HEC Ranchi Project Report

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In plant training report by Ravi Singh Choudhary MT 2017
Induction
Training Report
From 16.02.2017 to 17.03.2017
By Group 10, MT 2017
Group leader: Ravi Singh Choudhary
Under the Guidance of
S. Subramaniam Sir

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ACKNOWLEDGEMENT
I would like to show my greatest appreciation to the highly esteemed and devoted technical staff,
supervisors of the Heavy Engineering Corporation Limited, Dhurwa, Ranchi(Jharkhand). I am highly
indebted to them for their tremendous support and help during the completion my training.
My special thanks go to Mr. S. Subramaniam, Sr. Dy General Manager, HEC Ltd. for acceptance my
request for providing initial guidance for the visit to the company. I would like to thank all those people
who directly or indirectly helped and guided me to complete my training, including the following
instructors and technical officers of various sections.
Ravi Singh Choudhary

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Index Pages
Introduction 4
Journey of Corporation 5
Products of HEC 6-36
Plant Layout and Facility 37-58
Work Flow 59
Quality control and assurance & ISO Standards 60
Corporate Planning 61
Journey towards diversification 62
Awards 63
Health, Vision, Policies 64
Company ethics 65
Organization chart 66

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Introduction
Manufacturing involves turning raw materials into finished products to be used for some purpose.
That manufacturing or process plant itself requires machinery which is made by HEC. The tagline
itself says HEC builds an industry that builds the nation. The word “heavy” used here
means the manufacturing unit which cannot be assembled in plant shop floor.
HEC has facilities starting from steel melting, casting, forging, fabrication, machining,
and assembly & testing.
A detailed understanding of the manufacturing processes is thus essential for all engineers. This
helps them appreciate the capabilities, advantages and also the limitations of the various
manufacturing processes. This in turns helps in the proper design of any product required by them.
HECL Ranchi is well connected to the city so it can be considered as a Strategic location for the
country.

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Journey of HEC Ranchi
It was founded primarily to facilitate manufacture of steel plant equipment indigenously, HEC has
made an immense contribution in setting, expansion, 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. Heavy Engineering Corporation Ltd., is the
supplier of capital equipment in India for steel, mining, railways, power, defense,
space programs, nuclear and strategic sectors. It also executes turn-key projects from
concept-to-commissioning. Set-up in the year 1958.
The land is the hottest subject since the new Union government took over last year. Should the
farmer give up land or not, and if so, how and for how much, are all questions exercising the minds
of policy makers. But far away from the din of politicians and their polemics, a public sector
company is defying all the logic of land acquisition.
The land was acquired from 23 villages, obviously evicting farmers and tribal to set up Heavy
Engineering Corporation (HEC) in 1958, a mammoth company that was to produce heavy
machinery, equipment.
Acquisition spree went on from 1959 to 1973. The final handover of the “Conveyance deed” was
signed between Bihar government and HEC on February 26, 1996. Soon the new state of Jharkhand
was created, and its government began functioning out of the HEC campus. This was an opportunity
for the company which held 7000 acres of land encompassing the capital city of the new state.
In 2009, HEC’s revival package involved the sale of 2342 acres of land to the Jharkhand
government, which was paying Rs. 275.51 crore.
India’s Globalisation Policy of 1992 had hit hard to HEC primarily since then it incurred losses but
somehow got success in taking big projects and after introduction of Make in India Concept HEC is
hopeful for its future endeavours.

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Products of HEC
Steel and Metallurgical plant equipment
Mining and mineral processing equipment
Machine Tools
Defense and Strategic Sectors
Heavy Castings and forgings

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Steel and Metallurgical Plants Equipment’s
Blast Furnace
Blast Furnace (Volume 1719, 2000, 3200 CuM): Supplied to BSP, BSL, VSP and exported to
Turkey & Egypt. Supplies include:
 Technical Structure
 Ch. Column & Plants
 Cooling Plates
 Charging Arrangements
 Charging Distributors
 Skip winch
 Belt Control Winch
 Valves
 Rolling Stocks etc.
 Cast House Machines
 Pig Casting Machines etc.
Coke Oven
Batteries
Blast
furnace
Continuous
Casting
Machine
Steel
Melting
Converters
Forged
Rolles

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Coke Oven Batteries
Coke Oven Battery (4.3 M to 7.0 M high) :Supplied to BSL, BSP VSP, DSP and Exported to
Turkey, Egypt, USSR & Sri Lanka. Supplies include:
 Coke Pusher, Coal Charging Car, Coke Guide Car, Coke Quenching Car, Red Hot Coke Car
 Traveling hoist, Charging Hoist
 Charging Device
 Discharging Device
 Door, Frame, Flash plate and Sealing Frames
 Buck stays, Anchorages and Tie Rods
 Gas Collecting Mains and Cross Over Gas Mains
 Reversing Winch
 Skip Hoist
 Coal Tower Gates
 Primary Gas Cooler and Benzol Stripping Column
 Bend and Valve Assembly
Coke Oven Machine for Bhilai Steel Plant
Remote Controlled Wagon Pusher Hot Coke Car

