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INDUSTRIAL TRAINING
AT
DEE PIPING SYSTEMS
PRITHLA (PALWAL)
SUBMITTED BY-
AMIT KUMAR
B-TECH MECHANICAL
17001004011
PREFACE
As per the requirements of B-TECH degree course in MECHANICAL
ENGINEERING summer industrial training has to be undertaken after
second year.
To fulfill this requirement I took my training from DEE PIPING SYSTEMS,
PRITHLA (PALWAL).
The report contains all the necessary information of the plant viz. pipe
spools fabrication ,pipe fittings, pipe induction bending technology
,various welding method including inhouse robotic welding, blasting
process plant. It also contains an overview of the company. The
information has been prepared to best of data available at that my
knowledge and time.
Welded
ERW/EAW
Most commonly metals that are used for piping spools and fittings are:
SS(STAINLESS STEEL),CS(CARBON STEEL), LOW ALLOY STEELS( P91 , P92 ,
P11 , P5 , P9 , )
Pipe dimensions covered following standards;
ASME B36.10 and ASME B36.19
INDUCTION BENDING TECHNOLOGY
The main component in the induction bending machine is
inductor ring coil which consists of 3 ring coils i.e. air coil,
inductor coil, & water coil. The other components includes
pusher, bend roll, heat transformer, bend clamp & bend arm.
The inductor coil heats a narrow end for this to heat the
section, the coil generates a localized magnetic flux & induces a
electric current in the pipe underneath the coil. The material
resistance then creates the heat bend necessary to bend the
pipe .Pipes that are thick in size are usually bend by water bend
and the pipes that are thin in size are bend by natural air
cooling medium. There are 2 induction bending machines in
DEE PIPING SYSTEMS i.e. AWS SCHAFER & PB COJAFEX
SPECIAL. Nominal pipe range for bending for these machines is
8’’-48’’ & 2’’-16’’ .
FITTING PROCESS
This process basically required a FITTERMEN, ASSISTANT FITTERMEN,
GRINDERMEN, TACKERMEN. They should have required knowledge about
the piping spools and its process. Mainly spirit level & degree protector
are used to measure the angle for spools fittings
A spool is fitted according to the piping map provided by the production
engineers.
Various welding processes:
GMAW or MIG { METAL INERT GAS WELDING} ;
In this welding ,a DC power supply is used with reverse polarity.
Electrode is connected to +ve terminal & workpiece is connected to
–ve terminal. It is due to the principle of electric circuit which states
that 70% of heat is always on +ve side. So reverse polarity ensures
that the maximum amount of heat liberate at tool side which melt
the filler metal in proper way. Straight polarity can cause unstable
arc that results into large spatter. The shielding gas used in this
welding is carbon which protects the weld from atmospheric gases.
GTAW or TIG {
TUNGSTEN INERT GAS WELDING};
In this welding , a high intense arc is produced between electrode &
workpiece . In this welding straight polarity is used. Torch plays a
vital role in this welding in which collet is most important which is
used to hold the tungsten electrode. As compared to mig welding
joints are stronger in this but welding thickness is limited upto 5mm.
This welding process is slower and
costlier and hence mostly used to do
root of thick joints . In this welding
argon gas is used for shielding
effect.
FCAW { FLUX
CORED ARC
WELDING};
It is semi-automatic or
automatic welding process. This
welding is an alternative for mig
welding. Same procedure can
be used for this as used in mig
welding but the only difference
is that no shielding gases are
used in this welding . shielding
effect Is itself performed by tubular wire that is filled with flux, DCEP
(direct current electrode +ve ) is commonly employed in FCAW.
RT ( RADIOGRAPHIC TESTING) ;
Radiography has an advantage over some of the other processes in that
the radiography provides a permanent refrence for the internal
soundness of the object that is radiographed. The x-ray emitted from a
source has an ability to penetrate metals as a function of the accelerating
voltage in the x-ray emitting tube. If a void is present in the object being
radiographed, more x-rays will pass in that area and film under the part
in turn will have more exposure
than in non-void areas.
Generally x-rays & gamma rays
are used to produce a
radiograph of the specimen,
showing any changes in
thickness, defects (internal &
external) & assembly details to
ensures optimum quality in
your operation.
Positive
material
identification
( pmi ) test
It is the analysis of materials to determine the
chemical composition of a metal or alloy at particular (usually multiple )
steps of alloy manufacturing or in-process alloy installation. Knowing the
exact composition and grade of an alloy enables suppliers , plant
workers, and other responsible parties in the chain of custody of
components to match alloy specifications that are chosen for their
specific properties such as heat resistance, corrosion resistance ,
durability etc.
Stainless steel grades differ by chemical composition. The key difference
between the various grades are mainly the amount of Fe(iron) ,
Cr ( chromium), Ni ( nickel), Mo (molybdenum), & Cu (copper).
The most common , portable &
easy to use technology to this is
a handheld XRF ( x-ray
fluorescence) analyzer.
These instruments are highly
accurate at determining the
chemical composition of alloys
& their grades.
A operator can be trained to
use one within a few hours.
Hardness tests