ACKNOWLEDGEMENTAllpraise is to Almighty Allah, the Benefcent, and the Merciful.HeshoweredHisgreat blessingsuponusintheformof HolyProphet, Hazrat Muhammad (P.B..H!."ith much e#ort and time spent, we than$ %od for being able tocomplete the internship in HM&."e wish to ta$e this space and opportunity to e'press our than$sto all wor$ers for pro(iding us with helpful information ande'changing thoughts, family members for their fnancial supportand HM& for supporting us in doing our pro)ect.Thank you.Page 1 of 44 Table of ContentsSr. no Workshos ! Labs"a#e no.*.+ntroduction to HM& ,,,,-.. /rganizationand0unctionof PP&,,,..1-.Basic Machine 2hop ,,,,34.55& 6 Heat 5reatment,,,,.41.0abrication 2hop,,,,.78.9:5 ;ab,,,,--7.Material 5esting ;ab,,,,-4Page $ of 443. Pattern 2hop,,,,-8. +nspection ,,,,-%NT&OD'CT%ON TO (MC(ea)y Me*han+*al Co,le- .")t/ L+,+te0 is a leading engineering goodsmanufacturing enterprise in Pa$istan located at 5a'ila about -. @ilometersnorth of capital +slamabad. +t is a professionally managed progressi(eorganization with o(er *8>,>>> sA. meters co(ered facilities and *,*>>employees. Hea(y Mechanical &omple' ;td. (HM&!, 5a'ila is a ma)or hea(y engineeringsubsidiary of the 2tate Bngineering &orporation (2B&! under the Ministry of+ndustries 6 Production, %o(ernment of Pa$istan. +n * 5ons 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 nubering s!ste:-Thesalesordernumberingsystemallocatesauniueidentificationsystemtoeachorderacuired by the sales and mar!eting department. This sales order consists of si" digits. Thefirst twoof these numbers designate the product groupnumber of the products tobemanufactured or services to be provided by the organization. The ne"t two digits specify thefiscal year in which the order is received and the last two digits give the number of similarorders already received in the same fiscal year. #or e"ample$ a %ob order given as&&'&&'() is read as follows&&******* product group no for sugar spares&+*******represents ,(&+ as the fiscal year()*******specifies the fourth order for the current yearThat is fourth order of sugar spares in ,(&+. Page 6 of 44". Core Planning:-Core planning section has following wor!s. Master schedule planning. -rder .ctivity plans. Monitoring of all the schedules. Preparation of various periodic reports for MI/. Maintaining of balance order position. Maintaining sale and production report. /ale0production budget. Pro%ect 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 #lanning:- To ensure receipt of all drawings and documentation from design. To issue the material purchase reuirement. To prepare the reuirements of materials to be issued. To coordinate the production technology for preparation of necessary production documents for manufacture. To prepare and issue %ob orders and prepare the follow up. To suggest the alternate materials for use from available stoc! to design. To compile standard material reuirements for all products and pro%ects. To draw the standard items 0euipments from stores for dispatch to costumer sites. To prepare data for IC1 2Income ta" Cost and 1evenue3 for the survey by C41 2Central 4oard of 1evenue3. $.%aterial %anageent (%%&):- C-':- %%& Section:- Material reuirement planning. Intending and follow up of indent. To !eep updated purchase status of all pro%ect documents. 5stablish stoc! levels for general consumable items and raw materials.Coding of store items. Insurance of material to appropriate %ob. To !eep and maintain updated stoc! status of all store items. To loo! after stores and related functions.Page 5 of 44C-(:- &eneral Stores:- To receive and issue all the materials and euipments in stores as per laid down procedure. Maintain detailed record of stoc! movement. Maintain stoc! location system. 5nsure daily submission of issue and receipt statement to concerned department. 5nsure that all the storage areas 2open0covered3 are !ept properly secured and organized.). Production *ec+nolog!:- $-':- Feasibilit!,-uantitative $etail:- #easibility study and uantitative details of client6s enuiries for cost estimates.