A

CKNOWLEDGEMENT

ll praise is to Almighty Allah, the Beneficent, and the Merciful.

He showered His great blessings upon us in the form of Holy

Prophet, Hazrat Muhammad (P.B.U.H).
With much effort and time spent, we thank God for being able to
complete the internship in HMC.
We wish to take this space and opportunity to express our thanks
to all workers for providing us with helpful information and
exchanging thoughts, family members for their financial support
and HMC for supporting us in doing our project.
Thank you.

Page 1 of 44

Table
of Contents
Sr.
no
Page no.
1.

Introduction to HMC

Workshops

Labs

3
Organization and Function of PPC

2.

&

..

5
3.

4.

Basic Machine Shop

8

TTC & Heat Treatment

Fabrication Shop

NDT Lab

Material Testing Lab

24
5.

6.

27

33
7.
34

Page 2 of 44

8.

9.

Pattern Shop
36

Forge shop-I&II

38
10.
Inspection

39
11.
Recommendations

40

INTRODUCTION TO HMC
Heavy Mechanical Complex (Pvt) Limited is a leading engineering goods
manufacturing enterprise in Pakistan located at Taxila about 32 Kilometers
north of capital Islamabad. It is a professionally managed progressive
organization with over 160,000 sq. meters covered facilities and 1,100
employees.
Heavy Mechanical Complex Ltd. (HMC), Taxila is a major heavy engineering
subsidiary of the State Engineering Corporation (SEC) under the Ministry of
Industries & Production, Government of Pakistan.
In 1969, General YAHYA KHAN laid the basis of HMC. Then in 1971,
HMC started its production. In 1975, Prime minister of Pakistan ZULFIQAR ALI
BHUTTO inaugurated the HFF. For some years, these two industries worked
separately. But after some years, both were combined because for many
works they had need of one another

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HMC defines itself as A technical institute in which all types of machines

including Sugar plants, Cement Plants, Road rollers, Over Head Cranes
ranging from 0.5 to 50 tons Heat Exchanger boilers, Special Defense parts
(i.e., NDC works), Special Vibratory Rollers (which can bear statistically 10 to
12 tons vibratory load) and Pakistan steel works. Some other processes that
are also done by HMC are Designing and manufacturing and assembling and
installation with the certification of ISO 9001 and ASME Standards.
The Heavy Mechanical Complex (HMC), the biggest undertaking of its
type in Pakistan, was established in 1976 with Chinese assistance. The
Heavy Forge Factory (HFF) at this complex has proved crucial for Pakistan's
defense production needs. HMC has the capability for designing, engineering
and manufacturing of industrial plants and machinery. HMC has the largest
fabrication and machining facilities in the country equipped with Computer
Aided Designing (CAD) and can undertake a variety of fabrication /
machining jobs on sub-contracting basis.
HMC manufactures equipment for hydro-electric power plants, thermal power
plants, Sulphuric acid plants, industrial alcohol plants, oil & gas processing
plants, and chemical & petro-chemical plants, etc. Boilers, cranes,
construction machinery, material handling equipment, steel structure,
railway equipment, etc. are some of the other products which are produced
on regular basis. The company's capabilities include engineering and
manufacturing of Sugar Mills ranging between 1,500 - 12,000 TCD (tons of
cane crushing capacity per day), Portland Cement Plants of 700- 5,500 TPD
(tons per day) module and White Cement Plant of 50 - 1,000 TPD.
HMC have the resources to handle large projects with demanding delivery
schedules. Being the largest and most extensive fabrication and machining
facility equipped with state of the art technology. HMC provide
manufacturing services both on our own or customers design. .

PRODUCTS
HMC is one of the leading industries of Pakistan especially in the field of
Steel.
Heavy machineries are being produced here like:
Road rollers
Overhead cranes
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Mobile crane
Sugar plants
Cement plants
Oil refineries
Power plants
Pressure vessels
Boilers 40 to 80 Ton
Heavy duty machinery
Hydral power plants
Turbines
Rod construction machinery
Asphalt mixing plant etc.
First Boiler With Capacity of 140 Tons

Organization and Function of PPC (Production, Planning and Control)

Objective of PPC: - PPC is organized for improving the performance of company. PPC
department is headed by Dy. General Manager. It has following sections.

