REPORT ON

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.

It is pleasure to face the industrial life that helped me to convert my

theoretical concepts into practical knowledge.
 ACKNOWLEDGEMENT

I have undergone training at DEE PIPING SYSTEMS, PRITHLA

(PALWAL).During this training I have learnt a lot for which I pay my
heartiest gratitude to all the staff members of the company who helped
me in all respects in fulfilling my cherished desired of getting a successful
industrial training in an esteemed organization.

I am very grateful to Mr. BK PANDEY (GROUP HR-HEAD) and Mr. Vivek

(Sr. Executive –HR) who deputed me with senior engineers and provided
me sound knowledge of various process details .I pay my sincere thanks
to all the supervisors and the other official at the site for providing me
complete details of their respective plants.
 ABOUT THE COMPANY
It was founded by MR. K.L. BANSAL along with a team of two technocrats
in the year 1983. DEE PIPING SYSTEMS has made a name for itself in the
list of top suppliers of pipe spool and pipe fittings production in India.
The suppliers company is located in Palwal Haryana & is one of the
leading sellers of listed products. Dee piping systems is listed in Trade
India’s list of verified sellers offering supreme quality of pre fabricated
piping etc.
DEE manufacturing range includes variety of high pressure piping
systems, induction pipe bends, pressure vessels, accessories like boilers,
super heater tubes, economizer coils etc.
DEE has also installed two BIO MASS BASED POWER PLANTS Of 7.5 MW
& 8 MW both in the state of Punjab. It is ISO, OHSAS certified company.
It’s quality standards are based on ASME. DEE primarily caters to the
National & Multinational OEMS of power generation equipment,
Engineering, petroleum sectors, oil & gas, Marine & offshore and various
other process industries
TOTAL FACILITY AREA ~ 135,000 Sq.m.
COVERED AREA ~ 50000 Sq.m.
STORAGE AREA ~ 43500 Sq.m.
PARKING AREA ~ 7080 Sq.m.
  TRAINING SCHEDULE
It’s a 6 days industrial training in a weak (MONDAY-SATURDAY) .The
timing for training students is 9am -6 pm. Firstly we had taught
about the specific manufacturing process and working of machines
by our incharge training officer. Later on we are sent on various
workshops to observe the process and to learn about in detail so
that we can apply our theoretical knowledge to practical working.
Under the guidance of training officer we had perform some of
piping processes for better understanding.
 WORK DONE/OBSERVATIONS
I had performed GTAW, GMAW welding process, used EOT cranes, used
DFT GAUGE Meter to check the paint thickness, In my industrial I had
observed
and learned the induction bending process, cold bending process for
elbow formation and bending of pipes. I had also observed and learned
FCAW, SAW, SMAW WELDING, ROBOTIC MIG WELDING, AWL(AUTO
WELD LINE). I had studied about SHOT BLASTING PROCESS, various
NDT METHODS for welding inspection of pipes .They are as follows VT-
PT-MPT-UT-RT.
  LEARNING AFTER TRAINING

Various processes I had learned during my industrial training;

PIPING PROCESS ,Its COMPONENT,TYPES OF PIPES

PIPING: Assembly of piping components to convey, distribute,

mix, separate, discharge, control, start or stop fluid flow is
known piping
PIPING COMPONENTS: Mechanical elements suitable for
joining or assembly into pressure – tight fluid containing piping
systems {1.pipe
2.tubing 3.fittings
4.flanges 5.gaskets
6.bolting 7.valves 8.
Expansion joints
9.stream traps
10.separators}
TYPES OF PIPES:
Seamless Straight saw Single seam

SAW Double seam

Pipe Helical saw

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’’ .