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Continuous Casting Machine
Continuous Casting Machine/Plant: Supplied to RSP, BSL, BSP & VSP for Turnkey Project
execution/equipment.
MACHINE EQUIPPED TO CAST:
Slab Thickness 180 mm - 210 mm
Slab Width 800 mm - 1300 mm
Length 600 mm 800 mm
Cutting Length at Slab Sizing Unit 2200 mm - 2800 mm
SPECIFICATIONS OF SLAB CASTER:
Machine Radius 10 m
Machine Support Length 21 m
Maximum Casting speed : For 180 mm thick slab 1.5 m/min
For 210 mm thick slab 1.3 m/min
Maximum Machine Speed 2.5 m/min
Annual Output 1 million tones
Grade of Steel Cast Low & Medium carbon steel
Bit Speed 0 - 150 rpm infinitely variable
Bit rated torque 950 Kg M at 100 rpm
Crawled Heavy duty individually drove
by electric motor
Air Compressor 28 M3/min at 7kg/cm2

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Segments for Continuous Slab Caster Ladle Turret for RSP
Steel Melting Converters
Steel Melting Converters: Supplied to BSL, BSP, VSP, DSP, RSP, Malvika steel plants,
Indomag( Jindal) 5 nos. Converters and 10 nos. Mixers supplied.
L.D.Convertors 55T, 100T & 130 T
Hot Metal Mixer 600T, 1300T
Self-Propelled Transfer Car 130T
Steel Ladle transfer car 50T, 100T, 200T, 250T, 300T
Hot metal transfer car 100T, 140T
Slag Pot transfer car 16M3, 18M3
Ingot Mould car 160T, 180T
Ladles & Stands 40T to 100 T

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120 T Hot Metal Ladle Slag Ladle Car
Forged Rolls
Rolls: HEC is a pioneer in manufacturing of Forged Rolls in India and is a regular supplier to
major Steel plants of India. Dedicated facilities have been created for Induction hardened
CRM rolls. Stringent quality control ensures High-Quality Rolls.
INDUCTION HARDENED FORGED ROLLS:
Type Max Dia (mm) Max length(mm) Wt. (T) Hardness (shore)
HRM Rolls 1350 6000 35 45
CRM Rolls 600 6000 15 upto 100
Around 3800 nos. Rolls (CRM & HRM) supplied to various steel plants like:BSL, BSP, VSP,
DSP, RSP, TISCO, Jindal, Steelco, Balco, Tinplate, Nippon Dendro etc.
120 T Hot Metal Ladle

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Other Equipment to Steel Sectors
Sinter Plant Equipment
(75312 sqm)
24 nos. supplied to BSL,BSP, VSP,Turkey, USSR.
General Purpose & Steel
Plant Cranes
300 nos. supplied to BSL, BSP, VSP, (upto 450T capacity) RSP,
TISCO, BHEL, CIL, Malvika steel
Slag Cups Supplied to BSL, BSP, VSP, DSP, RSP, TISCO.
Machines Tools 150 nos supplied to BSL, BSP, VSP, RSP, TISCO, NINL
Rolling Mills of various
types & sizes
19 nos. including 3600 MW wide plate mill
Mixer (600 to 1300 T) 10 nos.
Steel Melting Converter (55
to 300 T)
10 nos.
Bull Gear Assembly (72T) Mill Stand for RSP

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Mining and mineral processing Equipment
Electric Rope Shovels (5 CuM)
Rugged design is suitable for mining Coal, Iron ore and other minerals in open cast mines.
Easy to maintain and one of the most reliable shovels in this capacity range.
HEC supplied over 550 shovels for various mining organisations in India and treated as one
of the most reliable mining shovels operating in Indian mining condition.
IMPORTANT PARAMETERS:
Bucket Size 5 CuM
Boom Length 10.5 M
Max. Digging Radius 14.4 M
Max. Digging Height 10.3 M
Max. Dumping Radius 12.65M
Max. Dumping Height 6.7 M
Hoist Force 45 T
Crowd Force 20.5 T
Electric
Rope
Shovels (5
CuM)
Dragline
s
Electric
Rope
Shovels
(10 CuM)

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 Individual DC drives for main mechanisms - hoist, crowed and swing / travel system.
 MG set with 250 KW squirrel cage induction motor as prime mover and 3 DC generators, one each for hoist,
crowed and swing / travel system.
 Magnetic amplifier controlled.
 Electrical supply 3.3 / 6.6 KV, 50Hz, 3
Electric Rope Shovel (10 CuM)
Highly Productive & reliable machines for Mining Operation. Over 30 numbers supplied to
Indian Coal Sector.
Bucket Size 10 CuM
Max. Digging Radius 17.12 M
Max. Digging Height 13.03 M
Max. Dumping Radius 14.61 M
Max. Dumping Height 14.27 M
Av. Cycle 28 sec
Hoist Motor 477 kw
Crowd Motor 97 kw

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Propel Motor 190 kw
Swing Motor 2x97 kw
Power supply 3.3/6.6 Kv, 3, 50Hz
MG set - for DC supply to main mechanism motors.
Draglines
HEC is the first Indian company to manufacture walking Dragline of 24 CuM Bucket
capacity. 12 nos. of Draglines of 24 /96 and 3 nos. of 20 / 90 Draglines supplied by HEC to
Indian Mining industry.
Bucket capacity 24 to 34 CuM
Boom length 74.6 to 95.6 m
Boom angle 300 / 380
Operating radius 64 to 88 m
Dump height 25.5 to 48.1 m
Digging depth 46.2 to 74.5 m
Base diameter 15.25 m

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Bearing area 182.65 sq.m
Average bearing pressure 0.95 kg / sq.cm.
Walking shoe bearing area (for2) 95.2 sq.m.
Walking speed (appx) 0.24 kmph
Hoist & Drag powered by 1300 HP motors, 2 for each systems.
Devised with MG set, all motions are powered by adjustable armature DC generators.
2 MG sets each driven by 1750 HP synchronous motor.
MG set - for DC supply to main mechanism motors.

