Loesche Technology - Always a Step Ahead: Loesche Mills for Cement Raw MaterialLOESCHE
Cement raw material has been almost exclusively ground in roller mills (vertical air-swept grinding mills) since the second half of the 20th Century. Loesche was and is the pioneer of this technology. Hundreds of Loesche mills have been used in the cement industry across the world to the present day. They operate with two, three, four and six rollers.
The document discusses the Bhilai Steel Plant in India and the cross cut shear machine used in its plate mill operations. It provides background on the steel plant, describing it as a symbol of Indo-Soviet collaboration established in 1959. The project aims to study the kinematic mechanism of the cross cut shear machine. An overview of the plate mill process is given, outlining the steps from slab heating to inspection, shearing, heat treatment, and dispatch of steel plates.
Crank case manufacturing at pritika industriesNaval Gupta
Pritika Industries Limited is a quality-driven organization that manufactures automotive components. It started in 1974 and produces machine components, heavy castings, flywheel housings, crankcases, and hydraulic lift covers. Pritika is a leading supplier of housings, castings, hydraulic lift covers, and engine covers. It supplies crankcases to Mahindra tractors and other casting components to renowned companies. The document then describes the multi-step process for manufacturing crankcases, including casting, various machining operations, and a time study analysis that found producing a crankcase takes approximately 1 hour and 24 minutes after casting.
The document describes the manufacturing processes used to produce key engine components. Engine blocks are typically made of cast aluminum alloys using a casting process. Pistons are commonly forged from aluminum alloys and undergo machining like cutting, drilling, and milling. Crankshafts are usually made from steel alloys using casting and machining processes like turning, drilling, and grinding. Gears are manufactured through gear forming methods like milling and broaching or gear generation processes like hobbing and shaping.
The document is a vocational training report summarizing Akhilesh Paikra's training at Bhilai Steel Plant. It provides an overview of Steel Authority of India Limited (SAIL) and Bhilai Steel Plant, including their production processes. It describes the plant's raw materials, major production areas like the plate mill, and achievements. The training covered safety practices, production workflows, and equipment in different areas of the large integrated steelmaking facility.
Loesche Technology - Always a Step Ahead: Loesche Mills for Cement Raw MaterialLOESCHE
Cement raw material has been almost exclusively ground in roller mills (vertical air-swept grinding mills) since the second half of the 20th Century. Loesche was and is the pioneer of this technology. Hundreds of Loesche mills have been used in the cement industry across the world to the present day. They operate with two, three, four and six rollers.
The document discusses the Bhilai Steel Plant in India and the cross cut shear machine used in its plate mill operations. It provides background on the steel plant, describing it as a symbol of Indo-Soviet collaboration established in 1959. The project aims to study the kinematic mechanism of the cross cut shear machine. An overview of the plate mill process is given, outlining the steps from slab heating to inspection, shearing, heat treatment, and dispatch of steel plates.
Crank case manufacturing at pritika industriesNaval Gupta
Pritika Industries Limited is a quality-driven organization that manufactures automotive components. It started in 1974 and produces machine components, heavy castings, flywheel housings, crankcases, and hydraulic lift covers. Pritika is a leading supplier of housings, castings, hydraulic lift covers, and engine covers. It supplies crankcases to Mahindra tractors and other casting components to renowned companies. The document then describes the multi-step process for manufacturing crankcases, including casting, various machining operations, and a time study analysis that found producing a crankcase takes approximately 1 hour and 24 minutes after casting.
The document describes the manufacturing processes used to produce key engine components. Engine blocks are typically made of cast aluminum alloys using a casting process. Pistons are commonly forged from aluminum alloys and undergo machining like cutting, drilling, and milling. Crankshafts are usually made from steel alloys using casting and machining processes like turning, drilling, and grinding. Gears are manufactured through gear forming methods like milling and broaching or gear generation processes like hobbing and shaping.
The document is a vocational training report summarizing Akhilesh Paikra's training at Bhilai Steel Plant. It provides an overview of Steel Authority of India Limited (SAIL) and Bhilai Steel Plant, including their production processes. It describes the plant's raw materials, major production areas like the plate mill, and achievements. The training covered safety practices, production workflows, and equipment in different areas of the large integrated steelmaking facility.