$-(:-Process Planning:-Preparation of following documents. Detail parts list. 1oute card 2machining and fabrication3 if reuired. Cutting plans. Time sheets.$-.:- *ool designing:- Designing of all types of press tools$ dies$ templates$ %igs and fi"tures. To produce drawings for machinery components for maintenance. Cutting plans$ cutting0mar!eting templates for shop.F.$is#atc+ Cell,%aterial /andling:-)-':- %aterial +andling:- To !eep all the material handling euipment operation worthy. Provide material handling services to stores and dispatch cells and shops as and when reuired. 7eep the open yard tidy and organized. 1eceive materials from shops for surface preparation. .rrange sand blasting0paint as per contractual reuirement. 1eceive raw materials from general stores for onward issuance to shops against %ob orders.)-(:- $is#atc+ Cell:- To receive finish goods from shops0material handling sections. To draw the standard items0euipments from stores for dispatch to costumer0sites. To organize preservation0pac!ing. Maintain detailed dispatch records of finished goods$ euipments$ standard items against each contract. -rganize transportation. 5nsure complete and accurate documentation along with each dispatch. To prepare the dispatch plans and ensure compliance.&. 0.C.1 (0ncoe ta2 Cost and 1evenue):-Page 3 of 44 To defend in litigation0ad%udication and contravention. To organize industrial survey. To obtain the consumption certificates and release of guarantee. To obtain e"tension0coordination from C41 2Central 4oard of 1evenue3 and custom collectrate. To deal with matter pertaining to custom duty and sale ta". To clear consignments for dry port and Islamabad airport. To !eep close contact with collectorates of custom$ sales ta"$ Central 5"cise Islamabad01awalpindi and Central 4oard of 1evenue 2C413 for all matters to 8MC6s imports.To follow up for the settlement of all customs and sales ta" matters with concerned agencies"asic %ac+ine S+o# +n the de(elopment of e(ery nation industries are (ery important andfor industriesmachineryis$eyfactor. 5ochec$thede(elopment of anyindustry chec$ itKs machinery.+nthemachineshopof Hea(ymechanical &omple'therearenearly1>>machines of di#erent sizes and capacities. 5he machine shop of HM&contains (arious types of machines.A)a+lable ,a*h+nes7 Lathe ,a*h+ne (three )aws and four )aws chuc$s, turret!. "laner. M+ll+n# ,a*h+ne. Dr+ll+n# ,a*h+ne. (DL (hea(y duty lathe!. 89T (boring (ertical turret lathe machine!. Gear hobb+n# ,a*h+ne. Gear shaer ,a*h+ne. Stra+#ht be)el ,a*h+ne. (or+:ontal lathe ,a*h+ne. &a0+al 0r+ll+n# ,a*h+ne. Slott+n# ,a*h+ne.Page ; of 44 Double hous+n# lanner. ues +n*lu0e Annealing. Hardening 5empering 9ormalizing 2tress releasing &arburizing Phosphating (phosphate coating is used to protect the surface from corrosion!HM& has following 5ypes of 0urnace and facilities which are use in heat treatment section H52=* Blectric carbon furnace Blectric bo' type furnace 0lame hardening machine for surface hardening &hamber type &leaner Blectric tempering oil bath High temperature salt bath ;owtemperature salt bath Medium temperature salt bath High freAuency induction heat treatment lab (eat treat,ent of ,etals an0 alloysPage $6 of 440ull hardening/urface hardeningCause hardeningMetallic materials consist of a microstructure of small crystals called LgrainsL or crystallites. 5he nature of the grains (i.e. grain size and composition! is one of the most e#ecti(e factors that can determine the o(erall mechanical beha(ior of the metal. Heat 5reatment pro(ides an eMcient way to manipulate the properties of the metal by controlling rate of di#usion, and the rate of cooling within the microstructure.AnnealingAnnealing is a techniAue used to reco(er cold wor$ and rela' stresses within a metal. Annealing typically results in a soft, ductile metal. "hen an annealed part is allowed to cool in the furnace, it is called a Lfull annealL heattreatment. :uring annealing, small grains recrystalliz to form larger grains.9ormalizing "hen an annealed part is remo(ed from the furnace and allowed to cool in air, it is called a LnormalizingL heat treatment. 