There after a cutting tool is fitted at the tool post with a depth
slightly less than the farthest distance between the centre of
live centre and perimeter of the job and m/c is started after

V.
VI.

engaging the appropriate feed rate and cutting speed.

The direction of feed is immediately reversed when the cutting
edge of the tool reaches the file mark.
The process is repeated with increasing depth of cut until it
reaches the point of contact of the biggest in circle at base and
perimeter of the job or until the value of the radius of desired
dimensions of the base is achieved.

59.

iii.

Thread Cutting on a part of studs

60.
61. Name Of M/C

: Lathe M/C

62. Specifications

: 4 Jaws Manually cantering Chuck 12 ft Bed Length

63. Position

: 27th M/C of New Machining & Fitting Shop

64.

Basic Principle

: If the feed rate of a m/c per unit rotation is

greater than the width of the cutting edge of the tool then it starts to
scratch the marks of cut on the rotating job. This property is used for
making external threads on the cylindrical surfaces.
65.

Procedure
I.
II.

: Process includes the following steps

The job is properly cantered in between the lathe m/c.
Now a tool with the depth of cut a little bellow the job
perimeter is fixed.

30

III.

The gears and levers are engaged to give the speed of cut and
feed rate so that a thread of desired pitch is obtained by using

IV.

the thread cutting manual on the headstock.

The direction of feed is immediately reversed as soon as the

V.

tool reaches the mark from which the thread has to be initiated.
The process is repeated with increasing depth of cut until it
reaches up to desired value.

66.

iv. Making Nuts with a hexagonal parallelepiped

67.
68.
69.
70.
71.

Name Of M/C
Specifications
Position
Procedure
I.
II.
III.
IV.

V.

VI.
VII.
VIII.

IX.
72.

: Lathe M/C
: 6 Jaws Self Cantering Chuck 6 ft Bed Length
: 28th M/C of New Machining & Fitting Shop
: Process includes the following steps
The job piece is marked with a file at an interval equal to the
height of the nut.
Now the marked job piece is inserted in the self cantering
chuck and fixed tightly.
The live centre in the tail stock is replaced with a drill bit of
tap drill radius equal to the inner radius of the nut threads.
Now the feed is given to the tail stock until it approximately
drills up to the depth slightly greater than the height of the nut
to be made.
After that the drill bit is replaced with an internal thread cutting
tool of L-shape and tightened in tail stock with the nuts
provided below so that the depth of cut equals the depth of
thread in nut.
Now the gear settings are changed to give auto feed to tailstock
and cutting speed for internal thread cutting of desired depth.
Now again the thread reaches the depth little deeper than the
height of the nut the direction of feed is reversed.
After completion of thread cutting in the groove a single point
cutting tool is fitted at tool post and placed at the mark of nut
height. Depth of cut is engaged to auto feed without giving any
feed to the horizontal motion of the tool post.
The m/c is allowed to run until the tool cuts off the nut.

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73.

74.

Live centre (top)

75.

Dead centre (bottom)

76.

77.Main Parts of a Lathe M/C

78.

80.
81. Main Parts of a Centrifugal Pump: a) Impeller
b) Casing
c) Suction Pipe with Foot valve and Strainer.
d) Delivery Pipe
82.

79.

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83.

84. The description and working principle of these parts are already stated in the marine
section (pg: 12 & 13). Under the heading Centrifugal Pump.
85.
86.
87.
88.

Section - III

89.

Section : - Boiler & Fabrication Shop

90.

Duration: - 14th July 2010 20th July 2010

91.
92.

Contents: - The section Contains-

93.
Layout Of Boiler and Fabrication Shop.
94.
Description of Machines Seen.
Bending M/C
Rolling M/C
95.
Power Transfer by Shafts.
96.
Making of Buoys Used for Traffic Control.
97.

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Various Welding Techniques and Parameters.

98.

99. Layout Of Boiler & Fabrication Shop

100.
101.

1.
2.
3.
4.
5.

Fabrication & Welding Zone

Bending M/C
Rolling M/C
Electric Motor
Staff Table & Planning Room.

102.

103.
104.
105.
106.
107.
108.
109.

Description of Machines Seen.

Name of the machine

: Bending M/C

Functions

: i. Straightening of bent rods or sheets.

ii. Bending the rods or the sheets as per need.
Mechanism
: The machine is made to run on
simple slider crank mechanism. First the input pulleys
of m/c are rotated by a belt which is coupled with a
overhead rotating shaft.

