Industrial Training report at Heavy Engineering Corporation, Ranchi Jharkhand

REPORT ON
INDUSTRIAL TRAINING
AT
HEAVY ENGINEERING CORPORATION,
DHURVA, RANCHI (JHARKHAND)
Submitted by
VANSH VARDHAN JHA
130929238
June 2016
DEPARTMENT OF MECHATRONICS ENGINEERING
MANIPAL INSTITUTE OF TECHNOLOGY
(A constituent Institute of MANIPAL UNIVERSITY)
MANIPAL - 576 104, KARNATAKA, INDIA

Contents
SR Topic Page No.
01 Acknowledgement 03
02 Introduction 04-08
03 Objective of the Training 09
04 Work Done 10-40
05 Inference 46
06 Bibliography 47

Acknowledgement
I would sincerely like to thank all the Engineers, technicians and the Vocational Training Cell of
the Heavy Engineering Corporation, Ranchi for helping me under the various aspects of this
organization. I am very thankful to the respective Heads of various shops of the three plants in
which I did my training for being ever supportive and for taking time out of their busy schedules
to interact with us, Trainees. Also, I would like to thank Mr. Sunder Subramanian, Sr. Dy.
General Manager, HEC ltd. For accepting my request to provide Industrial Training and giving
me an opportunity to become a Trainee.
I am very thankful to the various department in charge and technicians for helping me to clear my
concepts about the various aspects of the plant and helping me cope up with the sea of technical
information.
I would also be thankful to my group mates for their support and for accompanying me in the
training period.
VANSH VARDHAN JHA

Introduction
Heavy Engineering Corporation Limited or "HECLtd." is a Public Sector Undertaking ("PSU") in
Ranchi, Jharkhand India. HEC was established in the year 1958 as one of the largest Integrated
Engineering Complex in India. It manufactures and supplies capital equipment & machineries and
renders project execution required for core sector industries. It has complete manufacturing set up
starting from casting & forging, fabrication, machining, assembly and testing - all at one location,
Ranchi, backed by a strong design - engineering and technology team.
HEC Ltd.'s Plants
It consists of three units:
Heavy Machine Building Plant (HMBP).
The Plant has a fenced area of 5,70,000 sq. and a floor area of nearly 2,00,000 sq. It is well
equipped with sophisticated machine tools and handling equipment to undertake manufacture of
heavy machinery and equipment of top quality. It is engaged in design and manufacture of
equipment and components for Steel Plant, Mining, Mineral Processing, Crushers, Material
Handling, Cranes, Power, Cement, Aluminum, Space Research, Nuclear Power etc.
Heavy Engineering Corporation Ltd., is one of the leading suppliers of capital equipment in India
for steel, mining, railways, power, defense, space research, nuclear and strategic sectors. It also
executes turn-key projects from concept-to-commissioning. Set-up in the year 1958, HEC has
acquired expertise in its field through its more than half a century's experience.
With the seamless integration of its facilities, HEC is one of the largest integrated engineering
complex. Sprawling in an area of around 2100,000 sq.m, HEC has facilities starting from steel
melting, casting, forging, fabrication, machining, assembly and testing. It has its own in-house
research and product development wing to deliver products suiting customers' specifications.
HEC is headquartered at Ranchi, the capital city of Jharkhand, in eastern part of India, and also
has its manufacturing facilities located here. A well-suited location nearing to customer sites and
proximity to the ports for import items, is an added advantage for its cost-effectiveness.
Founded primarily to facilitate manufacture of steel plant equipment indigenously, HEC has made
immense contribution in setting-up, expansion and modernization of steel plants in India. In due

course, HEC had diversified to different sectors and made commendable contributions towards
manufacture and supply of import-substitute products. Bestowed with the onus of making the
country self-reliant for heavy engineering equipment and services, HEC continues to contribute in
the nation-building endeavor.
1.0 Major Achievements
 Over 550 thousand tons of equipment manufactured and supplied to Steel Sector.
 Significant contribution in setting up of Bokaro and Vizag. Steel plant.
 Equipment supplied for expansion of Bhilai Steel Plant.
 Supplied to almost all the Steel plants of India.
 Supplied over 580 Excavators (of 4.6 /5 /10 CuM capacity)
 Supplied 12 numbers of 24 CuM Draglines.
 Supplied over 10 numbers of Heavy Duty Gyratory 1500 TPH crushers.
 Manufactured over 300 numbers of Cranes.
 Supplied over 900 Machine Tools.
500th Excavator ready for dispatch (2008)

1.1 Cyclotron Magnet Poles
HEC successfully manufactured Magnet Poles and associated components for VECC (Department
of Atomic Energy) and supplied in the year 2002.
 Exceptionally low carbon steel. Variation in carbon content within 0.07% and other
elements within 0.10%.
 Ultra clean steel, free from alloying & tramp elements and gaseous contents.
 Very high homogeneity level.
 Control of grain size and micro structure to ensure best magnetic permeability.
 Free from non-metallic inclusions and other ultrasonic defects.
 Precision machining of complex geometry shapes.
Fig. 1 - Pole Tip Assembly
Fig. 2 - Cyclotron Magnet Assembly

1.2 High Impact Steel for DMRL
 Two grades of steel 249 A (ABA) and 249 AB2 developed for application in NAVY.
 Excellent Mechanical properties of the material achieved which is the manifestation of its
internal soundness and cleanliness of steel composition.
 Impact test result achieved 170 Joules / cm2
 Commercial production of the established grade of steel started.
 A mile stone achievement in Indian metallurgy
1.3 Contribution to Nuclear Energy
 HEC has successfully manufactured special forging of nuclear grade.
 The ultra-clean liquid steel has been developed with close control of chemical composition
& impurities.
 HEC has now established the technological processes and controls needed to make
forgings for nuclear power sector.
 CNC Vertical Turning & Boring machine for Durgapur Wheel and Axle Plant
15 nos. of machines were manufactured with Automatic Wheel Handling System to cater the
production of 1 lakh wheels per year from rough forging to finish stage. These wheels are being
supplied to INDIAN RAILWAYS for direct mounting on axles. The machines were equipped with
FANUC 12 T with Auto Tool Changer.
 CNC Deep Hole Boring machine
The machine was designed & developed with Sinumerik 810 M.GA3. The machine was
commissioned in 1994 at Field GUN Factory, Kanpur for deep hole drilling/trepanning of large
size gun barrels. Its performance was appreciated by the user.