A. Sales order numbering system:The sales order numbering system allocates a unique identification system to each order
acquired by the sales and marketing department. This sales order consists of six digits. The
first two of these numbers designate the product group number of the products to be
manufactured or services to be provided by the organization. The next two digits specify the
fiscal year in which the order is received and the last two digits give the number of similar
orders already received in the same fiscal year.
For example, a job order given as11-11-04 is read as follows
11_______ product group no for sugar spares
13_______represents 2013 as the fiscal year
04_______specifies the fourth order for the current year
That is fourth order of sugar spares in 2013.
Page 5 of 44

B.

Core Planning:Core planning section has following works.

Master schedule planning.

Order Activity plans.
Monitoring of all the schedules.
Preparation of various periodic reports for MIS.
Maintaining of balance order position.
Maintaining sale and production report.
Sale/production budget.
Project review meeting and follow up.
Data entry for DP list and updating of all files.
Processing of all data and generation of reports.

C. Project planning:

D.

To ensure receipt of all drawings and documentation from design.

To issue the material purchase requirement.
To prepare the requirements of materials to be issued.
To coordinate the production technology for preparation of necessary production
documents for manufacture.
To prepare and issue job orders and prepare the follow up.
To suggest the alternate materials for use from available stock to design.
To compile standard material requirements for all products and projects.
To draw the standard items /equipments from stores for dispatch to costumer sites.
To prepare data for ICR (Income tax Cost and Revenue) for the survey by CBR
(Central Board of Revenue).

Material Management (MMG):C-1:- MMG Section:-

Material requirement planning.

Intending and follow up of indent.
To keep updated purchase status of all project documents.
Establish stock levels for general consumable items and raw materials.
Coding of store items.
Insurance of material to appropriate job.
To keep and maintain updated stock status of all store items.
To look after stores and related functions.
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C-2:- General Stores: To receive and issue all the materials and equipments in stores as per laid down
procedure.
Maintain detailed record of stock movement.
Maintain stock location system.
Ensure daily submission of issue and receipt statement to concerned department.
Ensure that all the storage areas (open/covered) are kept properly secured and organized.

E. Production Technology:D-1:- Feasibility/Quantitative Detail: Feasibility study and quantitative details of clients enquiries for cost estimates.

D-2:-Process Planning:Preparation of following documents.

Detail parts list.

Route card (machining and fabrication) if required.
Cutting plans.
Time sheets.

D-3:- Tool designing: Designing of all types of press tools, dies, templates, jigs and fixtures.
To produce drawings for machinery components for maintenance.
Cutting plans, cutting/marketing templates for shop.

F. Dispatch Cell/Material Handling:E-1:- Material handling: To keep all the material handling equipment operation worthy.
Provide material handling services to stores and dispatch cells and shops as and when
required.
Keep the open yard tidy and organized.
Receive materials from shops for surface preparation.
Arrange sand blasting/paint as per contractual requirement.
Receive raw materials from general stores for onward issuance to shops against job
orders.

E-2:- Dispatch Cell:To receive finish goods from shops/material handling sections.
To draw the standard items/equipments from stores for dispatch to costumer/sites.
To organize preservation/packing.
Maintain detailed dispatch records of finished goods, equipments, standard items against
each contract.
Organize transportation.
Ensure complete and accurate documentation along with each dispatch.
To prepare the dispatch plans and ensure compliance.

G. I.C.R (Income tax Cost and Revenue):Page 7 of 44

To defend in litigation/adjudication and contravention.

To organize industrial survey.
To obtain the consumption certificates and release of guarantee.
To obtain extension/coordination from CBR (Central Board of Revenue) and custom
collectrate.
To deal with matter pertaining to custom duty and sale tax.
To clear consignments for dry port and Islamabad airport.
To keep close contact with collectorates of custom, sales tax, Central Excise
Islamabad/Rawalpindi and Central Board of Revenue (CBR) for all matters to HMCs
imports.

To follow up for the settlement of all customs and sales tax matters with concerned agencies

Basic Machine Shop

In the development of every nation industries are very important and
for industries machinery is key factor. To check the development of any
industry check its machinery.
In the machine shop of Heavy mechanical Complex there are nearly 500
machines of different sizes and capacities. The machine shop of HMC
contains various types of machines.

Available machines:

Lathe machine (three jaws and four jaws chucks, turret).

Planer.
Milling machine.
Drilling machine.
HDL (heavy duty lathe).
BVT (boring vertical turret lathe machine).
Gear hobbing machine.
Gear shaper machine.
Straight bevel machine.
Horizontal lathe machine.
Radial drilling machine.
Slotting machine.
Page 8 of 44

Double housing planner.