This document describes a tilting kneader extruder machine. It lists the team members and describes the main components of the extruder - the sigma blades, mixing trough, stuffing box, cover, and control panel. It explains how the machine works through loading, homogenization using the rotating Z-shaped blades, and discharge by tilting the mixing trough. Applications include sealing compounds, asphalt derivatives, rubber compounds, and advantages are automation capabilities and heating/cooling functions.
The document discusses Autoclaved Aerated Concrete (AAC) block making machines. It provides an introduction to AAC, describing its advantages for construction. It then outlines the production process for AAC in 2-3 steps, involving mixing raw materials, pouring the mixture into molds, and curing the blocks in an autoclave. The document promotes AAC block making equipment from the company hiimac and provides contact information.
Udaipur Cement Industries Limited is a fully government-owned cement plant in Nepal established in 1987 with financing from the Japanese government. The plant produces 277,200 metric tons of ordinary Portland cement per year. Limestone is mined 30km from the plant and transported via a 13.8km ropeway. The limestone is crushed and stored, then milled along with other raw materials before being preheated and fired in a rotary kiln to produce clinker. The clinker is ground in a cement mill and stored in silos before being packed and dispatched.
This document is a presentation on a vocational training at Bhilai Steel Plant submitted to Chhattisgarh Swami Vivekanand Technical University. It provides an overview of Bhilai Steel Plant, which is one of the largest steel producing plants in India established in 1959. It describes the raw materials used, production processes like plate mill and foundry shop, major productions including wheels, axles, rails, and safety guidelines for the industry.
The engine block is a critical component that houses the internal parts of an engine. It is typically made of cast iron or aluminum alloys due to their ability to withstand high stresses and temperatures. The manufacturing process involves pattern making, casting, and machining. Patterns are used to create molds for casting the block. The block is then machined to final specifications. Proper material selection and manufacturing processes are needed to produce an engine block that can withstand combustion pressures and temperatures for the life of the vehicle.
The document describes the components and operation of an asphalt batch mix plant. The plant uses aggregates that are fed into bins then dried and heated. The heated aggregates are mixed with asphalt in a mixing chamber. Additional components include asphalt tanks, mineral filler units, and load out conveyors. Controls and monitoring are centralized in a control panel. Batch mix plants generally cost between 60-75 lacs depending on capacity. Major manufacturers of batch mix plants in India are listed.
The document discusses the design and manufacturing process of a dome shaped piston head. It provides details on the components of a piston, how the shape changes during operation, piston rings and their purpose. It also describes the various manufacturing steps including casting, forging, heat treatment, machining processes like CNC turning, drilling and grinding. Additional steps discussed are deburring, coating and final inspection. Performance and cost matrices are presented comparing forging, casting types and coatings. Recommendations to improve casting and forging processes are provided. The conclusion is that forging produces the strongest piston with greatest lifespan and is the best manufacturing technique.
GGB-BP25 is an oil-impregnated sintered bronze bearing produced through powder metallurgy. It is suitable for general engineering applications under relatively light loads and high speeds. Key characteristics include a maximum load of 2,900 psi static and 1,400 psi dynamic, operating temperatures from -290°F to 570°F, and oil impregnation for lubrication. Standard dimensions are available for plain cylindrical and flanged bushes, while custom sizes and shapes can be made to order.
This document describes an AAC block cutting machine. It cuts autoclave aerated concrete (AAC) blocks into their final shapes in a single automated step. The machine cuts the AAC "cake" into blocks with six sides within tight tolerances of ±2mm. It works by flipping the cake, moving it to cutting positions, and using level and crossing cuts to shape it. The machine cuts waste and recycles slurry with no secondary pollution. It has advantages like compact design, single-step cutting, tight tolerances, and safety features. Technical parameters and models that can cut blocks from 4050x1240x650mm up to 6050x1540x650mm are provided.
Complete Rolling Mill & Equipment Manufacturer ---Hani TechKerri Zhang
Design, manufacture and revamp, upgrade your rolling mill plant according to your tech requirements. Hani is the one-stop supplier able to design, manufacture, install and commission your hot rolling mill plant from A to Z.