 CNC Planing machine for Copper Mould machining
Designed for machining Concave / Convex profile on the copper mould to be used on continuous
casting machine. The machine was developed with FANUC 0-MC CNC System for Rourkela Steel
Plant, in the year 1995.
 Heavy Duty CNC Roll Turning Lathe for Rolling Mills
4 nos. of machines were developed & manufactured for rough & finish machining of Rolls with
very high skin hardness. These machines with a use of FANUC 0-TD CNC System were supplied
& commissioned at Bokaro steel Plant in the year 1997.
 Wheel Lathe for Tramways
 Conversion of Hydromotor to DC Feed Drive for Horizontal Boring machine
 Twin Horizontal Boring machine system for Co-Co Bogie machining for CLW
 HEC has successfully developed High Strength Low Alloy Steel Grade DMR-249A and
249B for Naval Application
 HEC has taken up developmental work of large size rings of special material for ISRO.
2.0 Operating Units
2.1 Heavy Machine Building Plant (HMBP)
The Plant has a fenced area of 5,70,000 sq.m and a floor area of nearly 2,00,000 sq.m. It is well
equipped with sophisticated machine tools and handling equipments to undertake manufacture of
heavy machinery and equipment of top quality. It is engaged in design and manufacture of
equipments and components for Steel Plant, Mining, Mineral Processing, Crushers, Material
Handling, Cranes, Power, Cement, Aluminum, Space Research, Nuclear Power etc.
2.2 Foundry Forge Plant (FFP)
It is the largest foundry and forging complex in India and one of the largest of its kind in the world.
The area of the Plant is 13,16,930 sq.m accommodating 76,000 tonnes of installed machinery to
cope up with the various operations effectively. This Plant is the manufacturer of heavy castings

and forgings for various HEC make equipment related to Steel plant, Defense, Power, Nuclear
energy etc. It also manufactures Forged Rolls for Steel Plants, Crank Shafts for Railway Loco etc.
2.3 Heavy Machine Tools Plant (HMTP)
HMTP is the most modern and sophisticated of its kind in the country which produces machine
tools in heavier ranges. The Plant covers an area of over 2,13,500 sq. It designs and manufactures
medium & heavy duty CNC and conventional Machine Tools for Railways, Defense, Ordnance
factories, HAL, Space and other strategic sectors.
2.4 Projects Division
Design, Engineering and execution of Turnkey Projects related to Bulk Material handling, Steel
Plant projects, Cement Plant and other sector

Objective of the Training
The objective of this training is to know about the working of HEC, Dhruva, it’s purpose and it’s
3 Mega plants namely –
 Foundry Forge Plant
 Heavy Machine Tool Plant
 Heavy Machine Building Plant
In the 30 days of training I would also be exposed to the various departments of the organization
 Administrative divisions
 Business functions of the Organization
 Services provided by the organization
This would give me an overview of HEC, Dhurva and allow me to see my theoretical knowledge
of various subjects be put into action.

Work done during the Training
1.0 Foundry Forge Plant (FFP)
1.1 Introduction
The Foundry Forge Plant is one of the largest of its kind, spread over an area of 13,16,930 m2
. The
factory is about 2km in length and 1.2 km in breadth. About 76,000 tons of machinery installed in
the plant to cope with various operations efficiently. A special feature of this plant is the
underground electric furnace, some measuring up to 20 m deep and 1.9 m in this plant. Casting
and forging of practically any type and composition from few kg to as heavy as 100 tones pieces’
weight can be produced to meet the need of industries like steel, cement, ship building, electrical
in the core sector, manufacture of sophisticated forging and forged rolls with latest technology
from HITACHI ltd. Japan is on the anvil. The various features of FFP are:
 Area of plant: 13.16 lakh m2
 Total Machineries installed: 76,000MT.
Various steps in which its constructions took place:
1st
stage: Non-ferrous, iron foundry, light forge section.
2nd
stage: Iron foundry, Steel Foundry, Forge shop, M/C Shop and other auxiliary units.
3rd
stage: 6000ton press
Year of starting of production: 1964 in iron foundry.
The FFP comprises of the following units:
1. Grey iron foundry 01 Shop
2. Steel foundry 02 Shop
3. Forge shop 03 Shop
4. Machine shop 04 Shop
5. Fettling shop 05 Shop
6. Pattern Shop 06 Shop
7. Pattern Storage and repair 07 Shop
8. Tool and die shop 08 Shop

9. Installation workshop 09 Shop
10. Gas Plant 20 Shop
11. Boiler house 21 Shop
1.1 Quality Objective
 To demonstrate capability of the plant to meet customer’s requirement including functional
safety, statutory regulations, ease of maintenance.
 Continuous updating of knowledge base of personal with latest technologies of
manufacture, through development programmes.
 To control rejections and downtime to the level of
Rejection……………………3% Forging press down time…….10-12%
Machine Down time…………5-7% Furnace press down time…….12-15%
1.2 Wood Working and Pattern Shop (06-07 Shop)
1.2.1 Introduction
The pattern shop is unique of its kind in Asia. It is supposed to be the biggest in South East Asia
equipped to produce both wooden and metal pattern. This shop is set up to fulfil the demand of
pattern from iron and steel foundry, which is an important necessity for casting. Modern facilities
like cross cutting saw, circular saw, planners, wood seasoning etc. are capable of producing various
large pattern to 5000mm diameter and 3000 kg wt. It has mainly two wings:
06-Pattern shop area- 9,639 ft2
07- Repairing and storage area- 10,000 ft2
06 Shop is set up mainly for pattern making. 07 Shop, a separate building has been provided in
southern side of the shop for repair of old and used pattern of core boxes etc. There are two bays
meant for repair work and rest 5 bays for storing the used and new pattern, which are not used for
time being.

