1. 1
A PROJECT REPORT ON
“Modification of plant layout prior to safety and production rate.”
Submitted by
Modi Hardik A. (090430125061)
In the fulfillment for the award of the degree
Of
BACHELOR OF ENGINEERING
In
PRODUCTION ENGINEERING
SHANTILAL SHAH ENGINEERING COLLEGE, BHAVNAGAR-364060
Gujarat Technological University, Ahmadabad-Gujarat, India. 2012-13.
2. 2
IDP/ UDP Project Statement Form
STUDENT PARTICULAR
NAME MOBILE NO EMAIL ID
1. Modi Hardik A. 9429542460 hardikmodi024@gmail.com
COLLEGE
NAME Shantilal Shah Engineering college
COLLEGE
CODE 043
BRANCH Production
SEM. 8 YEAR 2013
TEAM
CODE Production-43
SIGNATURE
OF
STUDENTS
3. 3
INDUSTRY PARTICULARS / USER’S DETAIL
INDUSTRY DETAILS
NAME Ratnamani Metals & Tubes Ltd.
ADDRESS Plot no. 3306 to 3309, GIDC Estate, Chhatral Phase-IV,
Ahmadabad -Mehsana Highway, Chhatral, Kalol.
Dist : Gandhinagar, Gujarat-India-382729.
CONTACT
NO.
OFFICE (02764) 232234
MOBILE -
NAME OF INDUSTRIAL
ESTATE
Chhatral GIDC, Kalol.
COMPANY LOGO
( optional)
INDUSTRY GUIDE DETAILS
NAME Geetesh Mehta
MOB : ****
EMAL ID geeteshmehta2001@gmail.com
4. 4
TITLE OF PROBLEM / PROJECT
“ MODIFICTION OF PLANT LAYOUT PRIOR TO SAFETY & PRODUCTION RATE”
DICIPLINARY | INTER-
DICIPLINARY PRODUCTION/PRODUCTION
DISCIPLINE PRODUCTION ENGINEERING
5. 5
SHANTILAL SHAH ENGINEERING COLLEGE,
BHAVNAGAR-364060
¤¤¤CERTIFICATE¤¤¤
This is to certify that the dissertation entitled
“Modification of plant layout prior to safety & production rate” has been
carried out by Modi Hardik under my guidance in fulfillment of the
degree of Bachelor of Engineering Production Engineering (8th
Semester) of Gujarat Technological University, Ahmadabad during the
academic year 2012-13.
Internal guide Head of the department
Dr. M.G. Bhatt
Internal Examiner External Examiner
6. 6
Feb 08, 2013
CERTIFIACTE
This is to certify that Mr. Hardik A. Modi student of B.E Production Eight semester
(Shantilal Shah Engg. College at Bhavnagar) has successfully completed his
industrial (project) training at our organization from 3rd
Jan. to 2nd
Feb.2013 for
30 days.
We wish him all the best in his future career pursuits.
For, Ratnamani Metals & Tubes ltd.
Jignesh P. Barot
Sr. Officer (Human Resources)
7. 7
ACKNOWLEDGEMENT
We feel immense pleasure in completing this training and submitting this
report. The whole internship period with Training Engineers has been full of learning
and a sense of contribution towards increasing the practical knowledge. I would like to
thank Mr.Gitesh Mehta for giving me the opportunity to complete my training in such a
good organization.
A successful training can never be completed by the efforts of a single
person, but it also demands the help and guardianship of some conversant person who
helped the undersigned actively or passively in completion of successful training. During
the actual training Dr.M.G Bhatt. (Head of Production Department) has been a source
of inspiration through his constant guidance, personal interest, encouragement and help. I
would like to convey my sincere thank to him.
I wish to thank the principal Prof. M.V.Bhatti and all the staff members of
Production Dept., Shantilal Shah Engineering College., for their co-operation, guidance
and support during the work.
Yours Sincerely,
Modi Hardik.
8. 8
INDEX
SR.
NO
DEATAIL PAGE NO
1. Introduction of Ratnamani 11
4. Company product 12
5. Manufacturing process 13
6. Problem summery 16
7. Detail Description of problem 17
8. Possible Solutions 23
9 Detailed description of solution 26
10. Reference 31
9. 9
Introduction of Ratnamani
Since its inception in 1985, accepting challenges and ensuring
customer delight has been the hallmark of Ratnamani. In just two decade,
Ratnamani has grown to become a multi-product, multi location public
limited company providing total piping solutions to a diverse range of
industries.
