ORIENTAL INSTITUTE OF SCIENCE &TECHNOLOGY

MAJOR TRAINING REPORTON MECHANICAL/INSTALLATION

ACTIVITIESFROM

CENTRAL WORKSHOP JAYANT (N.C.L)SINGRAULI

Submitted in partial fulfillment of Bachelor’s degree inMECHANICAL ENGINEERING

OFRajiv Gandhi Proudyogiki Vishwavidyalaya(University of Technology of Madhya Pradesh)

SUBMITTED TO: SUBMITTED BY: PROF:KAILASHCHANDRA BHARDWAJ OM PRAKASH HOD (DEPT. OF M.E) (0105ME071069)

ACKNOWLEDGEMENT

The best part about completion of training is sense of achievement and that offer a wonderful opportunity to thanks all those who are directly or indirectly associated with the Training Program. It was undertaken as the requirement for the completion of B.E. It was not only a technical endeavor but also the initiation of a fresher into the world of mechanical engineering. Entire training session helps understand how machine works and brief study on functioning of various machines and their maintenance works. We consider ourselves fortunate enough to be in right place with right person. we are very much obliged to Mr. Sanjay Singh for their diligent support and invaluable guidance. we take this opportunity to express our deep sense of gratitude to CENTRAL WORKSHOP JAYANT(N.C.L), SINGRAULI, which gave us opportunity to take training in mechanical/installation activities. we are thankful to all teaching staff to have directly and indirectly helped in completion of our major training.

CONTENT

PROFILE OF N.C.L. MISSION AND ITS OBJECTIVES SALIENT FEATURES OF N.C.L. DIFFERENT SECTION IN CENTRAL

WORKSHOP JAYANT (N.C.L.) WELDING SHOP MACHINE SHOP TRANSMISSION SHOP ENGINE SHOP

COAL HANDLING PLANT(C.H.P.) CONCLUSION

PROFILE: Northern Coalfields Limited was formed in April 1986 as a subsidiary company of Coal India Limited. Its headquarter is located at Singrauli, Distt. Sidhi (M.P.). Singrauli is connected by road with Varanasi (220 Km) – a holy city on the banks of river Ganga, and Rewa (206 Km) – the state of white tigers and Sidhi (100 Km) – district headquarter town of Madhya Pradesh. The nearest railway station is Singrauli located on the Katni-Chopan branch line running parallel to the northern boundary of the Coalfield. The nearest railway station for reaching directly to Delhi and Kolkata is Renukoot that is located on Garhwa-Chopan railline.

Nearest (private) airstrip is at Muirpur.

The coalfield can be divided into two basins, viz. Moher sub-basin (312 SqK) and Singrauli Main basin (1890 Sq.Km.). Major part of the Moher sub-basin lies in the Sidhi district of Madhya Pradesh and a small part lies in the Sonebhadra district of Uttar Pradesh.The area of Singrauli Coalfields is about 2202 SqKm. Singrauli main basin lies in the western part of the coalfield and is largely unexplored.Thepresent coal mining activities and future blocks are concentrated in Moher sub-basi.

NCL produces coal through mechanised opencast mines but its commitments towards environmental protection is total. It is one of very few companies engaged in mining activities, which has got ISO –14001 Certification for its environmental systems.

NCL, through its community development programmes, has significantly contributed towards improvement and development of the area. It is helping local tribal, non-tribal and project-affected persons in overall improvement of quality of their life through self-employments schemes, imparting education and providing health care.

 

MISSION:THE MISSION OF COAL INDIA IS TO PRODUCE AND MARKET PLANNED QUANTITY  OF COAL AND COAL PRODUCTSEFFECIENTLY AND ECONOMICALLY WITH DUE REGARDSTO SAFETY,CONSERVATION QUALITY AND ENVIRONMENT.