Various types of timber used in pattern making are:
 Teak ● Ban sum
 Deodar ● Gamhar
 Lal
 Karram
At HEC, Gamhar and Deodar are used as pattern material for wooden pattern due to their easy and
cheap availability & also due to their light weight. The moisture in timber is 35% to 45% which is
brought down by means of seasoning by air, steam or by artificial mean. Artificial mean is faster
process. After seasoning moisture content in wood is 8% to 9%.
1.2.2 Various Equipment Used:
S/N Machine 06 Shop 07 Shop Total
1. Surface Planner 7 2 9
2. Thicknesses 6 2 8
3. Power Saw 1 0 1
4. Bend Saw 11 4 15
5. Wood milling Machine 4 2 6
6. German Lathe 1 0 1
8. Bench drill machine 4 1 5
9. Disc grinder 3 1 4
10. Boring machine 2 1 3
11. Segment cutting machine 1 0 1
12. Vertical milling machine 3 0 3
13. Centre Lathe 3 0 3
14. Radial drilling machine 1 0 1
15. Vertical turning & boring machine 1 0 1
Table 1

1.2.3 Colour Code used for various types of pattern:
1. Grey Al alloy pattern
2. Yellow Cu alloy pattern
3. Red Cast iron pattern
4. Green Master pattern
5. Blue Cast steel pattern
6. Black Core printing
1.2.4 Seasoning Section:
In this section, seasoning is done to remove excessive moisture of the timber and to maintain a
correct level of it, about 8% to 10%.
1.2.5 Process of Removing Moisture
a. Natural
b. Artificial
a) In Natural seasoning the timber is kept open in the air and seasoning is done by water,
then the timber is kept in pond. The pond water absorbs the moisture from the wood.
b) In artificial seasoning there are three process:
 In close chamber passing hot air.
 Passing steam in closed chamber.
 Passing a mixture of steam and hot air.
In artificial seasoning i.e. adopted in HEC, it takes 10-15 days depending upon the thickness,
moisture content and the type of timber. The hot air inside the closed chamber is disturbed by
means of fan. The temperature is maintained about 60- 80 o
C.

1.2.6 Selection of Timber for Pattern making:
At HEC the pattern material is selected according to number of casting to be produced. There are
different grades of pattern materials divided according to the properties of the material.
Grades Number of castings Pattern Material
IV or V 1-2 pieces Any type of material
III 2-10 pieces Deodar, pine, Gamhar
II 11-50 pieces Teak or Deodar
I 50-100 pieces Teak
O Above 100 Metals
Table 2
1.2.7 Pattern Making:
The drawing of components whose pattern is being made is to be studied first. According to the
customer specifications allowances are calculated on different scales like shrinkage, machine
allowances etc.to the machine drawing to be done on a card board and then patterns are prepared
with the help of different tools.
1.2.8 Contraction Rules/ Shrinkage Rules:
For Grey cast iron 1% scale (10mm)
For Al & Al alloy steel 2% scale
For Carbon steel, low/ medium alloy steel 2% scale
White cast iron 1.5% or 2% scale
Copper base alloy Depending upon nature
High alloy steel 2.5%

1.2.9 Permissible Tolerance (According to IS 1513-1971)
Size range(mm) Wooden Pattern Metallic Pattern
Hard Soft Sand Mold Shell Mold
Up to 50 0.5 0.8 0.4 0.25
50-150 0.6 1.0 0.5 0.30
150-300 0.8 1.2 0.6 0.35
300-500 1.0 1.5 0.7 0.40
500-800 1.2 2.0 0.9 0.50
800-1200 1.5 2.5 0.9 0.60
1200-1800 1.8 3.0 1.0 -
1800-2500 2.1 3.5 1.2 -
2500-4000 2.4 4.0 1.5 -
Table 3
1.2.10 Pattern Materials Types of Pattern
1. Timber 1. Single piece pattern
2. Cast iron 2. Split Pattern
3. Steel/Brass/Bronze/Copper/Al-alloy 3. Match plate pattern
4. Plaster of Paris 4. Core assembly pattern
5. Wax 5. Sweep Pattern
6. Epoxy resin 6. Master Pattern
7. Plastic 7. Skeleton Pattern
8. Form polystyrene 8. Old casting as a pattern
1.2.11 Types of Core boxes Joining material
1. Split Type 1. Glue
2. Clamp type (height up to 200mm) 2. Screw

3. Wedge type (from 200mm to 1m) 3. Epoxy resin
4. Double wedge type (more than 1m) 4. Nuts and Bolts
5. Dumping over type (for mass production)
6. Cotter type (up to 200 mm height)
1.2.12 Fettling Materials:
1. Lifting strips
2. Conveying strip
3. Metal strip on stickle
1.2.13 Painting and Coating:
To obtain good resistance to moisture, long storage life, it is essential that all the surface of pattern
should be given suitable coating of paint or varnish by brush or spray.
1.2.14 Coating Materials:
1. Filter materials Acetone putty, Timber putty, French chalk
2. Paint Nitrocellulose base Al paint
3. Polish material Spirit + Chapra
4. Metal spray
1.2.15 Pattern Inspection
After making pattern, it is time for inspection for accuracy. General procedure for inspection is:
1. Visual inspection 3. Dimensional inspection
2. Stage inspection 4. Final inspection
1.2.16 Pattern Storage
Once the pattern has been used or prepared it is stored for future order or to be used by some minor
repairs in storeroom. They are given specific coding for easy recovery.