Ratnamani’s manufacturing facilities employ state-of-the-art technology to
produce a wide range of Stainless Steel Welded / Seamless Tubes & Pipes
and Carbon Steel Welded Pipes.
The company caters to the niche markets of almost all the emerging sectors
like oil and gas, refineries, petrochemicals, process industries, power plants
and water distribution.
This has been made possible by continuous innovation and focused vision of
the management.
Ratnamani follows a total quality approach and its products conform to the
highest international standards.
The company’s unflinching commitment to delight customer has ensured
client loyalty.
The company uses green power and has a robust safety, health and
environment.
The company make mainly three type of pipes according to :
API (American Petrolium Institute) – For various chemicals,acids.
ASTM(American Standerds for Testing of Materials) – For high pressure
gas, fuels.
IS(Indian Standerds) – For sewage and water supply.
10. 10
Company Products
(1) ERW/ HFW Pipes
RATNAMANI has diversified into manufacturing of Carbon Steel High
Frequency Welded (HFW) / Electric Resistance Welded (ERW) Pipes with
an annual installed capacity of 150,000 MT.
HFW pipes are made from hot rolled flat steel strip, formed into tubular
shape and the longitudinal seam is welded by the application of heating the
edges through High Frequency Induction coil and by squeezing the edges.
The weld joint is achieved without addition of any filler metal.
(2)Submerged Arc Welded (SAW) Pipes
RATNAMANI’s Carbon Steel SAW Pipe manufacturing division consist of
a JCO Press
Helical / Spiral Mills, number of Three Roll Plate Bending Machine, Inside
outside welding lines, Heat Treatment Furnace and all necessary Testing
Equipments to produce high quality pipes confirming to various International
Standards.
These facilities are capable of manufacturing in various grades.
The pipes are supplied according to appropriate standards as well as
customer specifications in a large variety of steel grade and dimensions.
Specific requirements on execution, tolerances, lengths, mechanical and
corrosion properties are offered on request.
11. 11
Process Description
Firstly the plate is cut to Desire Width for making required diameter of pipe in
Right angles to each other.
AC² = AB² + BC²
For this one side of plate is cut by Gas cutting process using oxygen and LPG.
After that marking of desired width and rectangular measurement is marked on
plate. And then plate cutting as per marking is done.
12. 12
Width of plate is given as per following formula:
W= (O.D.-t) × π where, O.D. = Outside diameter
t = Thickness of plate
π is taken as 3.1416.
Then Edge preparation on plate is to be done by Edge cutting machine, Gas
Cutting or Grinding. Plate is made in fillet on both sides in edge preparation, as
well as both faces are grind for higher thickness.
Generally edge preparation done at 300
to 37.50
degree.
Then forming of plate is done by forming press. But for higher thickness
crimpling process is done on plate on both side 150 mm form both ends of plate.
13. 13
After crimpling the forming is done by J.C.O. process on Forming Press.
After forming plate will take form of pipe by sizing and take welding. Tack
welding is done by Gas Metal Arc Welding using copper rod of 1.2 mm or 1.6 mm
and CO2 as inert gas.
After it pipe is precede for SAW welding and then quality assurance.
14. 14
Problem Summary
We had visited industry named Ratnamani Metals & Tubes Ltd, produce
long seam welded pipes of carbon steel pipe which is used for supplying of various
chemicals, high pressure gas, water, etc.
At the plant we observe that the pipe after completion of forming & sizing process,
sent for backchip process on grinding m/c for making V-Groove on edge sides of
pipe. Due to generating V-Groove we can fill more welds which cause
strengthening the seam of pipe.
Backchip process on grinding m/c is one type of material removal process which
makes much more noise, as well as producing long range sparks which leads to
safety problem of employers.
Because of Noise & long range sparks of m/c the workers properly can’t give
attention on their task, feel awkwardness, scariness against spark to stand around
that m/c, circulation of materials & workers is not smoother. This is hazardous&
unobvious matter for workers.
So this matter influence the production time which cause production rate.
16. 16
As shown in above plant layout the various operation are held in sequent.
But as in fig. after the processing of forming, welding, sizing, the Backchip
process is executed.
As we know that backchip process is held for removing of C02 welding
which was filled between side edges of pipe for jointing purposes.
After it is removed with the help of grinding machine.