OBJECTIVES:

To ensure planned production of coal efficiently, matching with increasing demand of coal, which is the prime source of energy for the nation.To generate safety awareness amongst employees as also to create safe working culture.To ensure clean, green and pollution free environment at working places and also at surrounding areas.To ensure optimum capacity utilisation of men, machinery and available resources.To ensure cost control by developing cost consciousness.To ensure strict quality control for better consumer satisfaction.To ensure perfect manpower planning and also harness the best out of available human resource.To ensure improved quality of life of work force through welfare measuresTo be concerned for the community especially for the tribal and backward sections of the society residing in and around mining projects.To ensure rehabilitation of project affected people (PAP) as per the guidelines provided by Coal India Limited and approved by the Ministry of Coal and also taking PAPs into confidence to elicit their co-operation in achieving Corporate Objectives.To develop good work culture through disciplined, contended and motivated workforce for achieving Organizational Objectives

SALIENT FEATURES:TOTAL AREA 2202 Sq.Km.AREA OF MOHER BASIN 312 Sq.Km.AREA OF MAIN BASIN 1890 Sq.Km.ESTIMATED RESERVES OF MOHER BASIN

As on 31.03.078.31 Billion Tonnes

BALANCE MINEABLE RESERVES OF MOHER BASIN (up to 300 meter depth) As on 31.03.07 2.68 Billion Tonnes

LIFE OF COALFIELD AT SCHEDULED RATE OF PRODUCTION. 37 YRS.

COAL SEAMS IN MOHER BASIN, THICKNESS & GRADE

JHINGURDA 130-138 m D-EPUREWA TOP 9 m D-EPUREWA BOTTOM 12 m C-DTURRA 20 m C-E

GRADIENT 2 to 5 DEGREESNote: Jhingurda seam is the Thickest Coal Seam of India 

DIFFERENT SECTIONS:

1. WELDING SHOP Defination - Welding is a process  of  joining two metal pieces as a result of significant diffusion of the atoms of the welded pieces into the joint (weld) region.Welding is carriedoutby heating the joined pieces tomelting point andfusing themtogether (with or without filler material) or by applying pressure to the pieces in cold or heated state.

Advantages of welding: Strong and tight joining; Cost effectiveness; Simplicity of welded structures design; Welding processes may be mechanized and automated.

Disadvantages of welding:

Internal stresses, distortions and changes of micro-structure in the weld region.

Harmful effects: light, ultra violate radiation, fumes, high temperature.

Applications of welding:

Buildings and bridges structures Automotive, ship and aircraft constructions Pipe lines Tanks and vessels Rairoads Machinery elements

Welding processes

Arc  welding Carbon Arc  Welding Shielded Metal Arc  Welding   (SMAW) Submerged Arc  Welding   (SAW) Metal Inert Gas  Welding   (MIG, GMAW) Tungsten Inert Gas Arc  Welding   (TIG, GTAW) Electroslag  Welding   (ESW) Plasma Arc  Welding   (PAW)

Resistance  Welding   (RW)

Spot  Welding   (RSW) Flash  Welding   (FW) Resistance Butt  Welding   (UW)  Seam  Welding   (RSEW)

Gas  Welding   (GW)

Oxyacetylene  Welding   (OAW) Oxyhydrogen  Welding   (OHW) Pressure Gas  Welding   (PGW)

Solid State  Welding   (SSW)

Forge  Welding   (FOW) Cold  Welding   (CW) Friction  Welding   (FRW)

Thermit  Welding   (TW)

Electron Beam  Welding   (EBW)Heat treatment chord for hardening

Material Job size(mm) Temp range Soaking time

EN-9 25 800-830(^C) 1hr-1:50hr EN-19 50 850-880(^C) #EN-24 820-850(^C) # EN-9 50 same 1:50hr-2hr EN-19 75 #EN-24 #

EN-9 75 same 2hr-5hr EN-19 100 #EN-24 #

EN-9 100 same 3hr-4hr EN-19 150 # EN-24 #

EN-9 150 same 4hr-5:50hrEN-19 200 #EN-24 #

EN-9 200 same 5:50hr-6:50hr EN-19 40 # EN-24 #

EN-9 250 same 6:50hr-7:hrEN-19 300 #EN-24 #

2. MACHINE SHOP

NO. OF MACHINES IN THE SHOP

LATHE MACHINE(1-22) SBCNC(1) NHCNC(2) BVS 25/50 PLANOMILLING MILLING(1-6) H. BOARING(1-2) RADIAL DRILL(1-2) SHAPER(1-3) SLOTER M/C (1-2) P.G(1-4) SURFACE GRINDER(1) CENTRELESS100 TOOL POST GRINDER(1-2) POWER HACK(1-2) BEND SAW GEAR HOBBING CIRCULAR SAW E.O.T CRANE 10T,C.R-16 E.O.T CRANE ST,C.R-17 E.O.T CRANE ST,C.R-12 E.O.T CRANE 20/ST,C.R-20