1.3 Grey Iron Foundry (01 Shop)
1.3.1 Introduction
It is the mother of foundry forge plant. In this shop, casting is made with the help of molding and
pattern casting. The melting section of the Grey iron foundry is equipped with 4 hot blast cupola
furnace of 1200mm dia and 10 tones capacity per hour. These cupolas are connected to two air
suppliers. The melting section has two crucible type induction furnace having capacity of 3 tones.
The flow of molten metal is channelled into three molding sections: dry, green sand and rolls.
In the core shop beside the normal sand core, oil sand and CO2 sand core can be produced. Gray
iron castings up to maximum piece weight of 100 tons can be done in this section. Grey iron is
widely used for molding different types of casting. Grey iron is basically eutectic alloy of Fe,
graphite and Si. It has good fluidity, high damping capacity and good heat conductivity. In
microstructure, it is marked by presence of flakes in matrix of ferrite, pearlite or austenite. In Grey
iron foundry the following types of products are generally produced:
1. Iron casting of pieces weight up to 80 tones.
2. Ingots moulds of pieces weight up to 75 tones.
3. Cast rolls of various types such finite chill rods, grain rolls.
The whole grey iron foundry shop is divided into seven sections:
1. Core sections
2. Light weight molding section
3. Medium weight molding section
4. Heavy weight molding section
5. Maintenance section
6. Sand plant
7. Non-ferrous section

1.3.2 Description of equipment in various bays:
a) AB Bay:
This bay is also known as raw material section. In this bay, raw material supplied to
cupola and induction furnace is stored, which is used for casting.
Equipment Present Qty. Capacity
1. E.O.T. cranes 1 2.5 tones
2. E.O.T. cranes 1 8 tones
3. Bracket cranes 2 200 kg
b) BC Bay:
This bay is divided into two halves. In the first half, system for supplying air to the
cupola and Mold drying ovens are kept and in 2nd
half bay maintenance section, which
perform all the maintenance work of 01 shop. In the first half, equipment present are:
1. E.O.T. cranes 12.5 tones
2. Mold drying furnace: Pattern are shifted in it to remove gas of moulds and core’s
moisture. It is operated by producer gas. Oil is required for charging process.
Equipment Present:
1. Drilling machine 4. Grinder
2. Lathe 5. Press
3. Shaper 6. Welding Requirement (only electric arc welding)
BC bay consists of 4 cupolas and two induction furnace of 3T capacity.
c) CD Bay:
Pit molding produces heavy castings. This bay is also known as melting section & is
equipped with 4 cupolas and an exhaust system. Dry sand and air hardened sands are
mostly used here.

d) DE Bay:
It is called medium heavy dry sand bay. Medium and heavy castings are produced by
means of floor and pit molding.
e) FG Bay:
This bay is called heavy core making section. Cores are prepared by means of Mold.
This bay has seven producers gas operated Mold and core drying furnaces.
f) GH Bay:
It is known as light green sand bay. In this section core and light castings are produced
by means of box and floor molding.
1.3.3 Sand Plant:
Sand used in various section of grey iron foundry shop is prepared in the sand plant. During
preparation, the sand is first dried in sand drying machine. After that it is shifted to mixing
unit. After the sand it is transported to different section by means of conveyor belt.
Sand plant is divided into six systems as follows:
i. Sand drier system 4. Green sand return system
ii. Green sand preparation system 5. Dry sand preparation system
iii. New sand transport section 6. Dry sand return system
1.3.4 Non Ferrous section:
In this section, Cu-base alloys, Tin, Bronze etc. are cast to fulfil the requirement of HMBP
& HMTP.
Raw materials:
Cu, Zn, Pb, Sn, Ni etc. all in pure form.

Products:
Bush, Bearing, washer, Nut, Al-machine cover
1.3.5 Inspection:
Inspection of finished product is done by means of following method:
1. Mechanical Testing
2. Chemical Testing
3. Visual Inspection
1.3.6 Details of Equipment:
1. Pit type crucible furnace:
There are 3 pit type crucible furnace. In this type of furnace oil feeding is done by gravity
and flame is rotating to prevent the heat accumulation.
2. Sand Plant:
This section has a separate sand plant where the sand required for Mold and core are
prepared. The various types of sand prepared are dry sand, green sand, No-bake sand, CO2
sand. The capacity of this sand plant is 1 ton.
3. Circular saw cutting machine:
It is used for cutting purpose only. Any type of cutting inclined, vertical, horizontal can be
done by this machine.
4. Grinding Machine
5. Lathe
6. Induction Furnace:
It has two crucibles. It is water cooled. Only treated water is used as coolant to prevent
chocking of cooling pipe.
7. Centrifugal Casting unit:

It is mainly used for production of hollow cylindrical pipe of any Non-Ferrous metal
depending on requirement of customer. At HEC maximum length of 2.2 m, outer dia 400mm
and minimum inner diameter 200mm can be produced.
1.3.7 Process done to get a product (Casting)
Generally, the following process are performed to obtain a product:
1. Sand preparation:
Different types of sand in grey iron foundry are produced and are prepared with the help
of an automatic sand preparation plant. Various types of sand prepared are CO2 sand, green
sand, dry sand, no-bake sand or resin sand etc. are used according to the casting produced.
For chunky and intricate casting CO2 sand is used. For light casting, there is special sand
but cores are made of CO2 sand.
2. Moulding:
Molding are done in molding boxes consisting of two parts cope and drag, but in case of
big castings moulds are prepared in pits dug in the foundry floor. Manual ramming is used
for ramming green and dry sand in the molding boxes. Generally, no rammers are used in
case of CO2 sand moulds and resin sand moulds.
3. Painting of Mold:
Paintings of moulds are generally done by water based graphite paints. Two coats of paints
are applied after drying of previous coatings. This facilitates good surface finish and
prevents sand fusion. Water base zircon paints are used for big chunky castings. Some
cores are painted with alcohol base zircon paints. They are dried by burning the alcohol.
4. Core making:
Cores are made in core boxes. Generally, cores are made by CO2 sand, however core oil
sand and phenolic sand are also used for core making.
5. Core and Mold drying:

Core and moulds are dried in oven for 5-6 hours at 300o
C. However, CO2 sand are not dried
in oven but their paint coatings are dried by gas burner using producer gas.
6. Melting:
There are 4 cupolas for melting cast iron. One induction furnace of 2-10-ton capacity is
also used for melting purpose.
7. Pouring:
Lip pouring ladles are used for cast iron molten metals. In lip pouring extra care is taken
for removing slag, after collecting the molten metal from the cupola.
8. Fettling:
This process is carried out in 05 shop. Risers are cut with the help of oxyacetylene flame,
sands are removed by shot blasting, hydro blast. In hydro blast high pressure water is
thrown on the casting, which washes out the sand. Shot blast is used to remove fused sand
from the surface of the casting.
1.4 Steel Foundry (02 Shop)
This foundry is designed mainly to fulfil the requirement of the forge shop and adjoining HMBP.
1.4.1 Introduction
Furnace Qty. Capacity
Electric Arc Furnace 1 60 ton
Induction Furnace 1 2 ton
Table 4

The electrodes are of graphite, whose length is adjustable and all the furnaces are hydraulically
operated. There is one Vacuum Arc Degassing (VAD) unit of capacity 60T, one Vacuum
Degassing (VD) unit of capacity 90T, which is used for purifying steel to produce ingots. The
whole steel foundry shop covered an area of 43,310 m2
. This shop is equipped with following
equipment:
a) Two numbers of 10T/hr continuous sand mixture for production of phenolic resin sand
mixture.
b) One shell core shooter for making intricate shapes.
1.4.2 Sand Plant
Sand required in molding section of steel foundry is prepared here. The various types of
sand prepared here and their composition are:
a) Dry sand: d) Green sand
Rajmahal/silica sand 70% Return sand 72%
Silica flour 10% New sand 15%
Bentonite 0.3% Bentonite 4%
Fire clay 10% Dextrin 1%
Water 0.6% Iron oxide powder 1%
Molasses 0.1% Water 7%
b) Zr- CO2 sand: e) Chemically treated
bentonite:
Zircon sand 45% Sand 90%
New sand 50% Sodium silicate 6%
Sodium silicate 5% Bentonite 3%
Water 1%
c) Oil core sand:
Sand 90%
Bentonite 3%
Dextrin 1.5%

Core oil 2.5%
Water 2.5%
Iron oxide powder 0.5%
1.4.3 Process:
1.4.3.1 Sand Preparation:
Same as that of Iron foundry.
1.4.3.2 Molding:
Same as that of iron foundry. Here for the opening of riser or gate, cracked core is
used. It gives safety of casting and helps in easy removal of casting. It is generally
used in Mg steel casting.
1.4.3.3 Painting:
1.4.3.4 Core making:
1.4.3.5 Core and Mold drying:
1.4.3.6 Melting:
1.4.3.7 Pouring:
In the case of steel casting bottom pouring is done. For this purpose, ladle with opening at
bottom is used. The flow of molten metal through the opening is controlled through a
stopper. Bottom pouring is done to prevent the screening effect.
1.4.3.8 Shake out:
1.4.3.9 Fettling:
Fettling is almost same as that of iron foundry. Sand plant is the most important part of any
foundry because sand prepared plays important role in casting. In 02 shop, Rajmahal sand

and Allahabad sand is used for molding. The sand used must be dry and must possesses
certain parameters as follows:
a) Refractoriness should be high fusion.
b) Grain size should be proper.
c) Free from impurities.
d) Must contain appropriate amount of clays etc.
1.4.3.10 Melting Section:
The melting section can also be divided into three units:
a. Charging unit
b. Melting unit
c. Die and pit unit (pouring unit)
1.4.3.10.1 Charging unit:
This unit is concerned with preparation of scrap on which composition of the melt depends.
In this unit the charge is mainly prepared for plane carbon steel, Alloy steel, Alloy steel
and cast iron materials. Basic composition of the melt contains C, Si, Mn, P and S, which
are also called primary elements.
Melt is alloyed with different alloying element such as Cr, Ni, Mo, V, Ti etc. to give certain
desired properties.
1.4.3.10.2Melting Unit:
This unit is equipped with electric arc furnace of various capacities and Vacuum arc-
degassing furnace.
Furnace Specification:
1) Electric Arc Furnace:
a. Capacity 10T
Transformer rating 3.8Mv,50 Hz
Electrode dia 10”

b. Capacity 30T
Transformer rating 3.8Mv,50 Hz
Electrode dia 14”
c. Capacity 60T
Transformer rating 36 Mv,50 Hz
Electrode dia 10”
The Electric Arc Furnace (EAF) consists of 3 Electrodes, molten bath tapping spout, refractory
brick movable roof, brick shell and a refractory lined bowl shaped vessel, water cooled in larger
size. The furnace is primarily split into three sections:
 Shell consists of the sidewalls and lower steel bowl.
 Hearth consists of the refractory that lines the lower bowl.
 Roof which may be refractory lined or water cooled and can be shaped as a section of a
sphere. The roof also supports the refractory delta in its centre, through which one or more
graphite electrodes enter.
The EAF is powered by a 3 phase electrical system and therefore has three electrodes. Electrodes
are round in section and in segments with threaded couplings, so that as the electrodes wear, new
segments can be added. The arc forms between the charged material and the electrode, the charge
is heated both by current passing through the charge and by the radiant energy evolved by the arc.
The electrodes are automatically raised and lowered by a positioning system, which may use either
electric winch hoists or hydraulic cylinders. The regulating system maintains constant current and
power input during the melting of the charge, even though scrap may move under the electrodes
as it melts. Since the electrodes move up and down automatically for regulation of the arc, and arc
raised to allow removal of the furnace roof, large water-cooled cables connect the bus tubes with
the transformer located adjacent to the furnace. To protect the transformer from heat, it is installed
in a vault and is itself cooled via pumped oil exchanging heat with the plants water cooling systems,
as the electrical conditions for arc furnace steelmaking are extremely stressful on the transformer.
The furnace is built on a tilting platform so that the liquid steel can be poured into another vessel
for transport. The operation of tilting the furnace to pour molten steel is called tapping.

