Our project consisted of learning the manufacturing processes & operations of each and every part related to Boiler Manufacturing such as Elements, Panels, Boiler Drum, Header along with its accessories. A brief of it has been attached in this presentation.

1. A presentation on Vocational Training at ALSTOM
India Ltd., the world leader in Thermal Power sector
and Boiler manufacturer at its Durgapur unit.

2. Contents
•About the company
•Policies
•Safety directives of the company
•About Supercritical Boiler
•Metallurgy & Testing
•Panel Shop
•Element Shop (I & II)
•Header Shop I
•Header II & Machine Shop
•Smithy Shop
•Maintenance Department
•Assembly Shop

3. About the Company
Alstom is a French multinational company which is the world
leader in the electricity generation and rail transportation mark
having an annual sales of €21 billion.
Alstom Durgapur unit:-
Location-Industrial Area, Durgapur, West Bengal 713201
Manufactured products-Boiler and its mountings.
Total manufacturing shops- There are main 9 manufacturing
departments where all the boiler parts and necessary
requirements are produced and measured.
Employee Strength- 2000(approx).
Technology used- Equipped with the latest in technology and
the factory is a state-of-the-art manufacturing facility to shape
large-capacity boilers

4. Policies
EHS Policy Smoking policy
Driving Safety Policy

5. PPE(Personal Protective Equipment Model)

6. About Supercritical Boiler
Why Supercritical?
"Supercritical" is a thermodynamic expression describing the state
of a substance where there is no clear distinction between the liquid
and the gaseous phase, so this boiler works by utilizing the steam
i.e a state between liquid and gas.
Pressure of operation- 22.1 Mpa.
Benefits:-
1. Helps in increasing the efficiency upto 45%.
2. Increased efficiency reduces fuel cost.
3. Reduced emission of SOx and Nox and particulate emissions.

8. Shop Division
Material Testing Lab:
The testing and quality of the objects are done keeping in mind the rules
and regulations of IBR(Indian Boiler Regulation), ASME(American
Standard of Mechanical Engineering) and Alstom own criteria for
testing.
Destructive Testing:
1. Universal Testing Machine
2. Impact Testing machine
3. Brinnel Testing machine.
Non Destructive Testing:
1. Real Time Radiography
2. Ultrasonic Testing
3. Magnetic Particle Testing
4. Dye Penetration Testing

9. Panel Shop
These are tubes in the Boiler where water is evaporated to steam
and transfers that steam into the boiler. So they are also called
Steam Generating Tubes.
Application: Forms the enclosure of the furnace so that no heat goes out of
it and the total heat generated gets directed in heating of the water inside the
boiler.
Material Used: T11,T12
Composition:
T11(Carbon-0.14,Silicon-0.61,Cromium-1.05,Molybdenum-0.46)
T12(Carbon-0.10,Silicon-0.50,Cromium-1.20,Molybdenum-0.50)

10. 6 torch and 4 torch Welding Machine
Weld Type Flux used Voltage(V) Speed of
travel(mm/
min)
Current
Range(A)
Preheat (deg.
Centigrade)
SAW Lincoln 781 27-33 780-910 340-430 10
Weld
Type
Joints Electrodes Gas
(%)
Preheat
Temp.
Interpass Temp.
GTAW Single J
groove
butt joint.
Lanthenum
Tungsten
(4mm dia.)
Argon
(99.9)
150deg. 400deg.
Straight Tube Welding

11. Element Shop
These tubes are used to preheat the water before it goes to the boiler
and transforms into steam by utilizing the flue gas which comes
from the combustion furnace.
Materials Used: T11,T22
Composition:-
T12-(Carbon-0.10,Silicon-0.50,Cromium-1.20,Molybdenum-0.50)
T22-(Carbon-0.15,Silicon-0.50,Cromium-2.60,Molybdenum-1.11)

12. System bender- Used for single bending of pipes.
Parts of the machine:-
1.Carriage
2.Offset bender
3.Rotator
4.Main Bender
5.Hot Bender
Furnace :-
Fuel used Grade of
material
Stress
Relieving
Temp.
LPG 91
11,12
1100 deg.
450deg.

13. Header Shop
Header is used to collect all the steam from the boiler, which will
include some water, and move it to the system risers allowing the
water to separate from the steam.
Material Used- P12,P22,P91
Composition- P91(Carbon- 0.10,Silicon-o.50,Cromium-5.0,Molybdenum-0.60)
P22(Carbon-0.15,Silicon-0.50,Cromium-2.60,Molybdenum-1.11)
P12(Carbon-0.10,Silicon-0.50,Cromium-1.20,Molybdenum-0.50)
Preheating using coil:-
Preheat Temperature (deg.
Centigrade)
Inter pass Temperature (deg.
Centigrade)
150 350

14. Post Weld Heat Treatment
Soaking Temperature (deg.
Centigrade)
Rate of Heating (deg.
Centigrade/hr.)
600-620 110-120
Weld Type Filler material Current Voltage
SMAW ER70S-2(solid
filler rod)
E7018(basic
coated)
85-100A 25-30V
Welding used
Weld
Type
Electrode Current Gas Voltage
GTAW Diathoriate
d Tungsten
90-110A Argon(99%) 15-20V

15. Machine Shop
Centre Lathe Vertical Turret lathe
Milling Boring machine
Vertical Drilling

16. SAW CUT Machine
Grade
of pipes
Cutting
Capacity
Cutting
Speed
Floor
Space
Size
Weight Total
Power
P12,P22,
P91
1000mm
dia.
15-80m/min L=6000
W=3600
H=3400
10500kg 23.75 HP
Harvey 8’ Horizontal boring &
Facing Machine
Grade of
pipes
Max.
facing
dia.
Floor
Space Size
Total
Power
P12,P22,P9
1
8’ 8’8.5’’*11.5’*
1’4’’
47.5HP

17. Smithy Shop
Maintenance Dept
The main function of this department is to fix and repair faulted machines, solving
electrical problems occurred during production. It consists of mechanical and electrical
departments. Their function is to maintain the whole unit so that production does not get
hampered.
In this shop header stubs are produced using lathe and drilling machine.
Depending upon the design and shapes the size of the nipples/stubs are
produced here.

18. Welding Training School
Here the welders practice their welding to check their credibility
and to improve themselves in their job. Weld Types and joints that
are performed;

19. Assembly Shop
The work in this shop is mainly categorized into three parts;
A. Loose Tube Area, Cutting and Bending Operation
B. Joint Section, Coil Making
C. Burner Panel
Welding Type:-
Type Electrode Diameter Polarity Current Speed
Range
Voltage
SMAW E308-16 2.5 DCRP 65-90 100-150 20-26
SMAW E308-16 3.15 DCRP 90-120 100-120 22-28
SMAW E308-16 4 DCRP 120-150 100-120 24-30
Furnace:-
Type Max. Temp. (deg.
Centigrade)
Max. Charge Wt.
(kg)
Fuel
Bogie 1200 1000 LPG/HSD/COG

20. Bending Machine- Used for bending of tubes depending upon the design
required .Here both automatic as well as manual help is needed to get the job
done.
Burner panel- It is one of the most complicated panels that is built in this
shop. The function of this panel is same but its design is different unlike
the straight panels.

21. Colouring and Final Despatch
After all the final testing and colouring the product is ready for shipment.

22. Submitted by;
Snehashish Mukherjee
College Reg.-121961034
Univ.Roll-27300712055
Univ. Reg. - 122730110127
Branch- B Tech. (ME)
NSHM Knowledge Campus, Durgapur
Project Duration-15days
Date of submission of project-30.6.2015