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Machine Tools
Vertical Turning & Milling Machine
6 Axis CNC Double Column Vertical Turning & Milling Machine (BV 40 / 50 NM) supplied to
Vikram Sarabhai Space Research Centre
Vertical Turning &
Milling Machine
Lathe
Roll Grinding
Machine
Deep Hole Boring
Machine
Horizontal Boring
Machine
Horizontal Boring
Machine
Special Purpose
Railway Machine
Tools
Plano Milling
Machine
Planning Machine
Radial Drilling
Machine

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3 Axis CNC Single Column Vertical Turning & Milling Machine (BVS 55 / 70 NM)
2 Axis CNC Vertical Turning Machine
(Mono-block type BV 5 - 16 NS)
CNC Double Column Machine Specification:
 Table Diameter : 3 to 5 meter
 Max turning diameter 4 to 6 meter
 Max turning height 3.1 to 4.2 meter
 Max weight of workpiece 30 to 80 MT

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Vertical Turning Machine
CNC Single Column Machine Specification:
 Table Diameter : 2 to 5.5 meter
 Max turning diameter 4 to 7 meter
 Max turning height 1.6 to 2.85 meter
 Max weight of workpiece 20 to 50 MT
Lathe
CNC Centre Lathe (LC 100 N)
CNC Centre Lathe Specification:
 Swing over Carriage 650 - 1000 mm
 Distance between centers 3 - 6 meter
 Max. wt of workpiece 8 - 15 MT
 CNC System - Fanuc / Siemens (2 axes)
 Centralised lubrication
 8 station programmable turret

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 2 Stage high-efficiency transmission headstock
 Spring clamped - Hydraulic unclamped tail stock
CNC Roll Turning Lathe with 4 Guideways (LTR 160 N / 8M), Swing over bed : 1600 mm
CNC Roll Turning Lathe specification:
 Swing over Carriage 650 - 1600 mm
 Distance between centers 3 - 10 meter
 Max. wt of workpiece 8 - 50 MT
 CNC System - Fanuc / Siemens (2 axes)
Conventional Lathe Conventional Lathe
Roll Grinding Machine
SPECIFICATION:
 Max. diameter to be ground : 575 - 1600 mm
 Distance between centers 2 / 3 to 6 / 7 M
 Max. weight of roll 3 to 6 T
 Rigid design for better efficiency & accuracy

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 Accurate concave & convex grinding
 Electronic / mechanical feed counter for pre-selection of cross feed
 Built in dynamic balancing device
 Automatic feed at reversing points
 Automatic cut-off device for grinding wheel
 Automatic wheel wear compensation
Deep Hole Boring Machine
CNC DEEP HOLE BORING MACHINE SPECIFICATION:
 Max. Solid drilling diameter 200 mm
 Max. Trepanning diameter 350 mm
 Max. Counter boring diameter 350 mm
 Max. Boring depth 12000 mm
 Swing over bed 1400 mm
 Mx. Wt. Job 15 MT
CNC Deep Hole Boring Machine BDH 140 N

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Horizontal Boring Machine
CNC HORIZONTAL BORING MACHINE SPECIFICATION:
 Boring spindle diameter 100 mm
 Max spindle travel 900mm
 Headstock vertical travel (Y-axis) 1120 mm
 Moving column type design
 Highly rigid construction
 Automatic clamping/unclamping of ISO-60 tooling facility
 Circulating lubrication system for H/S & Feed gear box.
Horizontal Boring Machine (BH-100 N)
Radial Drilling Machine
SPECIFICATIONS:
 Max. dia Drilled in steel 80 - 100 mm
 Min. distance of axis of spindle to column 530 mm
 Max. distance of axis of spindle to column 2520 / 3070 and 3620 / 4470 mm
Radial Drilling Machine(DR 8A)

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Planning Machine
SPECIFICATIONS:
 Planning width 1400 - 2000 mm
 Planning length 3000/ 4000 - 12000 mm
 Planning height 900 - 2000 mm
 Max. work weight per meter of planning length 2 MT
 CNC System Fanuc / Siemens (2 Axis)
Double Column Planning Machine (PD 16)
Plano Milling Machine
SPECIFICATIONS:
 Max. Milling width 1250 - 2000 mm
 Max. Milling length 10000 - 12000 mm
 Max. Job height 1250 - 2000 mm
Plano Milling Machine

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Special Purpose Railway Machine Tools
CNC UNDER FLOOR WHEEL LATHE:
 Gauge 1676 mm
 Max./Min. tread dia 1250 / 700 mm
 Uncoupled axle distance 1600 mm
 Coupled axle distance 1500 - 2650 mm
 Max. Axle load 25 MT
 Max. Axle load 1889 - 2750 mm
CNC Under Floor Wheel Lathe (LUW 176 N)
CNC SURFACE WHEEL LATHE:
 Gauge 1676 mm
 Max./Min. tread dia 1250 / 700 mm
 Max. axle distance 2750 mm
 Min. axle distance 1850 mm
 Max. weight of wheel set 3.5 MT
CNC Surface Wheel Lathe (LW 200 N)