EQUIPMENT USED TO PRODUCE COAL

DRAGLINE(24CuCapacity-96Boom Length,15-90,20-90) DOZER- to make road DUMFER(85,120,170 Tonnes) DRILL-Boring for blasting SHAWELL-(24CuMtr,30Tonnes) C.H.P-(Coal Handling Plant)

Defination Machine used to work in easily way and less time to produce product. Machine tool used to manufacture machine.

Kinds of machine tool

Subtraction type- ex- lathe,milling etc. Addition type- ex- welding etc. No subtraction & no addition-ex- heat treatment

assembling, casting etc. Lathe Types of lathe

Centre lathe- centre to centre point cutting Turret lathe- production lathe(tool turret head) Capstan lathe- gaping in total length Bench lathe- small machine tool(mini 10mm) Copying lathe- use master piece tool to perform the work CNC lathe- computer numeric control, SBCNC-sligned

bed cnc (40capacity),letter number symbols,G-code,M-code programme

Special lathe- for only one purpose machine

Lathe description Bed –carriage runs, rack, lead screw, feed road Headstock Gear spindle box Thread cutting Speed spindle Spindle chuck Tailstock Support job(centre) Revolving centre(small work) Dead centre(major work) Carriage Saddle Apron Cross slide Tool slide, tool post, tool holder Base

Lathe Working

1. Turning Surface turning , plain turning Step turning Taper turning

2. Drilling Boring Threading Facing Knurling Parting Reaming

Tool material

Mild steel- non ferrous metal , no iron High speed steel(H.S.S) Carbide bits Diamond bits

Thread

Metre thread(mm,60degree) British thread( BSP-for pipe ,BSW-for

worm,55deg) ,measure by thread/inch (tpi) , british associates

Acme thread( 29deg)- use for power transmit Square thread(90deg) Buttress thread(45deg)

Working

-lifting -temporary -power transmit -screw jack-sq thread -fixing lead screw

Chuck

3 jaw chuck- self centring 4 jaw chuck- free centre Collet chuck Drill chuck Magnetic chuck

Measuring instruments

Screw guage – least count ( .01) mini dist measure, ,micrometer ( L.C- .001)

Ratchet, thimball, thimball scale, main scale, lock nut, frame, anvil, spindle

Vernier micrometer- (L.C- .001mm,.0001inch)

D.T.I (Dial test indicator)- (L.C- .01mm, .001inch) , use for centring and checking plane surface

Vernier bevel protector(V.V.P) – (L.C- 5mm), use for tapered surface

Vernier caliper

Steel tapered scale

Pressure guage

Indirect measuring instruments

Gauges

Plunge gauge- use for limit and tolerance Surface or slip gauge- gapping maintained(1mm),(50-

125) Filler gauge- clearance used( inch 8,16,32,64) Ring gauge Wire gauge- measure wire dia(outer) Pitch gauge- checking thread pitch Spirit level gauge Trisquare gauge

Other machines

Shaper machine:- A shaper is a type of machine tool that uses linear relative motion between the workpiece and a single-point cutting tool to machine a linear toolpath.

Properties Quick return motion mechanism Circular to horizontal motion-

Sliding bar mechanism (pinion-bull wheel-centre pin- Sliding block – rocker arm – ram) Four bar mechanism – ( 216deg- forward motion, 144deg- return motion)

Clapper box- toolWorking: surfacing , keyways, bearing

Model- CSH-80 Make- cooperMilling machine:- A milling machine  is a machine tool used to machine solid materials.

Types of milling machine Horizontal machine- Plain horizontal machine(H&V, no angle)

Universal horizontal machine( H&V, with angles)

Omniversal horizontal machine (V&H or Up & down, with angles)

Vertical machine Plano milling machine- vertical & horizontal Gang milling machine- vertical( 2-3 spindle) Maho milling machine- small type milling m/c CNC milling machine- use code in computer Special milling machine- use purpose diamond

Parts

Ram Column Base Knee Table Know bed Attachment

Indexing head:- An indexing head, also known as a dividing head or spiral head is a specialized tool that allows a workpiece to be circularly indexed that is, easily and precisely rotated to preset angles or circular divisions.