9ormalizingJ &arbon steel is heated to appro'imately 11 N& abo(e Ac- or Acm for * hourO this assures the steel completely transforms to austenite. 5he steel is then air=cooled, which is a cooling rate of appro'imately -3 N& (*>> N0! per minute. 5his results in a fne pearlitic structure, and a more=uniform structure. 9ormalized steel has a higher strength than annealed steelO it has a relati(ely high strength and ductility .5ypical annealing processes include, LnormalizingL, Lstress reliefL annealing to reco(er cold wor$, and full annealing.Hardening and tempering (Auenching and tempering!5o harden by Auenching, a metal (usually steel or cast iron! must be heated into the austenitic crystal phase and then Auic$ly cooled. :epending on the alloy and other considerations (such as concern for ma'imum hardness (s. crac$ing and distortion!, cooling may be done with forced air or other gas (such as nitrogen!, oil, polymer dissol(ed in water, or brine. 5he Auenched hardness of a metal depends upon its chemical composition and Auenching method. &ooling speeds, from fastest to slowest, go from polymer (silicon!, brine, fresh water, oil, and forced air. Te,er+n# is a heat treatment techniAue for metals, alloys and glass. +n steels, tempering is done to LtoughenL the metal by transforming brittle martensite into bainite or a combination of ferrite and cementite.Page $5 of 44ntempered martensite, while (ery hard and strong, is too brittle to be useful for most applications. A method for alle(iating this problem is called tempering. Most applications reAuire that Auenched parts be tempered (heat treated at a low temperature, often three hundred degree 0ahrenheit or one hundred ffty degrees &elsius! to impart some toughness. Higher tempering temperatures (may be up to thirteen hundred degrees 0ahrenheit or se(en hundred degrees &elsius, depending on alloy and application! are sometimesused to impart further ductility, although some yield strength is lost."re*++tat+on har0en+n#2ome metals are classifed as precipitation hardening metals. "hen a precipitation hardening alloy is Auenched, its alloying elements will be trapped in solution, resulting in a soft metal. Aging a LsolutionizedL metal willallow the alloying elements to di#use through the microstructure and form intermetallic particles. 5hese 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 LnaturallyL meaning that the precipitates form at room temperature, or they may age LartifciallyL when precipitates only form at ele(ated temperatures. +n some applications, naturally aging alloys may be stored in a freezer to pre(ent hardening until after further operations = assembly of ri(ets, for e'ample, may be easier with a softer part.%n0u*t+on heat+n#+nduction heating is the process of heating an electrically conducting ob)ect (usually a metal! by electromagnetic induction, where eddy currents are generated within the metal and resistance leads to Poule heating of the metal. An induction heater(for any process! consists of an electromagnet,through which a high=freAuency alternatingcurrent (A&! is passed. Heat may also begenerated by magnetic hysteresis losses inmaterials that ha(e signifcant relati(epermeability. 5he freAuency of A& used depends onthe ob)ect size, material type, coupling (betweenthe wor$ coil and the ob)ect to be heated! and the penetration depth.