1. Induction furnace:
Capacity 5T
Frequency 1000Hz
Power consumption 700KW
2. Ladle Furnace (60T):
This type of furnace is not used for metal melting, metal addition & degassing
purpose, it is only used to reserve molten metal for pouring. Nozzle is placed in the
bottom of ladle, to control molten metal flow during pouring.
The ladle is fitted with a refractory lining that stops the steel vessel from suffering
damage when the ladle is used to transport metal with high melting temperature. If
the molten metal come in direct contact with the ladle shell, it would rapidly melt
through the shell. Refractory lining materials come in many forms. Traditionally
ladles used to be lined using pre-cast firebricks, however refractory concretes have
tended to supress these in many countries.
Types:
a) Casting ladle: It is used to pour molten metal into molds to produce casting.
b) Transfer ladle: It is used to transfer a large amount of molten metal from one
process to another i.e. from primary furnace to either a holding furnace or an
auto-pour unit.
c) Treatment ladle: It is used for a process to take place within the ladle to change
some aspect of molten metal. A typical example being convert cast iron to
ductile iron by the addition of various elements into the ladle.
3. Vacuum arc degassing:
During tapping of the steel, air bubbles are entrained into the steel where the tap stream
enters the bath in the tap ladle. The quantity of air entrained into the steel increases
with the increasing free fall height of the tap stream. The entrainment of a gas such as
air into a falling stream of liquid steel has been the subject of a number of studies,

however, a reliable prediction of the quantity of air entrained into a stream of liquid
steel during tapping is difficult because of the assumptions that have to be made.
To obtain a high quality steel or metal, it is important to remove the inclusions, slag
and undesirable gases which are dissolved in molten metal during melting and pouring
process. The VAD is used for purification of molten metal. VAD is equipped with
bottom plugs for argon bubbling. To achieve a homogeneous bath temperature and
composition, the steel in the ladle is most often stirred by means of argon gas bubbling.
The refining of steel in the ladle is broadly defined here as comprising the following
operations: DE oxidation, desulfurization, dephosphorization, controlled additions of
alloying elements and inclusion modification.
DE oxidation
The first step in the refining sequence in the ladle is usually the DE oxidation of the
steel with ferromanganese, ferrosilicon, silicomanganese and aluminium. There are
three categories of steel DE oxidation.
a) Steel deoxidized with ferromanganese to yield 100–200 ppm dissolved oxygen;
these are usually desulfurized steel grades.
b) Semi-killed steels deoxidized with:
I. Si/Mn to yield 50–70 ppm dissolved oxygen,
II. Si/Mn/Al to yield 25–40 ppm dissolved oxygen,
III. Si/Mn/Ca to yield 15–20 ppm dissolved oxygen.
c) Killed steels deoxidized with aluminium to yield 2–4 ppm dissolved oxygen.
4. Vacuum degassing:
Vacuum degassing of steel has an even longer history than the treatment of steel with
calcium, initially, vacuum degassing was used primarily for hydrogen removal. However,
during the last twenty years or so there has been an increased use of vacuum degassing for
the production of ultralow-carbon (ULC) steels with carbon contents of 30 ppm or less.

Furthermore, a relatively new family of steel grades, the so-called interstitial-free (IF)
steels with carbon and nitrogen contents of 30 ppm or less, has appeared on the scene. To
achieve these low carbon and nitrogen contents, a treatment under vacuum is mandatory.
Presently, almost every high-quality steel producer has installed a vacuum treatment
facility.
1.4.3.11 Pouring Unit:
After liquid metal has been prepared, it is taken to the prepared Mold boxes or ingot Mold with
the help of ladle using E.O.T. to the molding unit or pit-casting unit. The metal is poured and
allowed to solidify. The Mold after solidification of casting is broken and the product is sent for
further processes to carry out such as fettling, forging, heat treatment etc.
Major products of this shop:
 Ladles for steel plants ● Sand channel
 Casting of tank bodies ● Stopper body
 Cotter pillar frames ● Steel plant equipment
 Excavator ● Cement plant equipment
 Gears ● Power plant equipment
 Pulleys ● Drag line items
 Crushing balls ● Ingots
 Bottom housing ● Austenitic Manganese steel items
1.5 Fettling Shop (05 Shop)
It is separate shop well connected by railway track with all the production units of plants and is
situated side of grey iron and steel foundry, well equipped with conventional method of shot
blasting, chiselling, grinding.
Built up on area of 16600m2
, this shop has complete facility for heat treatment of different casting.
There are in all, 11 gas fired annealing furnaces ranging from 3272 m2
and capable of being heated

up to 1100 o
C. There are two cooling chambers provided for rapid cooling by air blowing. This
shop is divided into 9 bays, among these bays bay no.1 and 2 is under grey iron foundry control
whereas all other are under steel foundry. Following are the steps for finishing the casting:
a) After shake out of the casting, the sand lumps are removed. It is done in two ways:
i. For small casting operations performed are manually and is done by wire brush,
chisel, chipping, hammer etc.
ii. For huge amount adhere sand and large castings hydro-blast, shot blast, vibrators
are used.
b) Cutting of fins, parting line flash, pads, gates and unwanted projections of castings are
removed by:
i. Oxy acetylene gas cutting
ii. Fatal arcing
iii. Chipping
iv. Grinding etc.
c) Removal of riser
Preheating is done before cutting the riser to eliminate the cracking of the casting. But in
case of Austenite Mn-Steel, the cutting will be done in cold condition and the temperature
of the cutting zone should not exceed 1000 o
C., otherwise crack will develop. Before
cutting the riser of these steels, casting is preheated at 1050 o
C. -1100 o
C. and quenched
into water.
d) Rough finishing of the casting is done after riser cutting. It is done by grinding, rotary tools
etc.
e) Finishing of casting is done by brushing, polishing, painting etc. For grey iron foundry
flogging process does the removal of gating system and risers. Here are 4 hydro blasting
machines.
Cast iron castings required very less heat treatment, but steel castings need heat treatment
cycle, which depends upon size, shape and type of casting.