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Castings and Forgings
Steel Castings
Heavy Steel castings of piece weight 65 Ton finished weight (as cast weight up to 90 Ton)
(facility of liquid metal up to 120 T)
TYPICAL STEEL CASTINGS PRODUCTS ARE:
 Slag cups for Steel Plants ( 11/15/16/18 CuM )
 Roll chocks
 Roll mill housings
 Cement plant tyre (upto 45T piece weight and 6m dia )
 Cyclotron Magnet poles
Bottom Housing of Pinion Stand (Steel Casting, 65 T) Spindle Stand
Steel
Castings
Steel
Forgings
Gray Iron
Castings
Non-ferrous
Castings

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Mill Housing (Steel Casting) 20 CuM Slag Cup
Steel Forgings
Forgings of various grades of alloy material up to piece weight of 65 Ton finished wt.
Complete with heat treatment and machining.
 Forged Rings up to diameter : 4.2 M
 Die forgings
75 T Ingot under Forging Spindle for Hot Strip Mill (Steel Forging)
Forged Ball (1.35 M diameter) Ring Forging (4.2 M diameter)

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Gray Iron Castings
Iron castings of piece weight 70 Ton finished wt.
 Centrifugal Casting
TYPICAL IRON CASTINGS PRODUCTS ARE
 Coke Oven door bodies, door frames and flash plated for Coke Oven upto 7 m height.
 Base plate for Blast furnace stove
 Grate bars
Non-ferrous Castings
 Non-Ferrous Castings of piece weight upto 4 Ton (Click for forging facilities)
 Centrifugal Casting
 Copper based castings upto 2 Ton piece weight
 Aluminium based castings up to 300 Kg. piece weight
TYPICAL IRON CASTINGS PRODUCTS:
 Hollow Shaft for Stripper Crane Bushes, machine components, etc.

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Defense and Other Strategic Sectors
Crushing Equipment
Primary Gyratory Crusher
Designed for heavy duty services and stable product size. Supplied over 12 nos for Coal and
Iron ore crushing.
PGC 1500
Feed opening 1500 mm
Nominal Discharge 160-200 mm
Capacity (CuM/hr) 1450
Main Drive Motor 400 kw
Weight of Crusher 428 T (without electrics)
Cone
Crusher
Primary
Gyratory
Crusher
Four Roll
Crusher
Reversible
Hammner
Crusher
Other
Crushing
and
mineral
processing
products
Rod mill

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 Wide range of models with receiving opening ranging from 1350 to 1500 mm
 Adjustment provision for discharge setting to compensate wear & tear of concaves & mantel.
 Spider suspension of the main shaft assembly.
 Optional duel prime movers
 Different models available for various output range.
Cone Crusher
Cone Crushers both for Secondary & Tertiary Crushing suitable for ore dressing for
application in ferrous and non-ferrous metallurgical works, cement plants, and
construction material plants.
SHC 2200
Feed opening 130 mm
Discharge Opening 5-15 mm
Recommended deed size 100 mm
Output (CuM/hr) 75 – 220
Weight of Crusher 82 T (without electrics)

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Four Roll Crusher
For fine crushing of coke etc. for Sintering and other applications. Two stage crushing made
possible in one unit. Available in various capacity range.
900 x 700
Recommended Feed size Up to 40 mm
Diameter of Rolls 900 mm
Width of Rolls 700 mm
Other Drive 15/23 kw
Weight of machine 28.5 T (without electrics)

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Reversible Hammer Crusher
Applicable for the secondary & tertiary crushing of medium hard materials such as gypsum,
limestone etc. and bituminous coal. Designed for achieving very high reduction ratio.
Available in various models with capacity ranging from 80 to 550 T / Hr. (Coal).
155 x 1500
Diameter of Rotor 1500 mm
Width of Rotor 1500 mm
Recommended Mx. feed size 120 mm
Product size(coal) 0-3 mm
Capacity 350-550 T/hr.
Other Drive 15/23 kw
Weight of machine 28 T (without electrics)

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Rod mill
Applicable for the secondary & tertiary crushing of medium hard materials such as gypsum,
limestone etc. and bituminous coal. Designed for achieving very high reduction ratio.
Available in various models with capacity ranging from 80 to 550 T / Hr. (Coal).
Drum diameter 2700 to 3600 mm
Drum length 3100 to 5500 mm
Air Swept Coal Pulveriser is primarily of ball mill family and is designed for pulverising coal
to prepare boiler feed.