This document provides an overview of the Mangalam Cement Ltd cement production process. It discusses the key components of the plant including mines and crushing, raw material preparation and storage, the kiln process, cooling, cement milling, and packaging. The plant utilizes local limestone mines, crushers, raw mills, preheaters, rotary kilns, coolers, cement mills, and packaging facilities to produce Birla Uttam Portland Pozzolana Cement and various grades of ordinary Portland cement. The document also compares the characteristics of 43 and 53 grade cements and ordinary Portland cement versus Portland pozzolana cement.
Manufacturing Processes of Engine BlocksSandeep Saini
The document summarizes the process for manufacturing engine blocks. It discusses that engine blocks must withstand high pressures and temperatures from combustion. They are typically made of gray cast iron or aluminum. The sand casting process is most common, using green sand molds with wood or metal patterns. The molds contain cores to form water jackets around the cylinders. After casting, the blocks undergo machining like grinding, boring, and honing to produce smooth surfaces and precise dimensions for components to fit properly. Quality control of the sand mixture, mold compression, risers, and cooling rate is important to avoid defects from forming in the final casting.
Crankshaft Manufacturing Process sequence Omar Amen
This presentation slides Discusses how to manufacture crankshaft
Slides contains:
- Introduction to crankshaft ( what is the crankshaft ).
- Main parts of crankshaft.
- Types of crankshaft.
- Design of crankshaft.
- Finite element analysis for crankshaft ( Structure Analysis & Thermal Analysis ).
- Material selection ( select the suitable materials for manufacture crankshaft and suitable percentage of alloying elements in crankshaft according to required mechanical properties ).
- Manufacturing process sequence ( Forging steps & Machining steps ).
- field research for crankshaft manufacturing (Nallicheri, 1991, contains conditions of manufacturing , Cost Analysis according to factors, and Cost Analysis according to process ).
Drive Selection for Large LOESCHE Vertical Roller MillsLOESCHE
Rising demand from the cement industry for ever greater mill capacities is having implications for the drive systems that have been used up to now. With conventional drive solutions reaching their limits, the world's leading gearbox manufacturers are developing new systems that can offer realistic alternatives for the higher-capacity mills that are now being ordered and delivered.
Henan Dajia Mining Machinery Co., Ltd is a Chinese company that specializes in the design, production, and installation of rotary kiln systems. They offer comprehensive services including on-site analysis, training, and innovative solutions to help plants optimize operations. Rotary kilns are large rotating cylinders used for processes like drying, calcination, and sintering of materials continuously using hot gases generated inside or outside the kiln. Dajia designs kilns for applications such as cement production, pet coke calcination, and sponge iron manufacturing.
This document describes the components and processes involved in a batch type asphalt plant. Key components include cold aggregate storage, a dryer for heating and drying aggregates, screening to separate aggregates by size, hot bins to store separated aggregates, and a pugmill mixer. Aggregates are weighed and mixed with asphalt in the pugmill in batches before being discharged. Modern plants have increasing levels of automation but generally involve weighing aggregates from hot bins and mixing them with asphalt in the pugmill.
Vocational Training on Bhilai Steel PlantPiyush Verma
B.S.P a unit of steel Authority of India Ltd. Inagurated at 1959 by the President of India Dr. Rajendra Prasad with a production capacity of 1.0 million ton.
B.S.P is Indian sole procedure for rails and heavy steel plates and major producer of structural.
The plant is the sole suppliers of the country’s longest rail tracks of 260 meters. With annual production capacity of 3.153MT
The document provides an overview of lubrication at cement plants, breaking it down into 5 segments: mines, limestone processing, calcining, clinker grinding, and captive power plants (CPPs). It describes the typical equipment used in each segment, such as dump trucks and excavators in mines, crushers and ball mills in processing, rotary kilns and girth gears in calcining. The key lubricants used include hydraulic oils, greases, engine oils, and specialty greases. CPPs that run on diesel are noted to have the highest lubricant consumption of around 10,000 liters per month during peak seasons. The objective is to highlight typical equipment and lubricants without recommending specific brands.