1.6 Forge Shop (03 Shop)
Located in between the steel foundry and machine shop. This shop covers a floor area of 5000m2.
The entire forge shop is divided into 3 sub divisions.
1. Light Forge shop
2. Medium forge shop
3. Heavy forge shop
1.6.1 Light Forge Shop
In this shop job of weight less than 500 kg are forged. The forging arrangement includes:
i. 3T pneumatic hammer 1
ii. 1.6T pneumatic hammer 1
iii. 25T Pneumatic die forging unit 1
iv. Trimming die forging unit 1
v. 800T Horizontal forging machine 2
For handling the job while forging a manipulator is used. There is also heat treatment arrangement,
low frequency induction hardening machine and quenching arrangement in the shop.
1.6.2 Medium Forge shop
Here job of 5T-10T are forged. The forging equipment includes:
i. Hydraulic Press (3Pc)
a. Capacity 1000T
Type Single cylinder
b. Capacity 1650T
Type 3 cylinder & 3 staged
c. Capacity 2650T
Type 3 cylinder & 3 staged

ii. Gas Cutting machine
1.6.3 High Forge Shop
In this shop job weighing more than 10T are forged. The forging equipment consists of a very
special 6000T capacity hydraulic press. The jobs are held by their heads in a special 250T crane
while forging. Apart from all that, there is an electric manipulator for handling smaller jobs.
There is producer gas fired bogie type furnaces for preheating the jobs before the forging. But
due to unavailability of coal Hybrid furnace is being used in HEC, in which LPG and HSD (High
speed diesel) fuel is used for heating the job.
1.6.4 The Accumulator Section:
The presses installed in the forging shops are supplied with their working fluid at their respective
working pressure by the accumulator station built in between the MFS and HFS. The pressure of
emulsion provided by the station to HFS is 350 atm and to the MFS is 250 atm.
The Accumulator station consists of two parts:
a. Water purification and pre-treatment section.
b. Energizing section.
1.7 Machine Shop (04 Shop)
This shop consists of automatic machine tools for finishing the jobs sent out by the foundries (01
& 02 shops) and the forging shop. There are several general purpose machine and giant centre
lathes, Vertical turning & Boring machine, milling machine, roll grinding machine, Shapers,
Planners, Drilling machines etc. for handling smaller and larger jobs.
1.7.1 Some of the unique machines of this shop are as follows:
1. HEC inbuilt Horizontal Trepanning Machine
Trepanning diameter range 50mm-250mm
Solid drill diameter range 25mm-45mm

Size range of boring head available 50mm-350mm
Maximum trepanning length 20m
2. Giant centre Lathe
Swing over bed 2080mm
Swing over carriage 1700mm
Maximum length of job 40m
Maximum Trepanning length 24m
Maximum weight of job 28T
3. Vertical turning and Boring Machine
Operations- Turning, Boring, Tapering etc.
4. Roll Grinding Machine
Maximum job diameter 800mm
Maximum job length 9m
Maximum job weight 800T
5. Horizontal Boring Machine
Maximum job length 8000mm
Vertical movement 3150mm
Operations- Boring, centre making, key cutting, threading, tapper cutting, groove cutting,
facing etc.
6. Planner machine
1.7.2 Heat Treatment arrangements:
There are several electric and non-electric furnaces for the heat treatment of jobs like rolls,
crankshafts etc. after rough machining. Some of the furnaces are as follows:
1. Medium Frequency Induction Hardening Machine:

Job length 1-6m
Diameter 150-800mm
Weight 15T
Power input 600kW
2. Low Frequency Induction Hardening Machine:
Job length 5m
Diameter 300-650mm
Weight 15T
Power input 100kW
3. Nit riding Furnace:
The furnace is operated at 530-540 o
C. Prolong heating is done at this temperature (50hr).
Cracked ammonia gas is used as nit riding agent. The maximum case depth is achieved
about 5mm in 50 litre. Six jobs can be treated at a time.

2.0 Heavy Machine Building Plant
2.1 Introduction
The HMBP consists of following shops:
1. Shop 010-011
 Main processes: Turning, Boring, Facing, Grinding, Vertical milling, Grooving,
Threading, Parting, Slotting
 Production- Crushers, slab billets, other planer products
2. Shop 020-021
 Main processes: Turning, Boring, Facing, Grinding, Vertical milling, Grooving,
Threading, Parting, Slotting
 Production- Slab billets, Excavator
3. Shop 030-031
 Main processes: Milling, Hibbing, Grinding, Turning, Boring, Slotting
 Production: All types of gears
4. Shop 041-042
 Main Processes: CNC gas cutting sheet metal working, Welding, Sheet rolling &
punching, Planning
 Production: Fabrication assembled parts and components sheet metal works
5. Shop 043-044
 Main Processes: Planning, Turning, Boring, Tapering, Slotting, Grinding,
Threading
 Production: Assembled machine components after Machining as per requirement.