+nduction heating allows the targeted heating of an applicable item for applications including surface hardening, melting, brazing and soldering and heating to ft. +ron and its alloys respond best to induction heating, due to their ferromagnetic nature. Bddy currents can, howe(er, be generated in any Page $3 of 44conductor, and magnetic hysteresis can occur in any magnetic material. +nduction heating has been used to heat liAuid conductors (such as molten metals! and also gaseous conductors (such as gas plasma!. +nduction heating is often used to heat graphite crucibles (containing other materials! and is used e'tensi(ely in the semiconductor industry for the heating of silicon and other semiconductors%n0u*t+on furna*eAn induction furnace uses induction to heat metal to its melting point. /nce molten, the high=freAuency magnetic feldcan also be used to stir the hot metal,which is useful in ensuring that alloyingadditions are fully mi'ed into the melt.Most induction furnaces consist of a tubeof water=cooled copper rings surroundinga container of refractory material. +nduction furnaces are used in most modern foundries as a cleaner method of melting metals than a re(erberatory. Metals melted include iron and steel, copper, aluminum, and precious metals. Because it is a clean and non=contact process it can be usedin a (acuum or inert atmosphere. Facuum furnaces ma$e use of induction heating for the production of specialty steels and other alloys that would o'idize if heated in the presence of air.>> tons of fabricated eAuipment and parts to di#erent power plants. Ma)or strength is HM&Hs capabilities for manufacturing utility boilers pressure parts. 0or this purpose some of the ma)or machines areJ - roller bending machines for ma$ing drums Booster pipe bending machine for ma$ing super heater ?eheated and economizer coils 2pecialized machine for machining and welding of headers and complete train of machines for manufacture of membrane walls in panel and bent form HM& has the capability to manufacture following type of boilersJPage 44 of 44 9atural circulation steam generators Heat reco(ery steam generators 0luidized bed combustion boilers Besides Boiler +sland, HM& ha(e also capabilities and e'pertise for manufacture of balance of plant eAuipment I parts such asJ &ondensers ;.P. heater H.P. heater parts "ater treatment plant :eaerator and feed water tan$ Pressure (essels /il storage tan$s &ooling water system Heat e'changers 2teel structure Ble(ator hoist and cranes Piping /ther misc. items "ith a team of well e'perienced engineers and technicians, HM& is well prepared to carry out all site construction wor$ which includesJ 2ite fabrication Brection I installation and commissioning &i(il wor$s (if part of complete construction wor$, pac$age! Page 44 of 44HM& is also pro(iding ser(ices for repair I maintenance and BM? of e'isting power plant for its boilers, turbines, condensers, heaters and other eAuipment.8O%LE& COM"ONENTS Suer (eaters /ne of the most important accessories of a boiler is a superheated. +t a#ects impro(ementand economy in the following ways. 5he superheated increases the capacity of the plant. Bliminates corrosion of the steam turbine.?educes steam consumption of the steam turbine.ECONOM%SE&S 5his is feed=water heaters in which the heat from wastegases is reco(ered to raise the temperature of feed=watersupplied to the boiler. 5hey o#er the following ad(antagesJ 0uel economy ;onger life of the boiler +ncrease in steaming capacity 0inned 5ube Bconomizers &.+. %illed 5ube Bconomizers Plain 5ube &oil Bconomizers Stea, Generat+n# Tubes5hese are tubes in the Boiler where water is e(aporated tosteam and are also called 2team %enerating 5ubes. 5hese5ubes also form the "alls of the Boiler and are hence called"ater "alls or "ater "all Panels. 5hese 5ubes ha(e (erycomplicated shapes to allow +nspection openings andburner throats and fabrication reAuire bending Machines.Page 46 of 44Material purchase5hird party (erify materialMar$ing 6 cutting layoutPre bending?olling ;" ft up5hird party (erify material"elding ?e rolling ?adiography2tress releasingHydraulic testing5hird party test 8o+ler ues. HM& has -.1 meter rolling capacity. And itcan manufacture . ton to 3> ton boiler.

NON DEST&'CT%9E9E TEST%NG.NDT/+5 +9&;:B :+00B?B95 /PB?BA5+/92 +9:+&A5+/9 +95B?P?B5A5+/9 0A;2B ?B;BFB95 9/9 ?B;BFB95 BFA;A5+/9 A&&BP5 ?BPB&5 NON DEST&'CT%9E E9AL'AT%ON