Latest Technological Innovation in Grinding With the Vertical Roller MillLOESCHE
Without any doubt, today's grinding plants have to feature highly efficient mills with high efficiency classifiers showing low specific energy consumption and the highest possible mechanical durability.
The document provides information about Indo Farm Equipment Limited, an ISO certified company located in Himachal Pradesh, India that manufactures tractors, cranes, engines, and generators. It discusses the company's founding, facilities, research and development activities, and organizational structure. It also describes the foundry plant's objectives, core making process, types of cores used, and the activities completed during a 10-day training session in the core shop, including making different types of cores by hand and machine.
This 3 sentence summary provides the key details about the industrial training report:
The report describes Akbar's 4 week industrial training at the foundry shop of Indo Farm Equipment Limited in Baddi, Himachal Pradesh. The training involved learning the various processes used in the foundry shop such as core making, mold making, melting metals, and finishing casted parts. Akbar gained hands-on experience working in the core shop and observing the other processes like molding, melting, pouring, and fettling during his training.
This document describes a tilting kneader extruder machine. It lists the team members and describes the main components of the extruder - the sigma blades, mixing trough, stuffing box, cover, and control panel. It explains how the machine works through loading, homogenization using the rotating Z-shaped blades, and discharge by tilting the mixing trough. Applications include sealing compounds, asphalt derivatives, rubber compounds, and advantages are automation capabilities and heating/cooling functions.
The document discusses Autoclaved Aerated Concrete (AAC) block making machines. It provides an introduction to AAC, describing its advantages for construction. It then outlines the production process for AAC in 2-3 steps, involving mixing raw materials, pouring the mixture into molds, and curing the blocks in an autoclave. The document promotes AAC block making equipment from the company hiimac and provides contact information.
Udaipur Cement Industries Limited is a fully government-owned cement plant in Nepal established in 1987 with financing from the Japanese government. The plant produces 277,200 metric tons of ordinary Portland cement per year. Limestone is mined 30km from the plant and transported via a 13.8km ropeway. The limestone is crushed and stored, then milled along with other raw materials before being preheated and fired in a rotary kiln to produce clinker. The clinker is ground in a cement mill and stored in silos before being packed and dispatched.
This document is a presentation on a vocational training at Bhilai Steel Plant submitted to Chhattisgarh Swami Vivekanand Technical University. It provides an overview of Bhilai Steel Plant, which is one of the largest steel producing plants in India established in 1959. It describes the raw materials used, production processes like plate mill and foundry shop, major productions including wheels, axles, rails, and safety guidelines for the industry.
The engine block is a critical component that houses the internal parts of an engine. It is typically made of cast iron or aluminum alloys due to their ability to withstand high stresses and temperatures. The manufacturing process involves pattern making, casting, and machining. Patterns are used to create molds for casting the block. The block is then machined to final specifications. Proper material selection and manufacturing processes are needed to produce an engine block that can withstand combustion pressures and temperatures for the life of the vehicle.
The document describes the components and operation of an asphalt batch mix plant. The plant uses aggregates that are fed into bins then dried and heated. The heated aggregates are mixed with asphalt in a mixing chamber. Additional components include asphalt tanks, mineral filler units, and load out conveyors. Controls and monitoring are centralized in a control panel. Batch mix plants generally cost between 60-75 lacs depending on capacity. Major manufacturers of batch mix plants in India are listed.
The document discusses the design and manufacturing process of a dome shaped piston head. It provides details on the components of a piston, how the shape changes during operation, piston rings and their purpose. It also describes the various manufacturing steps including casting, forging, heat treatment, machining processes like CNC turning, drilling and grinding. Additional steps discussed are deburring, coating and final inspection. Performance and cost matrices are presented comparing forging, casting types and coatings. Recommendations to improve casting and forging processes are provided. The conclusion is that forging produces the strongest piston with greatest lifespan and is the best manufacturing technique.
GGB-BP25 is an oil-impregnated sintered bronze bearing produced through powder metallurgy. It is suitable for general engineering applications under relatively light loads and high speeds. Key characteristics include a maximum load of 2,900 psi static and 1,400 psi dynamic, operating temperatures from -290°F to 570°F, and oil impregnation for lubrication. Standard dimensions are available for plain cylindrical and flanged bushes, while custom sizes and shapes can be made to order.