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Other crushing and mineral processing products
 Jaw Crushers
 Two roll Crushers
 Sinter Crushers
 Apron feeders
Crane
HEC designs and manufactures heavy duty Electric Over Head (EOT) cranes for application
in Steel Plant, Engineering sector, Space Research etc. The highest capacity crane designed
& manufactured so far is 450 T Ladle Crane for handling hot liquid metal.
TYPICAL EOT CRANES:
 EOT Cranes for workshops and engineering sector up to 400 t capacity
 Ladle Crane for handling Hot metal Ladles in Steel and metallurgical plant up to 450 t
 Rotating Trolley Crane
 Tundish Handling Crane
 Magnet Grab Crane
 Slab handling Tong Crane for steel plant application
 Four girder double Trolley semi portal Scrap Charging Crane
 Cantilever Roof mounted Tower Crane
SPECIAL FEATURES:
 Digital AC Vector Drive for smooth control and creep speed
 Regenerative Active Front End (AFE) Converters for energy efficient operation
 Interface to automation systems eg. Coil Yard management system
 Planetary Gear system for continuous hoisting & lowering at half speed in case of failure of one drive system
 Double wire rope, double upper Block and double bottom pulley block system to facilitate emergency hoist
operation without tilting the load in case of failure of one rope system/one pulley system
 Emergency Braking system on Hoist Rope Drum to prevent free fall of load
 AC operators cabin and electrical panel room.
 Weighing system with VHF communication to ground station
 Anti-collision system

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 Radio remote control
 Automatic Track and wire rope lubrication system
SUPPLIES MADE TO:
 Bharat Heavy Electricals Limited, Hardwar
 Bhilai Steel Plant
 Tata Iron & Steel Co., Jamshedpur
 Bokaro Steel Limited, Bokaro Steel City, Bokaro
 Visakhapatnam Steel Project, Visakhapatnam
 Bhilai Steel Plant, Bhilai
 Jayant Coal Handling Plant, Northern Coal Fields Ltd., Jayant
 Durgapur Steel Plant, Durgapur
 Rourkela Steel Plant, Rourkela
 Isro, Sriharikota
 Konark Met Coke Limited
 Tamil Nadu Electricity Board
 Neelachal Ispat Nigam Limited
 Tiazhpromexport Moscow For Bulgaria
 TSVETMETPROMEXPORT, Moscow For Cuba
CAPACITY-WISE BREAK UP:
Capacity Nos.
Up to 50 t 102
50 t to 100 t 113
100 t to 200 t 83
250 t 3
320 t 4
400 t 1
450 t 7

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Capacity: 400 /60 T, Span : 32 M installed at the height of 46 M to handle GSLV and PSLV at
ISRO, Sriharikota.
Hoist Drum of diameter 3.3 M and length 7.5 M weighing 35 T.
Fabrication of 4 Girder Ladle Crane (180 T capacity) 450 T capacity Ladle crane in Assembly Line

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(a)Assembly of Rotating Trolley of a 25 T and 33 M span EOT Crane (b)18 T Capacity Tong

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Plant Layout and Facility
Heavy Engineering
Corporation
Foundry forge plant(FFP)
Gray cast Iron and Non
ferrous Foundry Shop
Steel Foundry Shop
Forging Shop Shop
Fettling Shop
Pattern making Shop
Forging Shop
Tool maintenance and Die
making Shop
Electrical Maintenance
Shop
Heavy Machine Building
plant(HMPB)
RPD (Research and
product Development)
Heavy Machine Shop
Small and Medium
Machine Shop
Reducing Gear box shop
Steel Structural Shop
Machine Assembly Shop
Heat Treatment Shop
Shipping and movement
Department
Heavy machine Tools
plant
RPD (Research and
Product Development
Machine Tools assembly
shop
Light machine shop
Heavy machine shop
Project Division

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The area of the Plant is 13,16,930 square meter accommodating 76,000 tons 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.
FFP Unit consists of following areas:
Shop floor Areas
02
Shop
Gas
Plant
01
Shop
03
Shop
Oxygen &
Acetylene
Plant
04
Shop
06
Shop
Compressor
House
05
Shop
07
Shop
08
Shop
09
Shop
Foundry Forge Plant

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PSD stands for power supply department
TSD (labs)
Universal Testing Machine Izod and Charpy Test Apparatus
Apart from above two testing apparatus there are other different techniques also like Gas sampling. Gas
sampling needs to be done to find the percentage constituents and there are other auxiliary machines like
notch making machines and also machines like lathe and milling machines for specimen preparations.

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Gas Plant
Producer Gas is produced in Gas plant having the main composition of carbon monoxide
and hydrogen gas used as a fuel in whole HEC plant area. It is produced in a machine called
Producer gas generator. There are total 34 units of producer gas generator.
Coal is crushed and Screened in CHP (Coal Handling Plant) -> sent to Producer Gas
generator (through conveyer belt) having air (coming from compressor house) and steam
(coming from the boiler).
Producer Gas (CO + H2)
Steam
Air
Coal
1 unit of air 1.5 unit of
producer gas

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Safety measures: CO is a poisonous gas so it is advised to go away from leakage area
immediately and inform to the concern department and safety.
Gas plant has its own ESP units (electrostatic precipitators unit) for as a segregation device
producing good quality of producer gas.
Oxygen and Acetylene Plant
This plant produces Oxygen used for different purposes throughout FFP like Cutting,
Welding and heat treatment.
Oxygen plant is producing more than 99% quality oxygen from the air. It uses multi-stage
vapor compression principles for reducing the air temperature till every constituent of air
liquefy. Then different absorption techniques are used to segregate constituents like using
caustic soda for absorbing carbon dioxide and moisture content. As refrigeration
technique is based on vapour compression cycle thus it is comprised of bigger centrifugal
compressors. The pipings are well insulated for loss of temperature. Temperature reading
is done by pyrometers.
Acetylene plant is not working that’s why it is being outsourced in standard cylinders.
Compressor House
Compressor House is giving compressed air mainly to Gas plant and other required areas.
4.5 kgf/cm2 that is 4.5 times of the atmospheric pressure. Some equipment in the plant are
hydraulic controlled and some are pneumatic controlled. All pneumatic controlled
equipment requires compressed air.

