INDUSTRIAL TRAINING.

•LARSEN AND TOUBRO PRIVATE LIMITED •SPECIAL STEELS AND HEAVY FORGING (LTSSHF)•MECHANICAL MAINTAINANCE AND FORGING DEPARTMENT.•LOCATED IN HAZIRA ( THE INDUSTRIAL ESTATE IN SURAT,GUJARAT).

INTRODUCTION.

• LTSSHF IS THE SUBSIDIARY OF M/S LARSEN &TOUBRO (L&T).• THE ONLY FORGING PLANT PARTNERING WITH NUCLEAR PLANT

CORPORATION OF INDIA LIMITED(NPPCIL).• IT SUPPLIES HIGH PRESSURE REACTORS AND HEAT EXCHANGERS AS

WELL AS ROTORS,SLABS AND SPECIAL STEELS.• THEY USE THE L&T JETTIES FOR TRANSFERRING THE PRODUCTS

RATHER USING ROAD TRANSPORTS. • ANNUAL MELTING CAPACITY – 1 MT

BRIEF PROCESS

•The steel is melted in the electric arc furnace(EAF) at more than 1800 Celsius. The molten metal is sent to ladle refining furnace(LRF)where steel is mixed with different alloys to make special steels.•These steels are further casted or used for

manufacturing of different products .•By casting, ingots are manufactured, so called ingot

casting.

SAFETY INDUCTION.

• THE SAFETY INDUCTION TRAINING WAS GIVEN TO WORK IN THE INDUSTRY KEEPING THE SAFETY RULES IN MIND.• IT INCLUDES SAFETY FROM HEAVY MACHINES AND BEING WELL

VERSED WHILE WORKING IN MACHINES.• PROTECTION LIKE HELMET,DUSK MASK,SAFETY SHOES TO BE USED IN

INDUSTRIAL SITES.• IT SHOULD NOT BE IGNORED,BUT TO BE FOLLOWED.

Mechanical Maintenance Department

MECHANICAL MAINTAINANCE DEPARTMENT

STEEL MELT SHOP

MACHINE SHOP

FORGE SHOP

Machine Shop

• THE SHOP COMES UNDER THE MECHANICAL MAINATANACE DEPARTMENT AND INCLUDES THE VITAL PRODUCTION MACHINES.

• THE MACHINE SHOP HAS:1. FLOOR TYPE HORIZNTAL BORING MACHINE2. VERTICAL TURNING LATHE3. HORIZONTAL TURNING LATHE

FLOOR TYPE HORIZONTAL BORING MACHINE(FHB).• MADE BY – TITAN TMG• The saddle is provided with servo oil so as to move freely. Hence

the saddle is lifted by 0.02mm.• It has 12m column assembly,5m head stock,1.5m spindle and

1.7m ram.• It works on CNC. Proper dimensions are feeded to get the

required size.• X-axis – column assembly horizontally.• Y axis – head stock vertically• Z- axis – spindle moves• W-axis– ram moves

• When the process starts the head stock ,spindle and ram move accordingly for cutting and finishing. It works on rack and pinion mechanism.• Coolant is provided to reduce the heat produced while operation.

Vertical turning lathe.• MAKE– TITAN TMG• MAX SPEED -- 450rpm• MAX FEED – 2.4m/min• CAPACITY – 125 TONNES• MAX TURNING – 8.5m• MAX HEIGHT – 5m• CHUCK DIAMETER – 5m• SWING DIAMETER – 8.5m• It has X and Y-axis for turning and U and W-axis for milling.• In this machine job having max height of 5m can be machined.it

also works on rack and pinion mechanism. Two rams are being used separately for turning and milling.

• Linear scales are attached for perfect measurements . Here also hydraulic oil is used for proper lubrication.• Conveyer belts are used to carry the chips and dispose them

properly for further treatment.

HORIZONTAL TURNING LATHE.• MAKE—KROMATORSK UKRAINE• MAX SPEED—0.5rpm-128rpm• MAX FEED – 2.9m/min• CAPACITY – 63 TONNES• TURNING DIAMETER– 1.6m• HEADSTOCK MOTOR – 110 KW• CHUCK DIAMETER – 2m• W-AXIS – TOOL POST MOVEMENT• X-AXIS – MOTION OF CARRIAGE 1• Z-AXIS– MOVEMENT OF CARRIAGE 2• The lathe working is done on the basis of CNC. It has two

carriages for doing multiple job operations.

Water jet machining

• MAKE—KMT GERMANY• TANK MANUFACTURER—SAINI INDIA• MAX PRESSURE– 6200bar• MAX THICKNESS– 400mm• Two intensifiers are connected to the single accumulator.• The booster pump provides cool water to the pistons with oil

pressure.• The required pressure for cutting is obtained which goes to the

nozzle.• Heat exchanger is used so that the exposed heat is cooled with the

help of coolant.