Types:- Direct indexing- use 24/N,N-no of teeth,use-

6,4,2,8,12,24) Compound indexing-(use 40/N, index plate- plate1-

15,16,17,18,19,20. plate2- 21,23,27,29,31,33. plate3 – 37,41,39,43,47,49)

Sloter machine:- Vertical motion

Working- Internal keyways, gearsModel- CH-20Make- cooper

Bend saw machine:- NC controlling , material partiting Timer set – TM- timer ,CR1-lots size(counter),CR2-length multiplier Model- 420DCA , 420 capacity , dia. cutting actionMake –ITL( India tools limited)

Power hacksaw:- Blade capacity, length 750mm,thikness 2.5mm, width 50mm, 6tpi

Circular saw:- Model –SPM

CNC machine:- automation of machine tools that are operated by abstractly programmed commands encoded on a storage medium opposed to manually controlled via handwheels or levers, or mechanically automated via cams alone.

Working- Symbols ,letters ,numbers

1. TRANSMISSION SHOP

Defination- A transmission or gearbox provides speed and torque conversion from a rotating power source to another device using gear ratios. Transmission refers to the

whole drive train, including gearbox, clutch, prop shaft (for rear-wheel drive), differential and final drive shafts. The most common use is in  motor vehicles, where the transmission adapts the output of the  internal combustion engine to the drive wheels. Such engines need to operate at a relatively high rotational speed, which is inappropriate for starting,stopping, and slower travel . The transmission reduces the higher engine speed to the slower wheel speed, increasing  torque in the process.

Transmission in various types of equipments Dozer (model no.3355)

High clutch(2plate+4disc) Low clutch(3+4) from lower First clutch(2+3)from upper Second clutch(2+3) lower Reverse clutch which is started(3+4) Forward clutch(4+5) with engine directly

Torque converter(made in Japan)

Ring gear , oil pressure – 26 kg/mm First gear- forward clutch, first clutch, low

clutch Second gear- forward clutch, second clutch, low

clutch Third gear- forward clutch, first clutch, high

clutch Fourth gear- forward clutch, second clutch, high

clutch Forward plate-(4plate+5disc),forward &reverse

are same

Reverse gear- first gear( reverse clutch, first clutch, low clutch) , second gear( rev. clutch, low and first clutch)

Dumper(HD-785,kamastu model, 85 tonnes) First gear – first clutch(4+5), low clutch(4+5) Second gear- second clutch(4+5), low

clutch(4+5) Third gear- second clutch, high clutch Fourth gear- third clutch(2+3) , low clutch(4+5) Fifth gear – third clutch , high clutch Sixth gear- fourth clutch (3+4), low clutch Seventh gear- fourth clutch , high clutch Eight gear – reverse gear(5+6) , low clutch

Graider gearing system First gear – first clutch, low clutch, forward

clutch Second gear- forward clutch, second clutch, low

clutch Third gear- forward clutch, low clutch, high

clutch Fourth gear- forward clutch, low clutch, fourth

clutch Fifth gear – first clutch , high clutch forward

clutch Sixth gear – second clutch, high clutch, forward

clutch Seventh gear – third clutch , high clutch,

forward clutch Eight gear – fourth clutch , high clutch, forward

clutch ,8 rev. gear are used

Grinding wheel

Abrasive – aluminum oxide(hard metal), silicon carbide( soft metal)

Grain or grit size Grade Structure Bond – mixture of all parts ( A A 4 6/ 5 4/ K5/

V8 this represent all oxide, grain size, grade, structure, bond.