ADVANTAGES OF INDUCTION BENDING :

 It reduces the no of welds
 They are stronger than the elbows with uniform wall
thickness
 It is fast and clean process as compared to welding joints
 They do not require heat treatment
 Accurate temperature control.
 INSPECTION PROCESS
In this process first step is raw material inspection at the receiving site .
In DEE PIPING SYSTEMS there are several colour codes on alloy material
pipes i.e. P91-GREEN, P11-YELLOW, P12-RED/YELLOW, P92-
BROWN/YELLOW. Punching is also done on pipes to identify the type of
material.PMI test is another method to find the material grade.
Then pipes are send for fitting according to requirements of client then
again inspection is done again by the production engineer. After that
welding is performed then it is checked by the welding engineer by
virtual testing, later on NDT tests are performed on the prepared spools
Paint is applied on the prepared spools then it is checked by the painting
inspector .final inspection is done by quality engineers, whether the
spool
prepared
are upto
the mark or
not , its
final
dimension
is also
checked by
them
 CUTTING PROCESS
For this purpose DEE PIPING SYSTEMS has centralized cutting station .
pipes with any kind of material or thickness are cut down here according
to the job requirement .Mainly cutting process is done by plasma arc
cutting. This method can cut any kind of material but this is specially used
to cut hard metals like stainless steels or p91. Other machines are also
there to perform cutting action i.e. cutting grinder generally used to cut
thin carbon pipes , band saw cutting machines is there to cut small
dimensions of any kind of material specially used in cnc shop for making
of pipe fittings. Gas cutting is itself performed on welding station or
fitting station if there is any change in pipe dimension, gases used in this
process are mostly LPG & OXYGEN.

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.

SAW {SUBMERGED ARC WELDING};

The welding is shielded by thick layer of granular flux fed into weld that
cover the weldzone. The granular flux is composite of silica,manganese
oxide, lime & calcium fluoride. Its flux is introduce to weld joints slightly
ahead of arc by gravity from hopper. This process requires a continuous
fed consumable electrode,&
electrode wire is automatically fed
from coil to arc . This welding
provides high welding productivity
& better strength. It is mostly used
to weld hard and very thick metals.
 ROBOTIC WELDING(MIG)
& AWL (AUTO WELD
LINE);

ROBOTIC WELDING is one of the most

common robotic applications in the
manufacturing industries. In DEE
PIPING SYSTEMS, FANUC robot is used for doing welding ,it uses two
welding system ,LINCOLN (USA) & MIGRATRONIC (DENMARK).Lincon
system is used to do mig welding mostly but migratronic robotic system
is used to do mig welding as well as plasma arc welding. SERVOMETERS
are used in this robotic welding which is much better than any kind of
robotic welding, basically it has 3 wires +ve, -ve & command wire .AXIS
OF MOTION is generally measured by ‘’degree of freedom’’ which refers
to the no of axis a robot arm is able to transverse. It has 6 axis ; x,y,z &
their negatives each axial motion is powered by servometers.
LINCOLN robotic system welding limit is 6’’-42’’ & MIGRATRONIC robotic
system welding limit is 4’’-24’’. Robotic welding system has 3 motion
system i.e. LINEAR , CIRCULAR &
JOINT MOTION.
AUTO WELD LINE;
This welding machine is highly
dynamic , automatic . With this
machine we can easily perform TIG,
MIG, FCAW, SAW welding process.
generally it is used to weld thin pipes irrespective of the nature of the
material. All types of materials can easily welded with the help of thus
awl welding machines. Their productivity rate is quite high and no of
defects in the welding joint are so less as compared to manual welding.
 BLASTING PROCESS
This process is used to create profile on material surface (inner & outer
both),which helps to hold the paint on the required spools as per the
need of the client. This process cleans the materials so well. In DEE
PIPING SYSTEMS shot blasting is generally performed which is of two
types i.e. AIR BLASTING & AIRLESS BLASTING (WHEEL BLASTING).
 Air abrasive blast cleaning uses an air compressors energy to deliver
an air/media mixture at certain speeds & volumes to impact the
surface or part being processed . A pressure regulator is used to
control the air speed of the compressor. Its main components are;
air compressor, blast pot, blast nozzle, dead man’s switch, blast
hood & interconnect hoses.
 Wheel blasting is an air airless blasting operation that uses a wheel
with centrifugal force to propel the abrasive against the parts.
Because of its wheel speed 3600 RPM it has high velocity, high
efficiency blasting operation, with typically quick time cycles.
The advantage of wheel blasting over air blasting is its speed of
cleaning, the ability to efficiently blast large components. Also it
does not require compressed air to operate like air blast equipment.
They are less expensive & also prevents from corrosion.
 DRY FIM THICNESS (DFT) GAUGE
OR
COATING THICNESS GAUGE
A coating thickness gauge ( also referred to as a paint meter ) is used to
measure dry film thickness . Dry film thickness is probably the most
critical measurements in the coating industry , because of its impact on
the coating process , quality & cost.
How to measure dry film thickness ;
DFT can be measured using two methods
Destructive thickness measurement
where the coating is cut ,to the substrate
using a cutter & Non destructive coating
thickness measurement , using techniques measurement which do not
damage the coating or substrate
The paint inspection gauge commonly known as PIG , is a popular
method for determining dry film thickness on non metallic substrate.
How does a coating thickness gauge work ;
DFT can be measured on either magnetic steel surface or non-magnetic
metal surface such as stainless steel or aluminium using a digital coating
thickness gauge .
The principle of electromagnetic induction Is used for non-magnetic
coating on magnetic substrate such as steel.
The eddy current principle is used for non-conductive coatings on non
ferrous metals substrate.
 NDT (NON-DESTRUCTIVE TESTING)
FOR WELDING INSPECTION ;
Nondestructive testing (NDT) or Nondestructive evaluation (NDE) refers
to techniques, which are used to detect, locate and asses defects or flaws
in materials or structures .
Various methods used in DEE PIPING SYSTEM are ;
VT PT MPT UT RT ;