Face plate machine.
Column drilling machine.

MACHINING OPERATIONS AND MACHINE TOOLS:

Turning and Related Operations

Drilling and Related Operations

Milling

Machining Centers and Turning Centers

Other Machining Operations

High Speed Machining

Machining

A material removal process in which a sharp cutting tool is used to mechanically cut
away material so that the desired part geometry remains

Most common application: to shape metal parts

Machining is the most versatile and accurate of all manufacturing processes in its
capability to produce a diversity of part geometries and geometric features (e.g. screw
threads, gear teeth, flat surfaces)

Classification of Machined Parts

1. Rotational - cylindrical or disk-like shape. Achieved by rotation motion of the workpart.
Ex. turning and boring
2. Nonrotational (also called prismatic) - block-like or plate-like. Achieved by linear motion
of the workpart. Ex. Milling, shaping, planing and sawing

Rotation
al

Non-Rotational

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Turning

A single point cutting tool removes material from a rotating workpiece to generate a
cylindrical shape

The tool is fed linearly in a direction parallel to the axis of rotation

Performed on a machine tool called a lathe

Variations of turning that are performed on a lathe:

Facing
Contour turning
Chamfering
Cutoff
Threading

Figure 1.2 - Turning operation

Facing
Page 10 of 44

Tool is fed radially inward to create a flat surface.

Chamfering
Cutting edge cuts an angle on the corner of the cylinder, forming a "chamfer".

Threading
Pointed form tool is fed linearly across surface of rotating work part parallel to axis of rotation at
a large feed rate, thus creating threads.

Page 11 of 44

Lathe Machines

Most lathe machines are horizontal but vertical lathe machines are also used for jobs with
large diameter relative to the length and for heavy work

The size of the lathe is designated by swing and maximum distance between centers

Swing is the maximum workpart diameter that can be rotated in the spindle

Maximum distance between centers indicate the maximum length of a workpiece that
can be mounted between headstock and tailstock centers

350 mm x 1.2 m lathe means a swing of 350 mm and maximum distance between centers
of 1.2 m

Page 12 of 44

Methods of Holding the Work in a Lathe

There are four common methods used to hold workparts in turning-to grasp the work, center and
support it in position along the spindle axis, and rotate it:

Holding the work

between centers

Chuck

Collet

Face plate

Holding the
Work Between
Centers

3 jaw self centered

Chuck

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Collet

Face Plate

Page 14 of 44

Boring

Boring is similar to turning. It uses a single-point tool against a rotating workpart

Difference between boring and turning:

Boring is performed on the inside diameter of an existing hole
Turning is performed on the outside diameter of an existing cylinder

In effect, boring is an internal turning operation

Machine tools used to perform boring operations are called boring machines

Boring machines
Horizontal or vertical - refers to the orientation of the axis of rotation of machine
spindle

Boring bar on tool

post

Boring bar between

centres

Page 15 of 44

Vertical Boring Mill

Figure - A vertical boring mill for large, heavy workparts

Usually the workpart diameter is greater than its length

Typical boring machine can position and feed several cutting tools

simultaneously

Drilling

Machining operation used to create a round hole in a workpart

Contrasts with boring which can only enlarge an existing hole

Cutting tool called a drill or drill bit-a rotating cylindrical tool which has two cutting
edges on its working end

Customarily performed on a drill press

Page 16 of 44

Radial Drill

Large drill press designed for large parts

Head can be positioned at significant distance from the column to accommodate large
work

Page 17 of 44

Milling

A machining operation in which work is fed past a rotating tool with multiple cutting
edges

Axis of tool rotation is perpendicular to feed direction

Creates a planar surface; other geometries possible either by cutter path or shape

Owing to the variety of shapes possible and its high production rates, milling is one of the
most versatile and widely used machining operations

Other factors and terms:

Milling is an interrupted cutting operation-the teeth of the milling cutter enter
and exit work during each revolution
Cutting tool called a milling cutter, cutting edges called "teeth"
Machine tool called a milling machine

Basic Types of Milling Operations

(a) Peripheral
milling

(b) Face milling

Page 18 of 44

Peripheral Milling vs. Face Milling

Peripheral milling or plain milling:

Cutter axis is parallel to surface being machined
Cutting edges on outside periphery of cutter

Face milling
Cutter axis is perpendicular to surface being milled
Cutting edges on both the end and outside periphery of the cutter