This document describes an AAC block cutting machine. It cuts autoclave aerated concrete (AAC) blocks into their final shapes in a single automated step. The machine cuts the AAC "cake" into blocks with six sides within tight tolerances of ±2mm. It works by flipping the cake, moving it to cutting positions, and using level and crossing cuts to shape it. The machine cuts waste and recycles slurry with no secondary pollution. It has advantages like compact design, single-step cutting, tight tolerances, and safety features. Technical parameters and models that can cut blocks from 4050x1240x650mm up to 6050x1540x650mm are provided.
Complete Rolling Mill & Equipment Manufacturer ---Hani TechKerri Zhang
Design, manufacture and revamp, upgrade your rolling mill plant according to your tech requirements. Hani is the one-stop supplier able to design, manufacture, install and commission your hot rolling mill plant from A to Z.
This document provides an overview of the Mangalam Cement Ltd cement production process. It discusses the key components of the plant including mines and crushing, raw material preparation and storage, the kiln process, cooling, cement milling, and packaging. The plant utilizes local limestone mines, crushers, raw mills, preheaters, rotary kilns, coolers, cement mills, and packaging facilities to produce Birla Uttam Portland Pozzolana Cement and various grades of ordinary Portland cement. The document also compares the characteristics of 43 and 53 grade cements and ordinary Portland cement versus Portland pozzolana cement.
Manufacturing Processes of Engine BlocksSandeep Saini
The document summarizes the process for manufacturing engine blocks. It discusses that engine blocks must withstand high pressures and temperatures from combustion. They are typically made of gray cast iron or aluminum. The sand casting process is most common, using green sand molds with wood or metal patterns. The molds contain cores to form water jackets around the cylinders. After casting, the blocks undergo machining like grinding, boring, and honing to produce smooth surfaces and precise dimensions for components to fit properly. Quality control of the sand mixture, mold compression, risers, and cooling rate is important to avoid defects from forming in the final casting.
Crankshaft Manufacturing Process sequence Omar Amen
This presentation slides Discusses how to manufacture crankshaft
Slides contains:
- Introduction to crankshaft ( what is the crankshaft ).
- Main parts of crankshaft.
- Types of crankshaft.
- Design of crankshaft.
- Finite element analysis for crankshaft ( Structure Analysis & Thermal Analysis ).
- Material selection ( select the suitable materials for manufacture crankshaft and suitable percentage of alloying elements in crankshaft according to required mechanical properties ).
- Manufacturing process sequence ( Forging steps & Machining steps ).
- field research for crankshaft manufacturing (Nallicheri, 1991, contains conditions of manufacturing , Cost Analysis according to factors, and Cost Analysis according to process ).
Drive Selection for Large LOESCHE Vertical Roller MillsLOESCHE
Rising demand from the cement industry for ever greater mill capacities is having implications for the drive systems that have been used up to now. With conventional drive solutions reaching their limits, the world's leading gearbox manufacturers are developing new systems that can offer realistic alternatives for the higher-capacity mills that are now being ordered and delivered.
Henan Dajia Mining Machinery Co., Ltd is a Chinese company that specializes in the design, production, and installation of rotary kiln systems. They offer comprehensive services including on-site analysis, training, and innovative solutions to help plants optimize operations. Rotary kilns are large rotating cylinders used for processes like drying, calcination, and sintering of materials continuously using hot gases generated inside or outside the kiln. Dajia designs kilns for applications such as cement production, pet coke calcination, and sponge iron manufacturing.
This document describes the components and processes involved in a batch type asphalt plant. Key components include cold aggregate storage, a dryer for heating and drying aggregates, screening to separate aggregates by size, hot bins to store separated aggregates, and a pugmill mixer. Aggregates are weighed and mixed with asphalt in the pugmill in batches before being discharged. Modern plants have increasing levels of automation but generally involve weighing aggregates from hot bins and mixing them with asphalt in the pugmill.
