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A REPORT ON

INDUSTRIAL INPLANT TRAINING AT

THERMAX LIMITED, CHINCHWAD, PUNE-411 019 FROM 1ST JANUARY 2006 TO 30TH JUNE 2006

SUBMITTED BY

ANAND DHARIYA B.E. MECHANICAL (SANDWICH) ROLL NO. 4212 EXAM SEAT NO. B2211212

UNDER THE GUIDANCE OF

PROF. P.V. DESHMUKH

DEPARTMENT OF MECHANICAL ENGINEERING, ALL INDIA SHRI SHIVAJI MEMORIAL SOCIETY’S, COLLEGE OF ENGINEERING, PUNE-411 001 2005-2006

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ABSTRACT

The following report gives a detailed and comprehensive insight into the work done i.e. the various projects and assignments completed during the course of 6 months ‘Industrial Inplant Training’ while working in the Manufacturing Department, Machine shop at Plant 11 of the Cooling & Heating Division of Thermax Ltd. Chinchwad, Pune from 1st January to 30th June 2006.

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TABLE OF CONTENTS SECTION TITLE

NO.

PAGE NO.

ACKNOWLEDGEMENT

1

2

3

INTRODUCTION TO ‘THERMAX LIMITED’

01 – 21

1. History of Thermax ltd.

01

2. Divisional Profile

05

3. Group Companies

15

4. Plant profile

16

TUBE-PLATE STAND

22 – 29

1. Objective and Need

22

2. Chiller tube plates

24

3. Design of Stand

26

4. Salient features

27

5. Benefits

28

6. Savings

28

7. Future Prospects

28

8. Conclusion

29

TPM STEP 3 OF CNC ARBOGA-3 CO-ORDINATE

30 – 68

DRILLING MACHINE 1. Introduction to TPM

30

2. AM Step 1

37

3. AM Step 2

50

4. AM Step 3

59

5. Savings

66

6. List of other TPM undertaken

68

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DESIGN OF TEMPLATE BOARD FOR ROUNDO

69 – 74

ROLLING MACHINE 1. Objective & Need

69

2. Preparation of Drawings of templates

70

3. Design of Shadow Board

72

4. Benefits of Shadow Board

73

5. Cost saving

74

6. Conclusion

74

CONCLUSION

75

REFERENCES

76

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ACKNOWLEDGEMENT Even after completing the first phase of sandwich training at Thermax, it was a great pleasure to undergo my second phase of training with the company. It is very difficult to express in a few words the gratitude towards people so near to the heart. Yet, I consider myself privileged in doing so. What can I say, but a big ‘THANK YOU’ to THERMAX LTD., to which I shall always remain indebted for the faith it has placed in me by letting me once again be a member of this great family, and allowing me to pursue and complete my second phase of Industrial in-plant training of Mechanical Engineering (sandwich) course at their Chinchwad plant.

I would also like to thank Mr. Ashok Sakpal for keeping trust in me and granting me the opportunity to work in this great organization. Thanks are also due to my company guide Mr. Ravi Inamdar and his colleagues Mr. Vinod Patil and Mr. Sachin Bhakade from Plant 11 Machine shop who also doubled up as friends, guided me throughout the course of my training with great affection and patiently answered all my questions. Mr. Mahendra Kadam deserves special thanks for making the drawings on Auto CAD and helping in other drafting work due to which all our designs could be materialized. All my efforts reached fruition, thanks to the employees of ACD who always extended a helping hand.

My sincere thanks to Prof. Chaitanya, Head of Mechanical Engineering Department, for making it possible for me to undergo training and Prof. P.V. Deshmukh, college guide, for his keen observation on my progress. Lastly, I would also like to thank all my trainee colleagues who always stood by me as brothers, and for developing a strong friendship.

Anand Dhariya. 28th June 2006.

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INTRODUCTION TO THERMAX

 INTRODUCTION TO THERMAX: 1. History of Thermax: In the beginning there was fire. Then there was steam. Steam produced mechanical movement. It could be used to produce electricity too. The use of steam rewrote the history of human civilization. It was the driving force of industrial revolution, the precursor of modern age, as we understand it. Even in this age of cybernetics, genetic engineering and information superhighways, boilers that produce steam are critical on-line equipment, across diverse industry segments – be it a small scale unit which needs a 600 kg/hr, or a fertilizer plant, which needs a 300 tones/hr high pressure steam generator. THERMAX means maximum utility of thermal energy, name itself specifies the accuracy and efficiency of this fast growing organization. At present, a Pune based engineering company ‘Thermax’ LTD was started in the year 1966, as a small boiler-manufacturing unit in Dadar (Mumbai). It was named initially as WANSON (INDIA) PVT. LTD as had technical collaboration with Belgian Company called WANSON’. It began manufacturing coil type packaged boilers unit called ‘Vaporax’ and then thermic fluid heater (Thermopac). The then factory, had occupied an area of 5000 square feet, but with increase in production and development of new techniques and wide varieties of boilers it faced the need for more space and hence was shifted to Chinchwad, Pune. In 1980, the company decided to go ahead individually and was named as ‘THERMAX’. From then till now, ‘Thermax’ has grown by leaps and bounds. Today activities of Thermax are no longer confined to boiler making, but are extended to the growing line of businesses like pollution control, industrial & domestic water treatment, surface coating heat recovery unit, chemicals, absorption cooling, & grain storage system

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INTRODUCTION TO THERMAX

Thermax has been rolling out a company-wide initiative to transform the way it does business; aimed at significant increase in customer satisfaction and top line and bottom line growth. The company is investing substantial resources in attaining operational excellence – focusing on processes and systems that have a direct impact on cost, quality, lead-time and on-time performance at every point of customer engagement. The following is the detailed description of the whole organisation. It includes the following divisions. 1.