Types of Milling

Peripheral Milling
Slab milling
Slotting
Side milling
Straddle milling

Face milling
Conventional face milling
Partial face milling
End milling
Profile milling
Pocket milling
Surface contouring

Milling Machines

Milling machines must provide a rotating spindle for the cutter and a table for fastening,
positioning and feeding the workpart
Page 19 of 44

Types:
Knee-and-column milling machine

Universal milling machine

Ram mill

Bed type milling machine

Planer type
Tracer mills
Tracer mills
CNC milling machines

Horizontal knee-and-column
milling machine Suitable for
peripheral milling

Page 20 of 44

Page 21 of 44

Vertical knee-and-column milling machine

Suitable for face milling

Ram type knee-and-column machine; ram can

be adjusted in and out, and toolhead can be swiveled

Universal milling machine

Page 22 of 44

Simplex bed-type milling machine: rigid construction for mass production

Hobbing
Hobbing is a machining process for making gears, splines, and sprockets on a hobbing machine,
which is a special type of milling machine. The teeth or splines are progressively cut into the
workpiece by a series of cuts made by a cutting tool called a hob. Compared to other gear
forming processes it is relatively inexpensive but still quite accurate, thus it is used for a broad
range of parts and quantities
It is the most widely used gear cutting process for creating spur and helical gears and more gears
are cut by hobbing than any other process since it is relatively quick and inexpensive.

Page 23 of 44

Heat treatment Shop

Heat treatment is a method used to alter the physical and sometimes
chemical properties of a material. The most common application is
metallurgical. Heat treatments are also used in the manufacture of many
other materials, such as glass. Heat treatment involves the use of heating or
chilling, normally to extreme temperatures, to achieve a desired result such
as hardening or softening of a material.. It is noteworthy that while the term
heat treatment applies only to processes where the heating and cooling are
done for the specific purpose of altering properties intentionally, heating and
cooling often occur incidentally during other manufacturing processes such
as hot forming or welding.
Page 24 of 44

Heat treatment techniques include

Annealing.

Hardening

Tempering

Normalizing

Full hardening

Surface hardening

Cause hardening

Stress releasing

Carburizing

Phosphating (phosphate coating is used to protect the surface from

corrosion)

HMC has following Types of Furnace and facilities which are use in heat
treatment section

HTS-1 Electric carbon furnace

Electric box type furnace

Flame hardening machine for surface hardening

Chamber type Cleaner

Electric tempering oil bath

High temperature salt bath

Low temperature salt bath

Medium temperature salt bath

High frequency induction heat treatment lab

Heat treatment of metals and alloys

Page 25 of 44

Metallic materials consist of a microstructure of small crystals called "grains"

or crystallites. The nature of the grains (i.e. grain size and composition) is
one of the most effective factors that can determine the overall mechanical
behavior of the metal. Heat
Treatment provides an efficient way to manipulate the properties of the
metal by controlling rate of diffusion, and the rate of cooling within the
microstructure.
Annealing
Annealing is a technique used to recover cold work and relax stresses within
a metal. Annealing typically results in a soft, ductile metal. When an
annealed part is allowed to cool in the furnace, it is called a "full anneal" heat
treatment. During annealing, small grains recrystalliz to form larger grains.
Normalizing
When an annealed part is removed from the furnace and allowed to cool in
air, it is called a "normalizing" heat treatment. Normalizing: Carbon steel is
heated to approximately 55 C above Ac3 or Acm for 1 hour; this assures the
steel completely transforms to austenite. The steel is then air-cooled, which
is a cooling rate of approximately 38 C (100 F) per minute. This results in a
fine pearlitic structure, and a more-uniform structure. Normalized steel has a
higher strength than annealed steel; it has a relatively high strength and
ductility .Typical annealing processes include, "normalizing", "stress relief"
annealing to recover cold work, and full annealing.
Hardening and tempering (quenching and tempering)
To harden by quenching, a metal (usually steel or cast iron) must be heated
into the austenitic crystal phase and then quickly cooled. Depending on the
alloy and other considerations (such as concern for maximum hardness vs.
cracking and distortion), cooling may be done with forced air or other gas
(such as nitrogen), oil, polymer dissolved in water, or brine. The quenched
hardness of a metal depends upon its chemical composition and quenching
method. Cooling speeds, from fastest to slowest, go from polymer (silicon),
brine, fresh water, oil, and forced air.
Tempering is a heat treatment technique for metals, alloys and glass. In
steels, tempering is done to "toughen" the metal by transforming brittle
martensite into bainite or a combination of ferrite and cementite.
Page 26 of 44