Vocational Training on Bhilai Steel PlantPiyush Verma
B.S.P a unit of steel Authority of India Ltd. Inagurated at 1959 by the President of India Dr. Rajendra Prasad with a production capacity of 1.0 million ton.
B.S.P is Indian sole procedure for rails and heavy steel plates and major producer of structural.
The plant is the sole suppliers of the country’s longest rail tracks of 260 meters. With annual production capacity of 3.153MT
The document provides an overview of lubrication at cement plants, breaking it down into 5 segments: mines, limestone processing, calcining, clinker grinding, and captive power plants (CPPs). It describes the typical equipment used in each segment, such as dump trucks and excavators in mines, crushers and ball mills in processing, rotary kilns and girth gears in calcining. The key lubricants used include hydraulic oils, greases, engine oils, and specialty greases. CPPs that run on diesel are noted to have the highest lubricant consumption of around 10,000 liters per month during peak seasons. The objective is to highlight typical equipment and lubricants without recommending specific brands.
Latest Technological Innovation in Grinding With the Vertical Roller MillLOESCHE
Without any doubt, today's grinding plants have to feature highly efficient mills with high efficiency classifiers showing low specific energy consumption and the highest possible mechanical durability.
The document provides information about Indo Farm Equipment Limited, an ISO certified company located in Himachal Pradesh, India that manufactures tractors, cranes, engines, and generators. It discusses the company's founding, facilities, research and development activities, and organizational structure. It also describes the foundry plant's objectives, core making process, types of cores used, and the activities completed during a 10-day training session in the core shop, including making different types of cores by hand and machine.
This 3 sentence summary provides the key details about the industrial training report:
The report describes Akbar's 4 week industrial training at the foundry shop of Indo Farm Equipment Limited in Baddi, Himachal Pradesh. The training involved learning the various processes used in the foundry shop such as core making, mold making, melting metals, and finishing casted parts. Akbar gained hands-on experience working in the core shop and observing the other processes like molding, melting, pouring, and fettling during his training.
This document provides an overview of the various departments within a steel plant, including the steel melting shop, continuous casting shop, blooming and billet mill, forge shop, plate mill, heat treatment and finishing shop, conditioning shop, mechanical repair shop, and boiler house. It describes the key processes and equipment used in each department to produce and process steel, such as electric arc furnaces, ladle furnaces, soaking pits, rolling mills, forging presses, and heat treatment equipment. The goal of the plant is to produce steel products like slabs, blooms, billets, rounds, and plates through melting, casting, rolling, forging, heat treating and other processes.
Industrial training report with Mechnaical Engineering department KashmirNauman Wani
This presentation is based on the industrial training that i did in Mechanical Engineering department Kashmir. this presentation has been Submitted in partial fulfillment of the requirement for the award of the degree of bachelor of Mechanical Engineering
The document provides information about Harpreet Singh's training report at Hindustan Machine Tools (HMT) Pinjore division from June 2nd to July 11th, 2014. It discusses the company profile and various divisions of HMT including the Tractor Division, Engine Shop, Heavy Machine Shop, Engine Assembly, and Heat Treatment processes. The key activities at each division involve manufacturing and assembling various components for tractors through machining and other processes.
Prince Gupta presented on the various production shops at Diesel Locomotive Works (DLW) in Varanasi, India. DLW was established in 1956 to manufacture diesel-electric locomotives for Indian Railways. It has production shops for heavy welding, maintenance, light machine work, and rotor assembly. Within these shops specialized welding techniques like SMAW are used to join locomotive components. Preventative maintenance is also important to minimize breakdowns and keep production efficient. The pipe shop specifically fabricates pipes to transport fuel, air, and water throughout the trains.
This presentation provides an overview of HMT Machine Tools Ltd. in Ajmer, India. It discusses the company's establishment, departments, manufacturing processes, products, achievements and customers. Key points include: HMT was established by the government of India in 1953 and diversified into various industries over time; the Ajmer unit focuses on precision grinding machines; major departments include manufacturing, assembly, and foundry; processes like pattern making, sand moulding, and metal melting are used; products include various CNC grinding machines; and customers are in automotive, engineering, defense, and bearing industries.