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110. Now this power is fed to a big fly wheel which

further transfers the power to the crank gear with the
help of a complex gear train. Now a slider is connected
with the crank at a very small offset of axis of rotation
causing the slider to reciprocate with immense amount
of power.
111.

112.
113.

Top view of Bending M/C

114.

115.

Operations

: For straightening
a) With the help of engaging lever the belt is force to slide from
free rotating pulley to the pulley engaged with gears.
b) There after an I-bar is placed between the hand wheel operated
supporting bars and bending slider.
c) Now the bent job is placed in between the I-bar and the slider
show that the point of bent or dent faces the slider.
d) The hand wheels are rotated to forward the I-bar placed ahead
of the supporting bars until the desired alignment is achieved.

116.

For bending

a) After engaging the pulley the job is placed in such a way that
the point of bent faces the siding jaw.

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118.
119.
120.
121.
122.

123.
124.

125.
126.

127.
128.

b) Then the both the hand wheels are separately rotated to achieve
the desired degree of bent.
117.
Name of the machine
: Rolling M/C
Functions

: i. Rolling flat sheets to make an arc shape.

Mechanism
: i. Here there are two
input pulleys which rotates lower rolls with the help
of suitable gear train.
ii. The upper roll is
used to maintain the required pressure by means of
hand wheel and screw gear mechanism depending
upon the the thickness of sheets and demand of the
work.
iii. The bar
provided before the rolls is used to support the
sheets while inserting them into the rolls.

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129.

130.

Power Transfer by Shafts

131.
In the shop the power to the each and every machine is transferred with the
help of a long motor driven rotating shaft fitted overhead with the roof of the shop.
For the reason a sufficiently large motor efficient enough to drive the all the machine
in the shop simultaneously is established at one end of the workshop. Now the output
pulley of the motor is connected to the shaft by means of a belt. Now this rotating
shaft acts as the prime source of power in the shop. The power from this shaft can be
extracted by means of pulley and belt whenever and whenever required.
132.
It is very often not possible to have a shaft of a length of the shop. Because
according to BIS standards the maximum length of a shaft is 13m for convenience in
its transportation. Hence the shafts are coupled in series to achieve the desired length.
133.
134.

The sufficient no of bearings and supports are provided with the shaft.

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135.

136.

Power Transfer by Shaft

Making of Buoys Used for Traffic Control

137.
138.
Buoys are hollow more or
less cylindrical barrels made up of
mild steel sheets and able to float
in the water which is used to locate
the path and signals in seas or
water ways. This is the only

1)

medium in the water ways to warn

the incoming stranger ships in a
water zone about the swallow
water and other dangers.
139.

First the 8mm thick ms sheets are rolled in rolling m/c and
then cut into a piece having a length equal to the perimeter of the barrel and width
equal to the height of the barrel.
2) There after the sheet is rolled to make a cylinder and welded at the joint.
3) Now a sheet of 10mm thickness is cut into a shape of circle and joined at both the
open faces of cylinder.
140.

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4) Now sufficient numbers of holding arrangement made up of 25mm thick m.s. sheets
and iron bars are welded at its top. These holding arrangements are used to hold the
buoy amidst of waves of seas.
141.

Various Welding Techniques and Parameters

142.

FEN
ulo
se
nic
fot
nru
i
s
c
iW
oe
ln
d
i
n
g

1. Metallic arc welding using A.C. transformer :- Used only for ferrous metal.
143.
2. Metallic arc welding using D.C. rectifier motor generator :- Used for both
ferrous and nonferrous materials like Brass, Copper etc.
144.

145. Types of Welded Joints

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146.

147.
148. Positions of Weld
149.
(1) Flat
150.

(2) Vertical

(3) Horizontal

(4) Overhead

151. Melting point of alloys

152. Alloys
154.
156.
158.
160.
162.
164.
166.
168.
170.

M.S.
W.I
C.I.
C.S.
Cu
Ni
Al
Brass
Bronze

153. M.P.
155. 1370C
157. 1535C
159. 1250C
161. 1500C
163. 1083C
165. 1445C
167. 630C
169. 930C
171. 900C

172.
173. N.B.
174. While welding nonferrous alloys D.C. is compulsory. Its +ve pole terminal is
connected with the job and ve with the holder. Low hydrogen evolving electrode (not above
2%). Open ckt. voltage 80V to 100V & close circuit voltage in a almost zero Where as close
ckt. voltage 15V to 25V with usually bare or lightly coated electrode and up to 45V with some
special electrode..
175.