Untempered martensite, while very hard and strong, is too brittle to be

useful for most applications. A method for alleviating this problem is called
tempering. Most applications require that quenched parts be tempered (heat
treated at a low temperature, often three hundred degree Fahrenheit or one
hundred fifty degrees Celsius) to impart some toughness. Higher tempering
temperatures (may be up to thirteen hundred degrees Fahrenheit or seven
hundred degrees Celsius, depending on alloy and application) are sometimes
used to impart further ductility, although some yield strength is lost.
Precipitation hardening
Some metals are classified as precipitation hardening metals. When a
precipitation hardening alloy is quenched, its alloying elements will be
trapped in solution, resulting in a soft metal. Aging a "solutionized" metal will
allow the alloying elements to diffuse through the microstructure and form
intermetallic particles. These intermetallic particles will nucleate and fall out
of solution and act as a reinforcing phase, thereby increasing the strength of
the alloy. Alloys may age "naturally" meaning that the precipitates form at
room temperature, or they may age "artificially" when precipitates only form
at elevated temperatures. In some applications, naturally aging alloys may
be stored in a freezer to prevent hardening until after further operations assembly of rivets, for example, may be easier with a softer part.
Induction heating
Induction heating is the process of heating an electrically conducting object
(usually a metal) by electromagnetic induction, where eddy currents are
generated within the metal and resistance leads
to
Joule heating of the metal. An induction heater
(for any process) consists of an electromagnet,
through which a high-frequency alternating
current (AC) is passed. Heat may also be
generated by magnetic hysteresis losses in
materials that have significant relative
permeability. The frequency of AC used depends
on
the object size, material type, coupling (between
the work coil and the object to be heated) and the penetration depth.
Induction heating allows the targeted heating of an applicable item for
applications including surface hardening, melting, brazing and soldering and
heating to fit. Iron and its alloys respond best to induction heating, due to
their ferromagnetic nature. Eddy currents can, however, be generated in any
Page 27 of 44

conductor, and magnetic hysteresis can occur in any magnetic material.

Induction heating has been used to heat liquid conductors (such as molten
metals) and also gaseous conductors (such as gas plasma). Induction
heating is often used to heat graphite crucibles (containing other materials)
and is used extensively in the semiconductor industry for the heating of
silicon and other semiconductors
Induction furnace
An induction furnace uses induction to heat metal to its melting point. Once
molten, the high-frequency magnetic field
can also be used to stir the hot metal,
which is useful in ensuring that alloying
additions are fully mixed into the melt.
Most induction furnaces consist of a tube
of water-cooled copper rings surrounding
a container of refractory material. Induction furnaces are used in most
modern foundries as a cleaner method of melting metals than a
reverberatory. Metals melted include iron and steel, copper, aluminum, and
precious metals. Because it is a clean and non-contact process it can be used
in a vacuum or inert atmosphere. Vacuum furnaces make use of induction
heating for the production of specialty steels and other alloys that would
oxidize if heated in the presence of air.

FABRICATION SHOP

Page 28 of 44

Customer
Fabrication shop
and marketing

Material issue to fab shop

Check the work

Design deppt

Fabrication CTC

Job planning for fab shop

PPC

Deliver to dispatch cell

HMC fabrication shop has full capacity to fabricate every part which is used
in boiler, gas tanks, teem boiler, roar roller parts etc; HMC has following
machine in fabrication shop.

Parallel cutting machine.

Trennjaeger circular saw.

CNC cutting Machine

Angle cutting machine

Boom Column sub march welding machine

Photo cell cutting machine

Semi automated machine

Page 29 of 44

Non ferrous steel cutting machine

Circular saw small size and large size.