Boilers & Heaters.

2.

Cooling & Heating.

3.

Water & Waste Solutions.

Current manufacturing facility of ‘Thermax’ in Chinchwad includes 14 plants & production utilities measuring 66,000 square meters. It’s management system conforms to ISO 9002 (1994) and follows national and international standards such as ASME Standards (USA), BS (UK). It also obeys IBR (INDIA) standards & DIN (GERMANY) standards for boilers manufacturing. In international market ‘Thermax’ holds office in Russia, Kenya, Indonesia, UAE, USA, UK, Malaysia, Thailand, Kazakhstan, Sri Lanka, Nepal etc and territorial representative in many other countries. Involvement of ‘Thermax’ in multi-products makes it necessary to collaborate with other companies and thus it entered into following ventures-

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INTRODUCTION TO THERMAX

2. Divisional Profile:

(I) Boilers and Heaters projects: a.

Boilers & Heaters:

Fig. 1.1 Organisational structure of B&H

Products: Hot Water Generators Hot water boilers in capacities upto 20 million kcal/hour. Steam Boilers, (Coil)

Gas / Oil fired Coil Fired Steam Boilers in capacities upto 850 kg/hr.

Steam Boilers

Gas / Oil fired Shell Type steam boilers in capacities upto 30 tons

(Shell Type)

per hour.

Thermal Oil /

Thermal Oil / Thermic Fluid heaters in capacities upto 3.5 million

Thermic Fluid

kcal per hour.

Solid

Fuel

fired Boilers firing fossil fuel and agro-wastes in capacities upto 30

boilers Process

tons/hr Integrated Process Integrated boilers for recovering useful heat from process

Boilers

gases

Exhaust Gas Boilers

Waste heat recovery boilers on DG system exhausts

Fired Heaters

Fired Heaters for critical process

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INTRODUCTION TO THERMAX

b. Cogen Division: Backed by its strong competencies in thermal engineering and energy management and its close familiarity with a wide range of fuels, Thermax provides competitive power solutions. In the current scenario, where power is increasingly becoming scarce and expensive, Thermax offers 'freedom from large power stations' through decentralized power. The power business of Thermax is conducted through Cogeneration Division. This Division caters to industry requirements of inexpensive and high quality power. Cogen Division offers captive power systems including Cogeneration. The Cogen plants from Thermax can utilize fuels like coal, lignite, husk and even agricultural waste (like Bagasse in sugar Cogen plants) to generate inexpensive energy, thus reducing overall energy costs upto 50%.

Cogen Division has the EPC expertise to design, erect and commission: ¾ Captive Power Plants ¾ Cogeneration Systems ¾ Sugar Cogen Plants Cogen Division works in synergy with the other divisions to offer 30 - 50 % of the systems and equipment of a power plant: ¾ Steam Generation Equipment ¾ Water Management Products and Systems ¾ Inlet Air Cooling for turbines & Control room air-conditioning ¾ Cooling Water Chemicals ¾ Air pollution Control Systems ¾ Construction Backup

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INTRODUCTION TO THERMAX

c. Enviro Division: Clear the air for better returns… Thermax's Enviro Division was set up with the belief that pollutants are inevitable but pollution is not. Catering to a wide range of industries, the Division has installed 3000 cyclones, 1400 bag filters, 50 ESPs and 55 Scrubbers and 20 pneumatic conveying systems. With the growing realization that pollution abatement pays, as it means better use of resources and improved competitiveness, environment protection systems are no longer end-of-the-pipeline fixtures. Thermax has kept pace with international technologies to offer turnkey projects as well as air pollution control products. The Enviro Division has the necessary infrastructure to undertake any small to large pollution control projects on a turnkey basis, from concept to commissioning. It can handle more than 100 types of dusts. Designing for Different Dusts Depending on the differing properties of various kinds of dust such as dust chemistry and flue gas composition, Enviro Division has the expertise to design and execute pollution control systems for varying industry requirements. Some of the ducts handled by the Division are: Aluminum Dust