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176. Size of Electrode

177. Dia of Electrode

178. Current Read

179.
182.
185.
188.
191.
194.
197.
200.
201.

180.
183.
186.
189.
192.
195.
198.

181.
184.
187.
190.
193.
196.
199.

16 S.W.G.
14 S.W.G.
12 S.W.G.
10 S.W.G.
8 S.W.G.
6 S.W.G.
4 S.W.G.

202.
204.
205.
206.
207.
208.
209.

1.5 M.M.
2 M.M.
2.5 M.M.
3.2 M.M.
4.0 M.M.
5 M.M.
6 M.M.

25-45 amp
50-70 amp
65-75 amp
90-130 amp
120-135 amp
150-250 amp
180-300 amp

Oxy Acetylene Gas Welding

203.

Gas used :-

Oxygen & Acetylene

Uses :-

a. Cutting b. Welding c. Brazing

Flames:-

1. Oxidising 2. Neutral 3. Carburising

Cutting
210.

Neutral Flame is used for cutting mild steel and Carburising Flame for
cutting cast iron.

211.
212.

Equipments

: i. By cutting torch ii. By profile cutting m/c

213. Regulators :
i.
Single Stage
ii.
Double Stage
214.
215.
216.
217.

i. Single Stage :
1/9 th of original pressure
Oxygen pressure = 1800 lbs
Single stage pressure = 1/9 x 1800 = 200lbs

218. ii. Double Stage :

219.
220.
221.
222.
223.

Single stage is fixed while double stage is adjustable with the adjustable screw.
Pressure of Oxygen cylinder = 1900lbs/sq inch
Volume of Oxygen Cylinder = 6.5 cubic meter
Dissolve Acetylene Pressure = 250 lbs/sq inch
Volume of each cylinder = 6cubic meter

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224.

225. Selection of Cutting Nozzle

226. Plate
Thickness
236. Nozzle
Size

227.

237.
1/32

228.

238.
3/64

229.
1
239.
1/16

230.

240.
/16

2 231.
4
1 241.
1/64

232.
6
242.
5/64

233.
8
243.
3/64

234.
10
244.
7/64

246.
247.

Welding
248.
249.

Flame

253.

Oxidising

250. Max.
Temp.
254. 3480C

259.

Neutral

260.

3230C

266.

Carburising

267.

3125C

270.

271.

251.
252.

Uses for Welding

255.
256.
257.
258.
261.
262.
263.
264.
265.
268.
etc.
269.

Brass (Cu 75% + Zn 25%) at 700C

Bronze (Cu 80% + Sn 20%) at 910C
Cast Iron at 1147C
Copper at 1050C
Stainless Steel at 1450C
Mild Steel at 1490C
Aluminium At 650C
Shear Blades , Shackles and Valve Seats

235.
12
245.
1/8

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272.

273.
274. Flames
275.

Brazing
276.
A method of joining dissimilar metals by means of an alloy (Cu & Zn)where
parent metals will not be melting.
277.
278.

279. Function of a Pressure Regulator

280.
1. To reduce the cylinder pressure to a workable pressure.
2. To maintain delivery pressure &gas volume with the pressure variation at the source.
281.
282.

283. Range of Pressure Gauge:

284.
285. Name of The
Gas
288. Acetylene
291. Oxygen
294.

286. Welding Pressure

Gauge
289.

0 2 Kg/Sq Cm

292.

0 14 Kg/Sq Cm

287. Cylinder Pressure

Gauge
290.
293.

0 40Kg/Sq Cm
0 200 Kg/Sq Cm

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295.
296.
297.

298. Bibliography
299.

During the making of the report I had to refer the following destination

300.

http://www.kolkataporttrust.gov.in
http://www.inthewoodshop.org/methods/trlathe.shtml
http://www.Wikimedia Foundation. Inc
http://www.uknationalmarinemuseum.org/methods/trlathe.

shtml
http://www. treatiseonengineering.com

301.
302.
303.

304.

305.
306.
307.
308.
309.
310.