VISUAL TESTING (VT); It is the oldest & most common NDT

techniques. This is typically the
first step in the examination
process to inspect. The inspection
process may be done using such
behaviours as looking, listening,
feeling, smelling etc.
PT ( LIQUID PENETRANT
TEST); The technique is based on the ability of a liquid to be
drawn into a clean surface discontinuity by capillary action. After a
period of me called the ‘’dwell me’’ excess surface penetrant is
removed & developer is applied. This act as a blower that draws the
penetrant from the discontinuity to reveal its presence. It can
inspect almost any material provided that its
surface is not extremely rough or porous.
  MPT ( MAGNETIC PARTICLE TESTING);
1) In this process , an electromagnet yoke is placed on the surface of
the part is to be examined & magnetic flux is induced.
2) If there is flaw on the surface, magnetic flux leaks into the air at the
position of the flaw.
3) Then magnetic particles (dyed or fluorescent) are applied to the
surface.
4) These magnetic particles will migrate to the flaw where the
magnetic flux leaks & forms a flaw indication.
5) The inspector visually identify the flow.

PROCEDURE ; precleaning > magnetization > applying magnetic

particles > observation > post cleaning.

UT ( ULTRASONIC TESTING ) ;

It uses a high frequency sound energy to conduct examination and make
measurements. It can be used for flaw detection, dimensional
measurements, material characterization & more. A typical UT inspection
system consists of several functional units, such as pulse receiver,
transducer & display device. The sound energy is introduced and
propagates through the materials in the form of waves and reflected.
from the opposite surface. An
internal defect such as cracks
or void interrupts the waves’s
propogation and reflects
back a portion of the
ultrasonic wave. The
amplitude of the energy and
the time required for return
indicate the presence and location of any flaws in the work piece.

 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

 BRINELL HARDNESS TEST;

Indentation tool material > Hardened steel
Shape of indentor tool > spherical dia =10mm
Applicable for materials > mild steel, aluminium, low carbon steel, copper
Principle of this test is based on area of penetration

 ROCKWELL HARDNESS TEST;

Indentation tool material > diamond
Shape of indentor tool > conical shape
Applicable for materials > all types of materials except hard materials like
stainless steel
Principle of this test is based on depth of penetration.
  VICKER’S HARDNESS TEST;

Indentation tool material > diamond

Shape of the indentation tool > pyramid with square base & an angle of
136o between opposite faces
Applicable for materials > high carbon steel, tungsten carbide & silicon
carbide
Principle of this test is based on the diagonals of indentation left on
surface.