Grinding machine Portable Tool & cutter Hand Surface Centre less Crankshaft

Types of coil

Reverse clutch coil First clutch Second clutch Third clutch Fourth clutch Low clutch High clutch Rev . gear(1+6) First gear(2+6) Second gear(3+6) Third gear(3+7) Fourth gear(4+6) Fifth gear(4+7) Sixth gear(5+6) Seventh gear(5+7)

Testing parameters for transmission Main oil relief pressure (35+-2kg/cm^2) Pilot reducing oil pressure( 1o.8+- .8) Lock up clutch oil( 14+- 1) Modulating oil pressure(30+-1)(5,6,7gear) Modulating oil pressure(15+-1)(3,4gear) Modulating oil pressure(15+-1) Regulate oil pressure (6+-1) Torque converter inlet oil pressure(8+-1)

Dumper- 85, 120, 170 tonnes) Made by caterpillar BEML Voltas

ENGINE SHOP

Defination- An engine or motor is a machine designed to convert energy into useful mechanical motion.Motors converting heat energy into motion are usually referred to as engines, which come in many types. A common type is a  heat engine  such as an  internal combustion engine which typically burns a fuel with air and uses the hot gases for generating power.

Engine system Air system

Pulley system

Lubrication system

Fuel system

Some types of engines

Mechanical engine

Electrical engine

Oil specification

Super 40- engine oil Super 30- transmission oil Ultra 10 – hydraulic oil Super 90- differential oil

Flow chart activities: Engine receiving from project Inspection

Washing of engines

Dismantling Inspection of dismantled

Cleaning of parts

Assembly & stage inspection

Cylinder block Crankshaft fitment Con. Rod & piston assembly fitment Cylinder head fitment Front & rear fitment Oil pump , oil pan fitment Rocker arm , intake manifold fitment Injector & p.t pump etc fitment Turbocharger, comp. , water pump fitment

Sub- assembly

Crank shaft grinding / polishing Con. rod measurements &piston assembly Cylinder head repair Rocker repairing Injector, p.t pump repairing Turbocharger ,water pump, comp. repairing

Cylinder head testing Pressure – 6 to 7 kg/cm^2 Water – 85 deg celcius

Thermostat: It is used to increase temp up to 60 to 85 deg Celsius or control the temperature

It maintain the temp up to 65 deg Celsius (normal temp)

If increase in temp then thermostat open & it goes into radiator become cool again & it rotate.

Engine testing machine

Oil temp – 82 to 107degcelcius Water temp- 78 to85 # Oil pressure – 107degcelcius oil temp Model low speed rated speed 495/743/855 1.4/2.0 3/5.1 1150/2300/3067 1.5/2.4 3.2/ 5.1 Air restriction: 15” water column – pure element 25” # - impure element Exhaust back pressure- 3”(mercury column) Collets- p.h- 8.5to 10 , chromate- 3500to 5000ppm Floor filter restriction : 4”(mercury column) - pure 8”( # )- impure Mini water column

COAL HANDLING PLANT (CHP)

Definition : A coal preparation plant (CPP) is a facility that washes coal of soil and rock preparing it for transport to market. A CPP may also be called a "coal handling and preparation plant" (CHPP), "prep plant," "tipple," or "wash plant".

The more of this waste material that can be removed from coal the greater its market value and the lower its transportation costs.

CHP:- It contains v-belts, conveyer belts , troughs( troughing angle -35deg) It divided into pulleys Drive pulley or discharge pulley Snap pulley Bend pulley Take up pulley Tail pulley

It contains three sections Crushing section Conveyer section Loading section

It process Crusher- apron feeder- bunker – C.C belts

Its specification RPM – 540, 6kv Full load current – 55amp Rotor voltage- 530v Rotor & stator - star connection Speed of crushing head – 80 oscillation per min Output of crusher – 1150m^3/m Maximum field size-1200m^3/m Width of disc opening- 180mm Width feed open – 1500mm Dia of crusher head – 2520mm Mantle -85tonnes Crushing - 1200hp Coal size- 800mm Lubricating oil – 20 hp

Apron feeder- 6 feeder , 3 crusher Belts- nylon, steel cords Sheet –R–belts Pressure – 2 kg/sec Silo capacity – 2400 tonnes 3000 tonnes

CONCLUSION

In this major training session we got a knowledge on machines, transmission, engine, welding etc. in the session we know that maintenance/installation activities of large machines like dumper , dozer ,shawell etc. will be done &used for coal producing and transferring them. It also gives knowledge about coal handling plant for transfer of coal to different areas for electricity generation . The knowledge we got in training session helps in future enhancement.