2.2 Machines used in this Plant
2.2.1 Lathe Machine
The lathe is a machine tool which holds the job between two rigid and strong supports
called centres or in a chuck or face plate which revolves. The cutting tool is rigidly held
and supported in a tool post which is fed against the revolving work. The normal cutting
operations are performed with the cutting tool fed either parallel or at right angles to the
axis of the work. The cutting tool may also be fed at an angle relative to the axis of work
for machining tapers and angles
2.3 Shop 010-011
1. Horizontal boring machine (M/C -1191)
Maximum Spindle diameter 320mm
Maximum Spindle travel 2.5m
Maximum Head travel 5m
X direction movement 8m
Feed rate 1-1.5mm/m
Table can be adjusted in 360 o
rotation
Operations: Drilling, Boring, Facing, Turning etc.
2. Vertical Turning & Boring machine (M/C No.1192)
Maximum job Height 3200mm
3. CNC Vertical Turning & Boring machine (M/C No.1262)
Maximum job height 4700mm
 Manually & automated
 3 Axis control

 Except shaping, slotting, planning all operation of lathe can be done.
4. Plano-Milling machine (M/C no.1170)
Table dimension 1800mm * 6000mm
Maximum height of job 1920mm
2.4 SHOP 021-022
Same type of machines which are available in Shop 011 are present in this shop. In this shop
medium weight type job is machined.
Some other machines which are available in this shop are:
1. Drill Machine
Maximum bore diameter 80mm
Column Height 2m
Operations- Rimming, Drilling, Taping, Threading
2. Slitter Machine
3. Shaper Machine
2.5 Shop 030-031 (Reduction Gear Shop)
2.5.1 Plant Specification:
1. Building area 8760m2
2. No. of machine tools 66
3. No. of unique machine tools 15
4. Maximum Plano-Milling capacity 8.5m * 2.5m * 25m
5. Maximum gear hobbling capacity 5.8m dia * 30 module
6. Induction hardening capacity maxim 5m(length) * 4m (dia)

2.5.2 Machine Tools:
1. Gear Hibbing Machine (Vertical & Horizontal)
2. Gear shaper Machine
3. Plano-Milling Machine
4. Planner Machine
5. Milling Machine (Horizontal & vertical)
6. Lathe (Caption, Turret, Centre)
2.6 Shop 041-042
In this shop sheet metal, fabrication and assembly of machine work is done.
2.6.1 Machine tools in the shop
1. CNC Flame Cutting
 Oxy-acetylene gas is used for cutting
 8-500mm thick job can be cut
 5 nozzle
 Cutting bed dimension- 6500mm * 25000mm
2. Shearing Machine(1Pc)
Sheet metal is being cut by machine by shearing process. It can cut from 1mm to 6mm
thickness. Maximum available shearing machine can cut up to thickness of 12mm. Cutting
tool is operated by Pneumatic.
3. Roller Straightening machine
This machine is used to straight the bended plate.
4. Radial Drilling Machine
5. Punching Machine

6. Bending Roll Machine
This machine is used to bend the plate into cylindrical shape.
Welding and fabrication is also done in this shop. Mainly Submerged arc welding, MIG welding
is done.
2.7 Product of HMBP plant
1. EOT Cranes:
HEC designs and manufacture heavy duty Electric Overhead Travelling cranes for
application in steel plants, Engineering sector, Space research application etc. The highest
capacity crane designed and manufacture so far is the 450T ladle crane to handle hot liquid
metal.
2. Mining Equipment
HEC pioneered the manufacture of heavy duty mining equipment in India and has supplied
over 260000T of equipment & components. Mining equipment supplied includes:
a) Power shovel 5CuM
10CuM
12.5CuM
b) Walking Dragline: HEC is the first Indian company to manufacture a walking
dragline of 24 CuM bucket capacity with 96m boom.
c) Crushers: A wide variety of crushing & grinding equipment is offered to meet the
requirements of ferrous and non-ferrous ore processing plants, cement, fertilizers,
chemical and coal Industries.
Types of crushers:
 Gyratory crusher ● Two roll crusher
 Cone crusher ● Single roll crusher

 Jaw crusher ● Four roll crusher
 Reversible hammer mill ● Rod mill etc.

3.0 Heavy Machines Tools Plant
3.1 Introduction
HEC manufactures machine tools in the heavier range that serve vital industries such as steel,
Railways, engineering, mining, defence, general workshops, space research & application etc.
HEC offers high precision machine tools of state of art design. In addition to the manufacturing
new machine tools, HEC also provides refurbishment and rebuilding services.
HMTP consists of following shops:
1. Shop 13
Main Processes: Turning, Milling, Gear hobbing, heat treatment, Carburizing, Lathe
operation
2. Shop 15
Main processes: Machining operations like planning, milling, boring, grinding, honing,
CNC operation
3. Shop 17
Main processes: Assembly of various components to form machine as per order of
requirement done in this section.
3.2 Products
Both CNC & conventional machine tools:
 Vertical Turning & boring machine
 Heavy duty centre lathe
 Double Column Plano milling machine
 Double Column milling machine
 Radial drilling machine
 Horizontal boring & milling machine

Inferences
How would you begin building a nation plagued with?
 too much diversity,
 over 75% illiteracy,
 almost no human resources and
 no unifying identity
And you need to make it self-sufficient.
1. Indigenous development
2. Production of Machines.
3. Rapid Industrialization.
Jawaharlal Nehru, our first Prime Minister built Industries. Technical Colleges. Steel Plants.
Nuclear power plants. He built cities and integrated townships with quarters and schools for all
employees. He did all this to inculcate Scientific thought. And to bring the poorest out of the loop
of poverty.
Once we enter HEC we see the Nehruvian dream in action. Here is a purpose for a company.
Heavy Engineering Corporation - builds machines that build the nation.
A large corporation to supply machines to all our steel plants. Integrated plants to produce any
kind of equipment from Space to Nuclear power. Train lines inside the plant to make sure raw
material reaches it easily. Quarters for all workers, Wide, clean roads, footpaths.
Bureaucracy, seniority, scheduled caste Politics, Backward Politics and a log jam of un-updated
Socialist policies have led to HEC's decline.
In the 30 days I spent at HEC, all I heard from all its employees was praise and a feeling of
appreciation for everything H.E.C. has done for them. The 30 days I spent has given me a
transformative experience about the inner working of Industries.

Bibliography
1. www.wikipedia.org
2. www.hecltd.com
3. Foundry Technology by Peter Beeley

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