And making V – Grooves for filling more weld materials which cause
increase the strength of pipe.
But at this process the two main problems are occurred.
The first one is producing noise which cause damaged to hearing ability.
Due to noisy atmosphere worker can’t hear instructions of their seniors.
Because of its either worker or engineer has to go that particular destination
& speak loudly with each other.
Their unexpected circulation leads to time wastage which also affect on
production rate, quality.
Here representing some important data about noise levels prior this grinding
machine.
In the table we can see that how much noise producing by grinding machine
according comparison of other sources of sounds it shows that what’s level
of intensity of grinding machine which causes harm to ear of workers.
17. 17
Table of sound levels L (loudness) and
corresponding sound pressure and sound intensity
Sound Sources (Noise)
Examples with distance
Sound Pressure
Level Lp dB SPL
Sound Pressure p
N/m2 = Pa
sound field quantity
Sound Intensity I
W/m2, sound energy
quantity
Jet aircraft, 50 m away 140 200 100
Threshold of pain 130 63.2 10
Threshold of discomfort 120 20 1
Grinding, 1 m distance 110 6.3 0.1
Disco, 1 m from speaker 100 2 0.01
Diesel truck, 10 m away 90 0.63 0.001
Kerbside of busy road, 5 m 80 0.2 0.000 1
Vacuum cleaner, distance 1 m 70 0.0063 0.000 01
Conversational speech, 1 m 60 0.02 0.000 001
Average home 50 0.00063 0.000 000 1
Quiet library 40 0.0002 0.000 000 01
Quiet bedroom at night 30 0.00063 0.000 000 001
Background in TV studio 20 0.0002 0.000 000 000 1
Rustling leaves in the distance 10 0.000063 0.000 000 000 01
Threshold of hearing 0 0.00002 0.000 000 000 001
18. 18
The other problem is when the grinding process is on due to material
removal process the long range sparks are producing which disturbing
concentration of workers on their work.
How long can a person endure a certain noise level
Sound Pressure Level Sound pressure Permissible Exposure
Time
115 dB 11.2 Pa 0.46875 minutes (~30 sec)
112 dB 7.96 Pa 0.9375 minutes (~1 min)
109 dB 5.64 Pa 1.875 minutes (< 2 min)
106 dB 3.99 Pa 3.75 minutes (< 4 min)
103 dB 2.83 Pa 7.5 minutes
100 dB 2.00 Pa 15 minutes
97 dB 1.42 Pa 30 minutes
94 dB 1.00 Pa 1 hour
91 dB 0.71 Pa 2 hours
88 dB 0.50 Pa 4 hours
85 dB 0.36 Pa 8 hours
82 dB 0.25 Pa 16 hours
19. 19
As shown in layout, no. 7 process of back chipping is executed after tack
welding and sizing.
If we do not remove the CO2 welding then it will become obstructions
for saw welding as well as various tests like X-ray radio grapy, M.P.T.,
Ultrasonic tests, etc. So we have to remove CO2 welding.
In short it is basically a material removal process.
But in this process the long range sparks are producing which are very
harmful for workers.
Because of these sparks workers of around the no.7 place can’t
concentrate on their work.
No any barriers or anything provided for preventing these sparks.
So they feel awkward to do their work. Workers can’t move easily from
their desired place.
Also the material circulation is become difficult & this takes more time.
Which influence the production time.
This is due to the place acquired for it is very small.
As shown in fig. the other place of no. 8, 6, 12, 3, and 2. Which are
around the no.7 0f backchip process all these workers have fear about
the generated sparks.
If we consider place of 7 and 12. The hydro test is held at no.12.
20. 20
In hydro test the pipe is filled with water at extreme pressure for
leakage testing.
So at the testing time the concentration is very much required yet the
back chipping process may disturbed them and then it convert
mistake.
The small mistake get converting into blasting of pipe.
The blasting of pipe is very hazardous for not only workers but also
for whole plant. So this need to improve safety standards.
Now if we consider the place of 2, 3, 8, as shown in below fig.
The internal welding held at no.8, crimping press at 3, and beveling is
at 2.
These all are connected with high tension electricity power supply if
any spark touch the wiring of these machines then it becomes in shot-
circuited.
Which is very dangerous for workers.
Addition to these the no. 6 place is also influenced by this problem.
All workers don’t have safety goggles ear-plugs, tight clothes,
industrial shoes etc. which comes under safety standards.
So the misallocated backchip process is significant problem of the
industry prior to workers’ safety.