Ammonium Sulphate

Asphalt

Bentonite clay

Carbon black

Cement

Clinker

Coffee

Detergent

Gypsum

Latrite

Limestone

Coal

Fly ash

Dead burnt magnesite

Projects ¾ Gas cleaning plants ¾ Gaseous scrubbing (including wet ESP) ¾

Coal preparation plants

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INTRODUCTION TO THERMAX

(II) Cooling and Heating (C&H) a. Process Heat Division: Process Heat Division (PHD) is the flagship Product Business Division of Thermax Ltd, which has its core business in the area of providing cost-effective process heating solutions for both energy generation and energy conservation. Thermax has begun its business way back in 1966 by manufacturing baby boiler. PHD is the seed for business growth for the company. Today its high quality products are demand in India and in International markets. Its products and expertise find applications in every conceivable heating application in the world. History To share the fond memories of Thermax and PHD, the company made a modest beginning to manufacture sterilizers for Hospitals way back in 1966. Small capacity steam boiler (Baby boiler) was much in demand. In order provide the customer complete solution PHD began its voyage into the Core sector of Energy by collaborating with Wanson of Belgium. The collaboration introduced baby boilers in India. The baby boilers, which were out side the purview of the Indian Boiler Regulation Act, were the most demanded product. Thermal Oil heating took the Indian industry by storm and today in India its brand Thermopac has become a generic name. Thermal oil heating replaced several other heating methods such Electrical, steam, steam-cum-electrical. The main reason is its highest energy saving capability due to high system efficiency. Today every industry looks to thermal oil heating as a most potential energy saving solution. The division then made a modest beginning with a turnover of USD 0.05 million in 1968, and now has grown to a USD 140 million group which offers a wide range of solutions to its customers in the areas of energy generation and conservation and environment Protection, all under one roof with a singular Mission.

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INTRODUCTION TO THERMAX

To pursue this mission Process heat division has been continuously designing and upgrading its products and services that results in energy efficient heating solutions to the customer making optimum use available energy resources - conventional, non conventional and the renewable energy sources. Process Heat Division over the last 30 years has evolved into an Engineering major well known for it’s core competencies in the field of Process Heating, Energy & Environment. Products and Services Our product portfolio encompasses providing process heating through different mediums such as… ¾

Steam

¾

Hot Oil

¾

Hot Water

¾

Hot Air

The product technology facilitates use of wide range of fuels viz.… ¾ Light & Heavy oil ¾ Natural gas ¾ LPG ¾ Bio-gas ¾ Coal – Low and high Calorific values ¾ Lignites Non conventional / agro-based fuels… ¾ Rice Husk ¾ Bagasse ¾ Groundnut shell ¾ Mustard stalk ¾ De-oiled bran ¾ De-oiled cake

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INTRODUCTION TO THERMAX

All these innovations of providing energy efficient solutions have been evolved through a close association of our R & D along with engineering to be abreast in the market with the changing needs of the customer across the world. To meet the growing demand of customer the division strives on it’s strength of… Market Reach Through a network of 100 sales representatives & Service Franchises and Spares parts stockists, 11 regional offices in India & 10 Overseas offices, Process Heat Division with it’s strength of over 150 qualified sales and service engineers are present where the customer needs them most. Service at your doorstep: Our aim is to provide prompt and efficient service to customers. To issue out this aim into action we have created a wide network of Service Franchises and our own Service engineers based in the local office, who are fully trained and have the right competence to service all the varied needs of customers in India & Overseas. Support With an engineering base of over 50 Design engineers of Process Heat Division can provide solutions to all your. R & D Facility Research and Development is continuously striving to upgrade the existing technologies to provide a product leadership edge and thus ensure the customer benefits through energy efficient solutions. R & D primarily focuses on new technology development in the chosen core areas. R & D has the entire necessary infrastructure to design, develop, manufacture and carry out proto-type tests on newer technologies. From the R & D the core technology is drawn by the business division and which are taken for commercialisation through the well-established Product Development Process (PDP); using the principles, tools & techniques of Total Quality Management.

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INTRODUCTION TO THERMAX

State of the art manufacturing set up State of the art manufacturing facilities are located in Pimpri Chichwad Industrial Zone of Pune in Maharashtra, India. The main manufacturing complex consists of 14 plants with total built up area of 51,345 sq. Meters and open area of 14,600 square meters. The plants are equipped with specialised machinery for light, medium & heavy fabrication, assembly, testing in “ferrous & non ferrous metals” in the area of fired, un – fired vessels, heat exchangers, reaction vessels, pressure vessels, and package boilers. With commitments to quality manufactures to national & international standards and codes like IBR, ISO, BS, DIN, GOST, ASME, Reputed agencies like SGS. (Switzerland), LIOYEDS (UK), TUV (Germany) and BUREAU VERITAS (France) are involved in customer inspection. The manufacturing facilities have been accredited by the SUHR and

PP stamp of quality, from the American Society Of Mechanical Engineers (ASME) and also accredited by the ISO 9002 certification by LRQA. With the strengths Process heat division caters to the need of variety of applications in process industries like… Agro products

Packaging

Bottling & beverages

Drugs & pharmaceuticals

Breweries & distilleries

Plywood

Chemical & petrochemicals

Rubber

Engineering

Edible oil / solvent extraction

Food & dairy

Textile / synthetic fibres

Hotels

Hospitals

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INTRODUCTION TO THERMAX

b. Heating: Heating, the prime mover of Thermax business continues to maintain its leadership in the Indian market for packaged boilers and heating systems. The wide ranges of customers further reinforce the domina...