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06/07 Shop: Pattern Making
For the metal castings the wooden patterns are required in the first place for mould box
preparation having cavities. Patterns are made up of mainly three kinds of woods
Teak (1st class), Devdar (2nd class) and Gambhaar (3rd class). Shop 07 is mainly warehouse
for storing finished wooden pattern.
06 shop is equipped with Bend saw for shearing woods. There is also lathe machine,
planner machine. Seasoning of wood is also taken care of. The shop is having wood-waste
collecting mechanism having suction impellers.
The shop is provided with engineering drawings and then the layout is made in 1:1 scale on
a big table. The better layout is; better will be the pattern.
01/02 Shop: Gray Iron and Non-ferrous foundry, Sand & Core
preparation
Product
Requirement
Flow Chart of Casting
Method
Pattern Allowance, Gating
System, Machining
Allowance etc.
Moulding &
Core Making
Pattern
Making
Mould & Core
Painting
Mould & core
assembly and
Closing of Mould
Drying in oven
Clamping &
Loading
Pouring of
Liquid Metal
Cooling &
Shake out
Cleaning &
Fettling (05
Shop)
Stress Relieving
(Heat treatment)
Machining
Shop (04 Shop)
Final Product

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Carbon-dioxide moulding: This is essentially a quick process of core or mould
preparation. The mould is prepared with a mixture of sodium silicate abd sand and then
treated with carbon dioxide for two to three minutes such that dry compressive strength is
arrived.
Single weight casting capacity: 120-130 Tone.
Melting Unit Die and pit Unit
Melting Section
Charging Unit
• Preparation of metal
scraps mainly for Plane
carbon steel, Alloy
Steel and Cast Iron
Materials.
• Basic components of
melt contains C, Si,
Mn, P etc.
• Metal is alloyed with
different alloying
elements Cr, Ni, Mo, V
etc.
Electric Arc Furnace, Induction
Furnace and Vacuum Arc Degassing
Furnace.
Molten metal is
poured into mold
cavity for casting
using ladle furnace
with the help of
E.O.T. crane.

44
Furnaces:
Induction furnace:
Based on heating effect due to surface eddy current is used in the induction furnace.
Electric Arc furnace:
• It is powered by a 3 phase electrical system and has three electrodes.
• Arc is formed between the charged metal and the electrode.
• The charge is heated both by current passing through the charge and by the radiant
energy evolved by the arc.
• Electrodes can move up and down automatically for regulation of the arc.
• To protect the transformer from heat, it is installed in a vault.
• It is cooled via pumped oil exchanging heat with the plants water cooling systems.
• It is built on a tilting platform to pour molten metal into another vessel for
transport.
Induction Furnace
Electric arc furnace
Vacuum Arc Degasing Furnace (VAD)

45
Vacuum arc degassing furnace:
• The VAD is used for purification of molten metal.
• It is equipped with bottom plugs for argon bubbling.
• To achieve a homogeneous bath temperature and composition, the steel in the ladle
is often stirred by means of argon gas bubbling.
• Hydrogen and oxygen gas is removed.
• Aluminium, ferromanganese is added for the removal of oxygen gas due to affinity
for oxygen is more than carbon
Ladle:
• It is not used for metal melting, metal addition & degassing purpose.
• This Furnace is used to reserve molten metal for pouring and degasing process.
• It is of three type.
a) Casting Ladle: For pouring of molten metal into mould.
b) Transfer Ladle: Transfer of molten metal from one process to other.
c) Treatment Ladle: Process to take place within the ladle to change some aspect of
molten metal.
05 Shop: Fettling Shop
• Process of cleaning of casting object from sand & gating elements i.e. Runner, riser,
Sprue basin & gates.
• Maximum sand is removed by pneumatic chipping hammer (operating press. 4 to 7
kg/cm2).
• Runner, Riser, Sprue basin and other extra metal is removed by gas cutting
(Lancing).
• Some extra metal is removed by Fettle Torch. (Graphite electrode for steel & general
purpose electrode is used for cast iron).

46
Surface Defect Testing:
Surface defect is being tested by using spray paint, using three sprays in a row; red dye
penetration, PC-5021B cleaner and developer. It is kind of non-destructive testing.
03 Shop: Forging and Heat treatment
Heavy forge shop
6000T press (water hydraulic)
Heating furnaces (LPG fired, HSD fired & producer gas)
Heat treatment furnace
Medium forge shop
2650T press (Oil hydraulic)
1650T press
1000T press
Heating furnaces (LPG fired and producer gas)
Light forge shop
1.6T hammer
3T hammer
Die forging
Trimming force
All are pneumatic controlled (4.5 kgf/cm2 to 5 kgf/cm2)

47
Heat treatment
Controlled heating & cooling of materials for the purpose of altering their structures and
properties
• Annealing
• Normalising
• Quenching
• Induction Hardening
04 Shop: Machining shop
After Foundry and Forging it is always required to machine to remove unnecessary parts
and finishing operation.
• Turning
• Boring
• Facing
• Grinding
• Vertical & Horizontal Milling
• Planning
• Grooving
• Threading
• Parting
• Slotting
• Trepanning