22. 22
Here we have two problems one of its producing more noise & second one is
producing long range sparks.
For solving this problem these are some suggestions:
Suggested solution (1)
Company provide already ear- plug but to limited men, so we have to
use higher quality ear plug which are capable to prevent the sounds
upto 110 dB
.
But on the basis of gathered information the ear plug can prevent noise
upto 34 dB.
Suggested Solution (2)
Company can use high quality sound absorber which are very useful for
diminish the some quantity of sound. But second problem can’t be
solved. .
Suggested Solution (3)
This machine place should be covered by air-tight glass for preventing
noise as well as long range sparks to go out. But the pipes are in giant
size so the glass may be broken in circulation or moving of material.
So glass chamber are not acceptable.
23. 23
Suggested Solution (4)
Company can use some barriers of metal sheets for preventing sparks
but noise can’t be prevented.
For safety against sparks goggles, tight denim clothes provide to
workers.
The workers which are work at & around the grinding operation should
wear tight cloths
Suggested Solution (5)
And the important suggestion is as name of our project is the
modification of plant layout.
As shown in plant layout of company the company has large open
space behind the place no. of 4, 5, 11, and 14.
If we use this open space for transferring the grinding operation and
other processes for maintaining the sequence of all operations.
With the help of this modification we can solve the problems which are
illustrated above.
26. 26
As a part of semester-8 project we here trying to show the modified
layout of plant.
After studying, out of other suggested layout this layout is best suited.
Because main two problems are solved by this modified layout.
Here we transfer the location of Backchip operation as shown in fig.
But only transferring of location of backchip operation is not possible
for it we change the other operation’s location like sizing ovality, Tack
welding, CO2 welding, surface finishing.
For maintaining of operation sequence these three location had to
change.
This modification is possible because of there is availability of large
space.
We use this un-useful space for transferring the operations. Which are
shown in fig.
Before changing After Changing
After comparing these two figures the proper utilization of open
space we can see.
The Backchip operation is now separated from other operation and
keeping safe distance from another operation by providing open space
at between of operation no. 8,912,13,14 and 7 which cause to reducing
noise to surrounded workers.
So our two said problems can diminish by this way.
27. 27
For more ensure we also change the location of parking and
Administration dept. as in fig.
Before Changing After Changing
The reason behind to interchange parking and admin. Is making more dist
from manufacturing, because admin dept. require some of quietness so if we
make parking between mfg. and admin then dist automatically increase and
noise can be avoid for admin dept.
Benefits of modified plant layout
(Approach to increasing Production rate)
As discussed earlier we can solve the problem of noise and long range
sparks produced by backchip operation which cause to affect
production rate.
The permanent solution leads to increasing production rate.
when the long range sparks produced at backchip operation the
workers don’t concentrate on their work so it influence on quality of
work and speed which leads to wastage of material and production
time respectively
After solution workers can be focus on their work which leads to
production rate.
This not only for workers doing work on grinding operation but also
for surround workers like workers of hydro testing, sizing & ovality,
Internal & External welding, plate edge beveling, crimping these all
workers feel awkwardness and scariness during working due to noise
and sparks.
28. 28
After solution these all surround workers can work in nice mood as
well as giving good performance because of no any disturbance or
obstructions.
So workers have good mental condition while working which leads
to decrease tense atmosphere.
The decreased noise is also desirable for test dept. like hydro test &
Ultrasonic test.
Hydro test. Dept. workers get freedom from these two problems and
can do work very easily, because Hydro testing is most sensitive part
of the mfg. process.
Man & Material circulation can be done easily.
Material handling becomes easier because of satisfied condition of
sequence of operation
Due to noise intercommunication was very difficult but after changing
the place of this backchip operation communication between
supervisors & workers become smooth.
The sequence of operation becomes easier because of acquiring
more space.
Operation sequence plays an important role in production and here
We can maintain this sequence so production becomes smoother
which increase production rate.
So this modified plant layout helping to maintaining safety matters and
also production rate.
Thus we can achieve the title of our project Modification of plant
layout prior to safety & production rate.
29. 29
Refrences
www.Ratnamani.com
Brochure of Ratnamani metals & tubes ltd.
www.gtu.ac.in (GTU INNOVATION COUNCIL)
www.sengpielaudio.com/TableOfSoundPressureLevels.htm
Our professors.
www.steel-pipes-tubes.com
THE END