HMT Machine Tools Ltd Ajmer Practical Summer Training PresentationSiddharth Bhatnagar
This presentation provides an overview of HMT Machine Tools Ltd. in Ajmer, India. It discusses the company's establishment, departments, manufacturing processes, products, achievements and customers. Key points include:
- HMT was established by the Indian government in 1953 and diversified into various industries over time. The Ajmer unit focuses on CNC grinding machines.
- Major departments include manufacturing, assembly, foundry, maintenance, inspection and HR.
- The foundry produces metal castings using processes like pattern making, sand moulding, and metal melting.
- Notable products are CGM-225, GTC28, and CGM-175 CNC grinding machines.
-
The document is a micro project report on the manufacturing of a camshaft. It discusses the various materials used to make camshafts such as cast iron, steel, and aluminum. It also outlines the processes involved which include designing, casting, forging, heat treatment, and machining operations like turning, drilling, and grinding. The aim is to collect information about the different materials and manufacturing methods for camshafts.
Scooters India Limited is an automobile manufacturing company located in Lucknow, India. It was established in 1972 and acquired technology and designs from Italian company Innocenti. The company produces three-wheelers and had previously also produced two-wheelers. It has various departments like production, design, finance, and marketing. Key production processes involve welding, machining, painting, and assembly of vehicle components. The main raw material used is mild steel and the company has detailed specifications for the components it manufactures.
The document summarizes the process for manufacturing a clutch bell at Scooters India Limited. The process begins with shearing steel sheet in the press shop (Line 12) to form strips. The strips then undergo blanking and drawing, re-striking, and piercing and embossing operations in the press shop. Next, the parts are heat treated in Line 05 before being phosphated in Line 14. The parts then return to the machining shop (Line 08) for inspection. Finally, the clutch bells are assembled into the gearbox and engine, which are then assembled into the final vehicle. The document provides details on the equipment, materials, and processes used in each manufacturing line.
SAM Turbo is an Indian company established in 1971 that is a leader in manufacturing centrifugal slurry, water, and chemical pumps and spare parts. It has over 44 years of experience and focuses on pumps and solutions for industries like mining, minerals, power, paper, and chemicals. The company has grown to 890 employees across two plants in Coimbatore and boasts an 85% market share in slurry pumps in India under the leadership of CMD K. Sambath Kumar and JMD S.K. Sentilkumar.
BWE Ltd, formerly Babcock Wire Equipment Ltd, has operated from its Ashford headquarters in the Southeast of England since 1969, when the company first produced cold welding machines. Conform™ machines have been manufactured since 1976 when they were initially used for extruding round wire. Continuous development aimed at extending the capabilities of the Conform process led to an
increasing number of applications including magnet wire, electrical conductors, refrigeration tube and ultimately, in 1984, the introduction of the Conklad™ process for aluminium clad steel wire and CATV and fibre optic cables.
This presentation discusses different types of boilers. It begins by defining a boiler as an apparatus that produces steam using heat from fuel combustion. Steam produced is used for power generation, heating buildings, and industrial processes. Boilers are then classified based on their orientation (horizontal, vertical, inclined), tube configuration (fire tube, water tube), firing method (internally fired, externally fired), circulation (forced, natural), pressure (high, low), and number of tubes (single tube, multi tube). Specific boiler types are also examined, including Cochran, Lancashire, and locomotive boilers. Key differences between fire tube and water tube designs are outlined.
This document provides a curriculum vitae for Gajanan N Sawant, who has 21 years of experience in manufacturing. It details his work history including his current role as Plant Head at Oriental Foundry Pvt Ltd since 2015, where he successfully completed a greenfield steel casting project. It also outlines his previous role as Manufacturing Head at Ashok Iron Works Pvt Ltd, where he increased production levels and reduced costs. The CV provides extensive details on the equipment and processes handled during his career in areas like moulding, melting, core making, and more. It positions him as an experienced professional conversant in quality systems and improvement techniques.
Industrial training presentation (mechanical engineering)Rahul Banerjee
Giving all the details on what are the process happen in a industry.Main focus on estimation.Effects are implanted too.
The presentation gives all the details of this industry as a trainee.