48
08 Shop
 Maintenance Shop (spares)
o Cutting tool making
 Die making
 Circular saw
o Spline making
 Die Sinking
 Vertical Turning boring machine
09 Shop: Electrical maintenance shop
 Electrical maintenance work
o Fabrication mainly welding (Arc/Gas/TIG)
 Machine Section

49
The Plant has a fenced area of 5, 70,000 square meter and a floor area of nearly 2, 00,000 square meter.
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, Aluminium, Space Research, Nuclear Power etc.
Heavy Machine Building
Plant

50
HMBP Unit consists of following areas:
Shop floor Areas
01 Shop: Heavy Machine Shop
This shop comprises of India’s biggest machine tools like Lathe machine, vertical turning
boring machine, Turning, Boring, Facing, Grinding, Vertical & Horizontal Milling, Planning
and Trepanning machines. Like every other shops it has its own mechanical maintenance
department which consists of basic tools to maintain the shop.
02
Shop
01
Shop
03
Shop
041-042
Shop
043-044
Shop
050
Shop
SMD RPD
061
Tool
shop

51
02 Shop: Medium and small Machine Shop
This plant again consists of machine tools but it do relatively smaller jobs than shop 01.
Like every other shops it has its own mechanical maintenance department which consists
of basic tools to maintain the shop.
03 Shop: Reducing gear box shop
Every machinery consists of power driven system which requires gears to control the feed
and rpm that’s why we have facilities of reducing gear box shop that manufactures gear
from cast products by means of gear hobbing and gear shaping machines. Like every other
shops it has its own mechanical maintenance department which consists of basic tools to
maintain the shop.

52
041-042 Shop: Steel structural Shop
Every finished machinery like coke pusher car needs structural work. Structural work like
of truss and. Structures are mainly made up of steels. In this shop work is done using gas
cutting and welding process. In terms technicality there is very simple works going on.
Tolerance level is high but structural defects are intolerable.
043-044 Shop: Machine Assembly Shop
While in 041-042 structural work is being done. In 043-044 shop machine related jobs are
done liking providing complete assembly to the bearings, couplings etc.
050 Shop: Heat treatment Shop
Every machined product needs heat treatment to recover its material properties.
Sometimes it may require to attain desired hardness, toughness or even surface hardness.
That’s why HMBP units has its own heat treatment workshop.
ANNEALING
Annealing is a rather generalized term. Annealing consists of heating a metal to a specific
temperature and then cooling at a rate that will produce a refined microstructure, either fully or
partially separating the constituents. The rate of cooling is generally slow. Annealing is most often
used to soften a metal for cold working, to improve machinability, or to enhance properties
like electrical conductivity.

53
NORMALIZING
Normalizing is a technique used to provide uniformity in grain size and composition throughout an
alloy. The term is often used for ferrous alloys that have been austenitized and then cooled in open
air. Normalizing not only produces pearlite, but also martensite and sometimes bainite, which gives
harder and stronger steel, but with less ductility for the same composition than full annealing.
QUENCHING
Quenching is a process of cooling a metal at a rapid rate. This is most often done to produce a
martensite transformation. In ferrous alloys, this will often produce a harder metal, while non-
ferrous alloys will usually become softer than normal.
There are other facilities too like Babbiting, Chrome plating, Case hardening, Acid Pickling of
two categories HCl and phosphate coating too.
Facilities like centrifugal casting is there but not in use.
061 Shop: Tool Shop
HMBP unit has its tool shop mainly comprises of shank making and HSS (high speed steel)
with brazing facilities. Carbide tool tip are purchased from outside or other ceramic tools.
SMD department
SMD stands for shipping and movement department. Every finished products need to be
dispatched to particular customer in a fixed period of time. SMD takes care of logistics of
finished products. It gives task to related authorities as rate contract. It also takes care for
the penalties in delay of the products.

54
RPD department
RPD stands for Research and product development.
RPD consists of following sub-groups:
 Iron-plant
 Steel making group
 Coke oven Bureau
 Crane Bureau
 Auxiliary Bureau
o Reduction gear
o Lubrication Bureau
o Electric drives
Apart from doing Initial Research and Design Activities RPD gets involve in other areas also like
 Problem in procurement
 Tolerance Variance
 Involvement at the site i.e. final delivery site
RPD prepares GAD (general assembly drawing)
RPD point outs the item which is termed as DIP items i.e. Difficulty in procurement.

55
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 square meter It designs and
manufactures medium & heavy duty CNC and conventional Machine Tools for Railways, Defense,
Ordnance factories, HAL, Space and other strategic sectors
HMTP unit is consists of following areas:
Light
machine
shop
Heavy
machine
shop
RPD
(Research and
Product
Development)
Machine
tools
Assembly
shop
Heavy Machine Tool Plant

56
Customers:
 Railways
o SAIL
 Coal India (spares only)
HMTP also helps in off-loading of work orders of HMBP units.
Product portfolio:
CNC lathe/Conventional Lathe
CNC drilling/Conventional lathe
DHB (deep hole boring machine)
Planar machine
Horizontal boring machine
VTB (vertical turning boring machine)
CNC Wheel lathe for Railways
Sail Gear box