Straight rolling machine

Rerolling machine

Plasma cutting machine

100ton press machine

160ton brack press machine

3000ton press machine

Membrane water wall welding machine etc

Fabrication is the process of forming, casting, machining and welding of

metals.
Fabrication, when used as an industrial term, applies to the building of
machine, structures and other equipment, by cutting, shaping and
assembling components made from raw materials. Small businesses that
specialize in metal are called fabrication shop. Steel fabrication shops and
machine shops have overlapping capabilities, but fabrication shops generally
concentrate on the metal preparation, welding and assembly aspect while
the machine shop is more concerned with the machining of parts.
Metal fabrication
Metal fabrication is a value added process that involves the construction of
machines and structures from various raw materials. A fabrication shop will
bid on a job, usually based on the engineering drawings.
Raw materials
Standard raw materials used by metal fabricators are

plate metal
welding wire
Page 30 of 44

co gas

argon gas

Cutting torches

silica etc

The raw material has to be cut to size. This is done with a variety of tools.
Cutting
The raw material has to be cut to size. This is done with a variety of tools.
The most common way to cut material is by Shearing (metalworking);
Special band saws designed for cutting metal have hardened blades and a
feed mechanism for even cutting. Abrasive cut-off saws, also known as chop
saws, are similar to miter saws but with a steel cutting abrasive disk. Cutting
torches can cut very large sections of steel with little effort.
Forming
Hydraulic brake presses with v-dies are the most common method of forming
metal. The cut plate is placed in the press and a v-shaped die is pressed a
predetermined distance to bend the plate to the desired angle. Tube bending
machines have specially shaped dies and mandrels to bend tubular sections
without kinking them. Rolling machines are used to form plate steel into a
round section.
Machining
Fabrication shops will generally have a limited machining capability
including; metal lathes, mills, magnetic based drills along with other portable
metal working tools.
Welding
Welding is the main focus of steel fabrication. The formed and machined
parts will be assembled and tack welded into place then re-checked for
accuracy. A fixture may be

Page 31 of 44

Used to locate parts for welding if multiple weldments have been ordered.
The welder then completes welding per the engineering drawings, if welding
is detailed or per his own judgment if no welding details are provided.
Special precautions may be needed to prevent warping of the weldments
due to heat. These may include re-designing the weldments to use less weld,
welding in a staggered fashion, using a stout fixture, covering the weldments
in sand during cooling, and straightening operations after welding.
Straightening of warped steel weldments is done with an Oxy-acetylene
torch and is somewhat of an art. Heat is selectively applied to the steel in a
slow, linear sweep. The steel will have a net contraction, upon cooling, in the
direction of the sweep. A highly skilled welder can remove significant war
page using this technique.
Final assembly
After the weldments have cooled it is generally sand blasted, primed and
painted. Any additional manufacturing specified by the customer is then
completed. The finished product is then inspected and shipped.
TYPE OF WELDINGS

Stick welding

Tig welding

Mig welding etc

Shielded Metal Arc Welding (SMAW) is

frequently referred to as stick or covered
electrode welding. Stick welding is among
the most widely used welding processes.
The flux covering the electrode melts during
welding. This forms the gas and slag to
shield the arc and molten weld pool. The
slag must be chipped off the weld bead after
welding. The flux also provides a method of
adding scavengers, deoxidizers, and alloying elements to the weld metal.
Page 32 of 44

Tungsten inert gas (TIG) welding,

Gas tungsten arc welding (GTAW), also known as tungsten inert gas
(TIG) welding, is an arc welding process that uses a no consumable
tungsten electrode to produce the weld. The weld area is protected from
atmospheric contamination by a shielding gas (usually an inert gas such as
argon), and a filler metal is normally used, though some welds, known as
autogenously welds, do not require it. A constant-current welding power
supply produces energy which is conducted across the arc through a column
of highly ionized gas and metal vapors known as a plasma .GTAW is most

Commonly used to weld thin sections of stainless steel and light metals such
as aluminum, magnesium, and copper alloys. The process grants the
operator greater control over the weld than competing procedures such as
shielded metal arc welding and gas metal arc welding, allowing for stronger,
higher quality welds. However, GTAW is comparatively more complex and
difficult to master, and furthermore, it is significantly slower than most other
welding techniques. A related process, plasma arc welding, uses a slightly
different welding torch to create a more focused welding arc and as a result
is often automated.
BOILER FABRICATION
In the energy sector HMC has supplied over 30,000 tons of fabricated
equipment and parts to different power plants. Major strength is HMC's
capabilities for manufacturing utility boilers pressure parts. For this purpose
some of the major machines are:

3 roller bending machines for making drums

Booster pipe bending machine for making super heater

Reheated and economizer coils

Specialized machine for machining and welding of headers and

complete train of machines for manufacture of membrane walls in
panel and bent form

HMC has the capability to manufacture following type of boilers:

Page 33 of 44

Natural circulation steam generators

Heat recovery steam generators

Fluidized bed combustion boilers

Besides Boiler Island, HMC have also capabilities and expertise for
manufacture of balance of plant equipment / parts such as:

Condensers

L.P. heater

H.P. heater parts

Water treatment plant

Deaerator and feed water tank

Pressure vessels

Oil storage tanks

Cooling water system

Heat exchangers

Steel structure

Elevator hoist and cranes

Piping

Other misc. items

With a team of well experienced engineers and technicians, HMC is well

prepared to carry out all site construction work which includes:

Site fabrication

Erection / installation and commissioning

Civil works (if part of complete construction work, package)

Page 34 of 44

HMC is also providing services for repair / maintenance and BMR of existing
power plant for its boilers, turbines, condensers, heaters and other
equipment.
BOILER COMPONENTS Super Heaters One of the most important
accessories of a boiler is a superheated. It affects improvement
and economy in the following ways.

The superheated increases the capacity of the plant.

Eliminates corrosion of the steam turbine.

Reduces steam consumption of the steam turbine.

ECONOMISERS
This is feed-water heaters in which the heat from waste
gases is recovered to raise the temperature of feed-water
supplied to the boiler. They offer the following advantages:

Fuel economy

Longer life of the boiler

Increase in steaming capacity

Finned Tube Economizers

C.I. Gilled Tube Economizers

Plain Tube Coil Economizers

Steam Generating Tubes

These are tubes in the Boiler where water is evaporated to
steam and are also called Steam Generating Tubes. These
Tubes also form the Walls of the Boiler and are hence called
Water Walls or Water Wall Panels. These Tubes have very
complicated shapes to allow Inspection openings and
burner throats and fabrication require bending Machines.

Page 35 of 44

Boiler Fabrication Techniques. HMC has 3.5 meter rolling capacity. And it
can manufacture 2 ton to 80 ton boiler.
Material purchase

Radiography

Re rolling

Stress releasing
Hydraulic testing

Third party verify material

Welding
Marking & cutting layout

Third party test

Third party verify material

Pre bending
Rolling

LW fit up

NON DESTRUCTIVEVE
TESTING(NDT)
IT INCLUDE DIFFERENT OPEREATIONS
INDICATION
INTERPRETATION
FALSE
RELEVENT
NON RELEVENT
EVALUATION
ACCEPT
REJECT
NON DESTRUCTIVE EVALUATION FACILITIES:
1- X-ray radiography
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2- Gamma rays radiography

3- Ultrasonic
4- Magnetic particle inspection
5- Liquid penetrant method
6- Eddy current spectroscopy
RADIOGRAPHY TESTING METHOD:
Radiography testing is most universally used NDT method for the detection
of gas porosity in weldments. The radiographic image of a round porosity will
appear as oval shaped spots with smooth edges, while elongated porosity
will appear as oval shaped spots with the major axis sometimes several
times longer than the minor axis. Foreign material such as loose scale flux or
splatter will affect validity of test results.
ULTSONIC TESTING:
Ultrasonic testing equipment is highly sensitive, capable of detecting
micro separations.
Surface finish and grain size will affect the validity of test results.

EDDY CURRENT TESTING METHOD:

Normally confined to thin wall welded pipe and tube

Penetration restricts testing to a depth of more than one quarter inch

LIQUID PENETRANT TESTING METHOD:

Normally confined to in process control of ferrous and non ferrous

welds

Liquid penetrant testing like magnetic particle is restricted to surface

evaluation

Extreme caution must be exercised to prevent any cleaning material

and liquid penetrant materials from becoming entrapped and
contaminating the rewelding operation

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MAGNETIC PARTICLE TESTING METHOD:

Not normally used to detect gas porosity. Only surface porosity would be
evident. Near surface porosity would not be clearly defined since indications
are neither strong nor pronounced.