• Air blocks happen while the pressure goes to the nozzle. Dump valves are used for this cases.• Gantry moves in horizontally as well as vertically in X-axis and Y-

axis respectively.• The intensifiers have pressure ratio of 1:38.• Booster pumps are used to provide a particular pressure at which

the machine should work.

FORGE SHOP

• THE DEPARTMENT COMES UNDER MECHANICAL MAINTAINANCE DEPARTMENT.

1. BANDSAW MACHINE2. PRE-HEATERS3. RAIL BOUND MANIPULATORS4. HYDRAULIC PRESS5. REHEATING FURNACE

BAND SAW MACHINE (BSM)

• USED FOR GIVING PROPER HORIZONTAL CUT.• THE JOBS ARE PLACED ON THE CARRIAGES AND IS CARRIED

FORWARD BY BELT DRIVES.• SMALL PART OF THE JOB IS CLAMPED, TO PROVIDE OPTIMUM

PRESSURE TO THE CUTTING AREA.• THE GANTRIES CAN MOVE HORIZONTALLY.• BSM 260,BSM 360 AND BSM 530 ARE SOME OF ITS TYPES.

PRE HEATERS.

• THESE MACHINES ARE AVAILABLE IN STEEL MELT SHOP.• THE HEAT TREATMENT IS DONE AT 1600 TO 1800 DEGREE CELSIUS.• BUT BEFORE THAT THE LADLE IS ITSELF HEATED.• THIS IS BECAUSE THEY CAN HANDLE THE TEMPERATURE OF THE

MOLTEN METAL.• OTHERWISE , A BREAKDOWN MIGHT HAPPEN.

REHEATING FURNACE

• BOGGIE HEARTH FURNACE.• NATURAL GAS FUEL• MAX FURNACE—1300 DEGREE CELSIUS• NORMAL OPERATING TEMP—1260• RATE OF HEATING– 20 TO 100 DEGRRE CELSIUS /HR• TOP– REGENERATIVE BURNERS• BOTTOM—COLD AIR HIGH VELOCITY BURNERSHANDLING—CRANES AND TONGS

RAIL BOUND MANIPULATOR

• MAKE—GLAMA INDUSTRIES• CARRYING CAPACITY—150MT• CHARGE CAPACITY—WITH EXTENSION:• MAX—4000mm , MIN—100mm• THE RAIL BOUND MANIPULATORS ARE USED TO CARRY THE MOLTEN

METAL BROUGHT FROM THE REHEATING FURNACE.• THE MANIPULATORS CARRY THEM TO THE FORGE SHOP SO THAT IT

CAN BE PLACED THE FORGING PRESS.

HYDRAULIC PRESS

• MAKE—NKMZ• TYPE – 4 COLUMN PUSH DOWN• FORCE – NORMAL– 7200MT UPSETTING—9000MT• MAX PRESS STROKE – 3500mm• THE HYDRAULIC PRESS USED IN LTSSHF IS THE ONLY PRESS IN ASIA

THAT HAS A CAPACITY OF 9000MT.• THE FORGE SHOP CAN MANUFACTURE 120 MT TO 40000MT PER

YEAR.

CASE HANDLING—TELESCOPIC COVERS BREAKDOWN• THE CASE WAS HANDLED BY THE MECHANICAL MAINTAINANCE

DEPARTMENT.• IT HAPPENED N THE VERTICAL TURNING LATHE WHERE THE

TELESCOPIC COVERS HAVE BROKEN DOWN.• TELESCOPIC COVERS ARE THE ALUMINIUM BOX TYPE MATERIALS.• THEY ARE LAYERED ONE AFTER THE OTHER IN A SERIES.• THE LAST BOX TOUCHES THE LEG PART OF LATHE.

• THE BREAKDOWN OCCURRED DUE TO THE SLIPPING OFF THE TELESCOPIC COVERS.• AS A RESULT, THE WORKING OF LATHE WAS HAMPERED.• THE LOCKING PART WAS DAMAGED,SO THE SMALL PART OF THE

COVER WAS CUT OFF TO FIX IT TO THE LATER COVER.• THE LOCKING ARRANGEMENT WAS WELDED ,SO THAT IT GETS

LOCKED PERMANENTLY.• THE LAST PART WAS AGAIN BOLTED WITH THE GANTRY FOR

PROPER FUNCTIONING OF LATHE.

MONTHLY INSPECTION.

• A MONTHLY INSPECTION IS CARRIED OUT BY THE DEPARTMENT ON ALL THE THREE SHOPS TO CHECK THE MACHINES AND EQUIPMENTS. BASICALLY,IT IS CARRIED OUT FOR :

1. LUBRICATION2. FITTINGS3. CNC DISPLAY CHECKINGS4. SMOOTH FUNCTIONING