57
Project division do two subsequent engineering called;
Basic Engineering & Detailed Engineering
Turn-key projects involve mainly three disciples
Mechanical + Civil + Electrical
Project division works on EPC concept.
Engineering -> Procurement -> Construction.
Specimen copy from Internet; work of project division
18.12.2014 - LAUNCH OF GSLV MARK III FROM SECOND LAUNCH PAD, SRIHARIKOTA
MAKES HEC PROUD
Contribution to GSLV Mark III
On 18.12.14, ISRO has made India proud again by its successful launch of India's next generation launch vehicle
GSLV Mark III. It is said to be one of the most powerful and heaviest. GSLV Mark III has been launched from the
second launch pad of ISRO at Sriharikota.
HEC extends its heartiest wishes to ISRO and simultaneously thanks them to give an opportunity to HEC to
be part of its success.
It is a matter of great pride for HEC to have contributed in the Second Launch Pad Project of ISRO at Sriharikota.
With every launch from the second launch pad, ISRO makes HEC proud.
Project Division

58
HEC had supplied the Mobile Launch Pad (MLP), the Tower Crane, the Horizontal Sliding Doors, 400T EOT Crane
and the Folding-cum-Vertically repositionable platform installed for assembly of launch vehicles.
HEC had executed the design; manufacture and erection of the Mobile launch Pedestal (MLP). The MLP had a total
weight of approx. 800T and it comprised of nine modules which were fabricated at HEC and assembled at site. The
MLP carries the integrated vehicle from the Vehicle Assembly Building to the launch site, in vertical position using a
rail track and the launch takes place in the same position.
The 10T Tower crane installed at the top of Umbilical tower at a height of 80m had been designed to sustain huge
wind pressure. The Horizontal Sliding Doors had special features such as Cyclone Locks and Rain-water sealing
arrangement.
From the second launch pad, India has successfully launched its other prestigious missions such as Chandrayaan - I
and other Communication satellites.

59
Common Work Flow in different units of HEC
After commencement of shop floor production following tasks are done
Assembly -> Quality Control -> Dispatch
Marketing
•Which collects
orders from
market
RPD
•for Design
Clearance
Engineering
Department
•For drawing
preparation
PPC (production
planning and
control)
•Resource
Allocation like
which items
need to be
purchased
from outside
Shop floor
•Actual
production

60
Quality policy

61
Corporate Planning
It is top management work
Objective 1: Corporate Identity; what are we & what will be in course of year
Objective 2: Corporate Mission which includes Qualitative terms and Quantitative terms.
Following flow charts gives the basic idea about corporate planning.
Key elements for success and failure:
Planning
Leadership
Direction
System & Procedure
Care for people
Forecasting
SWOT
ananlysis
Forecast II
Strategy to
breach the
Gap
Forecast III
Functional
Plans
Functional
plan
Material plan
Production
plan
Marketing
plan
R & D plan
Manpower
plan
Facilities
plan

62
Journey towards diversification

63
Awards
 HEC Ltd. has won "SCOPE AWARD" for Excellence and Outstanding contribution to Public
Sector Management - Special Institutional (Turnaround) Category 2007-08.
 Indian Nuclear Society (INS), Mumbai, a premiere organisation for encouraging the growth of
science and technology in a nuclear field has recognized the efforts of HEC, in the category of
'Industrial Excellence'. The INS Industrial Excellence award is given to an Indian Industry that
has, during the previous three years made a significant contribution in the nuclear field through
innovative technology and management approaches.
 HEC was bestowed with "BRPSE Turnaround Award 2010" In recognition to the
metamorphosis in HEC, resulting in a turnaround of the Corporation,. The award was given by
the Board for Reconstruction of Public Sector Enterprises (BRPSE) on 10th March, 2011.
 At the Asia Pacific HRM Congress 2010, held at Bangalore on 3rd & 4th Sept.2010 with the
theme "Unleashing Positivity in the Workplace", HEC was awarded under "Innovation in HR
Development &Change" for good work & internal development in HR processes.
 HEC has been conferred with "BT - STAR PSU EXCELLENCE AWARD 2012" in TURN AROUND
CATEOGORY for its outstanding contribution to the Industry. It recognized those who have
driven India's rapidly transforming economy by providing the base on which today's Indian
economy has grown and flourished.

64
Vision, Health and Policies
TO BE A MARKET LEADER IN HEAVY ENGINEERING INDUSTRY IN INDIA PROVIDING
QUALITY PRODUCTS AND SERVICES TO THE STEEL, MINING, RAILWAYS AND OTHER
STRATEGIC SECTORS.
TO ACHIEVE GROWTH OF 20% IN TURNOVER AFTER COMPLETION OF MODERNIZATION
/ UPGRADATION OF PLANT/FACILITIES.
Policy section
It comes under P&A department.
HEC Employees are abide by rules mentioned in
HEC EMPLOYEES CONDUCT DISCIPLINE AND APPEAL RULES 1981.
On whole rules indicate that a company officer should not only follow rules within the premises of
HEC but even in employee’s residence area.
12 Casual Leave, 12 National Holiday, 20 Half Paid Leave, EOL is leave without pay.
Intimation to the company is necessary for marriage, property buying or selling or even buying an
entity more than 2 month.
No earning outside HEC is allowed.

65
Company ethics

66
Organization chart

HEC Ranchi Project Report

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