MATERIAL TESTING LAB

There are three sections of the lab;
1- Chemical section
2- Metallographic
3- Mechanical
CHEMICAL SECTION:
The chemical section lies in the steel foundry. So, it mainly concerns with the
determination of the chemical composition of steel. However, samples from
cast iron foundry are also brought here to determine the chemical
composition.
EMISSION SPECTROMETER:
In emission spectrometer, a 2*2 sample is used. Arc is produced by using a
tungsten electrode. Argon gas is used for shielding. The atoms got excited.
When they return to their ground state, they emit radiations. Each element
emits radiations of some specific wavelength. So, from the wavelength
element and its percentage can be calculated.
WET ANALYSIS:
The chemical composition can also be determined by wet analysis. Different
chemicals are used in different proportions. The color achieved at the end is
a measure of element and its percentage.
Other facilities include;
1. Spectrophotometer

2. Carbon apparatus

MECHANICAL SECTION
HMC has a capability to test for metal mechanical properties like hardness,
strength, shearing, crushing, impact bend test etc.
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HMC mechanical testing lab has following facilities

FACILITIES:
30 ton universal testing machine (UTM)

60 ton UTM

10 ton UTM
100 ton UTM
Charpy impact testing machine
Brinell hardness tester 2 pieces
Rockwell hardness tester 2 pieces
Vicker hardness tester TESTS:
Tensile

Bend

Shear
Compression/crushing

METALLOGRAPHY:
Here, the macrostructure and microstructure is determined. A number of
microscopes are placed here in lab having different
magnifications such as;
100 X
450 X
1000 X

2000 X

A hardness tester with 450 X

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PATTERN SHOP
The purpose of pattern shop is to make wooden or metallic
components for casting process.
TYPES OF PATTERN: One piece or solid pattern
Two piece or split pattern
Three piece pattern
Loose piece pattern.
Self core pattern.
Sweep pattern.
Skeleton pattern.
Match plate pattern.
Connecting pattern.
Master pattern
TYPES OF CORE PRINTS: Top print.
Bottom print.
Side print.
Tail print.
Hang print.
Balancing print.
TYPES OF CORE BOX : Box type core box.
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 Shake out type core box.

Gang type core box
MACHINES IN PATTERN SHOP: Band saw.
Joint planner.
Thickness planner.
Disc and spindle sander.
Wooden lathe machine.
Wooden milling machine.

Forging Shop
In HMC there are two forging shop that differs in capacity and type of job.
They are also facilitated with heat treatment processes.

Forging shop I:
In this shop die forging is done.

Die forging:
In this type of forging method specific dies are used to produce the specific job
for this allowance is very low.
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Requirements:
For die forging we need:

Furnace
Hammers
In HMC forging shop 1 has following facilities:
150kg hammering machine
300kg hammering machine
750kg hammering machine
800 ton hydraulic press with 3 ton manipulator
25 to counter blow
Trimming press
Crew presser
63 ton power press
400 ton press
1250 ton press
Swelling crane of 1 ton capacity

Forging shop II
In this shop free forging is done. Free forging is method of producing jobs without using
dies. In free forging large allowance is present.
HMC have following facilities in this shop:
1 ton hammer
2 ton hammer
3 ton hammer

Forge:
It is the ability of the material to undergo deformation under compression without rapture.
Any material or alloy which can be brought to plastic stage through heating can be forged the
extent to which the material can be forged is governed by its compositions as well as
temperature of the forging. Selection of the forging material depend upon certain mechanical
prosperities inherent in the material like strength, malleability, resistance to fatigue ,
durability, shock or bending machinability . Some forgeable materials are listed below:
Pure aluminum
Pure magnesium
Pure copper
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Aluminum alloys
Magnesium alloys
Copper alloys
Carbon and low alloy steels
Stainless steel
Nickel alloys

INSPECTION
QUALITY INSPECTION
It is one of the most responsible and sensible department of the complex. If
some part fails outside in the field, it is not the mistake of the production
department but of quality inspector who passed it. So, the repute of any
industry depends to a great extent on this department. This department
checks each and every material which comes in or goes out of the factory,
i.e. from the raw material to the final product. There is at least one quality
inspector always present in a shop for the stage inspection and the final
inspection. If something exceeds the tolerance, they have the right to reject
it. They have different tools with them for the measurements. Some of them
are;
Inside micrometer
Outside micrometer

Mercer gage

Vernier caliper

Bevel protector etc.

Recommendations
We would like to give some recommendations to improve the quality of work and save time
along the health of the workers because during our visit we observed that the workers are not
playing with their own lives which are a great loss of man power. To eradicate it we recommend
following things:

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Safety should be made necessary for each and every one especially for the fabrication shop
Their should be check and balance of these safety steps
Trained labor must have junior or fresh labor because in the future they can take their seats.
Environment should be made clean and healthy by planting plants and keeping the surface clean
To increase the rate of work the repeated jobs should be given to that person who had worked on it
but this should be made necessary for that person that he will convey his knowledge to his subordinates.

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