MULTI PURPOSE HYDRAULIC MACHINE PROJECT Chirag Patel
this is PPT of B.Tech project of
MULTI PURPOSE HYDRAULIC MACHINE
see the video on this link => https://youtu.be/JsXd869-aaY
for more contact 9898398625
Final Project Report- Shreyas Gupta, IIT GuwahatiShreyas Gupta
1. The document discusses implementing automatic program selection for machining crankcases on a Makino PS 65 CNC machine. Currently, workers manually sort and select programs and offsets, risking wrong machining.
2. It reviews casting techniques and identifies pressure die casting as most suitable for crankcases, providing close tolerances, surface finish, and high production rates. However, minor offset differences between dies still require manual offset selection.
3. The proposed solution is to use model sensing to automatically identify the die type and select the correct program and offsets, eliminating human error while machining crankcases on the CNC machine.
Raghunath V completed an industrial training at Salem Steel Plant from December 4-15, 2017. The report summarizes the processes and facilities within the plant's Hot Rolling Mill and Cold Rolling Mill. It describes the key units of each mill, including walking beam furnaces, roughing mills, annealing lines, and various rolling, cooling, and cutting equipment. The goal of the training was for Raghunath to understand the steel production processes firsthand at one of Steel Authority of India's special steels units known for stainless steel sheets and coils.
Neel Auto Pvt. Ltd. Pantnagar Internship ReportPradeep Yadav
The JBM Group is an Indian automotive components manufacturer established in 1983. It has over 42 manufacturing plants globally and supplies components to major automakers. Neel Auto Pvt Ltd is one of JBM's companies and a supplier of components for two-wheelers. It has facilities for pressing, welding, painting and other operations. The document provides details about Neel Auto's departments, production processes like pressing and quality policies. It describes the press shop operations and types of presses used for manufacturing parts like fuel tanks, chains and swing arms.
Similar to Full Industrial Report Milnars Pump Ltd. (20)
Presentation of IEEE Slovenia CIS (Computational Intelligence Society) Chapte...University of Maribor
Slides from talk presenting:
Aleš Zamuda: Presentation of IEEE Slovenia CIS (Computational Intelligence Society) Chapter and Networking.
Presentation at IcETRAN 2024 session:
"Inter-Society Networking Panel GRSS/MTT-S/CIS
Panel Session: Promoting Connection and Cooperation"
IEEE Slovenia GRSS
IEEE Serbia and Montenegro MTT-S
IEEE Slovenia CIS
11TH INTERNATIONAL CONFERENCE ON ELECTRICAL, ELECTRONIC AND COMPUTING ENGINEERING
3-6 June 2024, Niš, Serbia
DEEP LEARNING FOR SMART GRID INTRUSION DETECTION: A HYBRID CNN-LSTM-BASED MODELgerogepatton
As digital technology becomes more deeply embedded in power systems, protecting the communication
networks of Smart Grids (SG) has emerged as a critical concern. Distributed Network Protocol 3 (DNP3)
represents a multi-tiered application layer protocol extensively utilized in Supervisory Control and Data
Acquisition (SCADA)-based smart grids to facilitate real-time data gathering and control functionalities.
Robust Intrusion Detection Systems (IDS) are necessary for early threat detection and mitigation because
of the interconnection of these networks, which makes them vulnerable to a variety of cyberattacks. To
solve this issue, this paper develops a hybrid Deep Learning (DL) model specifically designed for intrusion
detection in smart grids. The proposed approach is a combination of the Convolutional Neural Network
(CNN) and the Long-Short-Term Memory algorithms (LSTM). We employed a recent intrusion detection
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train and test our model. The results of our experiments show that our CNN-LSTM method is much better
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5214-1693458878915-Unit 6 2023 to 2024 academic year assignment (AutoRecovere...
Full Industrial Report Milnars Pump Ltd.
1. Milnars Pumps Ltd.
89-90 TONGI INDUSTRIAL AREA, GAZIPUR
ME370 INDUSTRIAL TRAINING
REPORT SUBMITTED BY
1410156 SHAFAT SHARAR
1410141 MD. SAMIM UL ISLAM
2. Overview
Milnars Pumps Limited is primarily a pump manufacturing company which also produces a number of
other machine parts. Being one of the rare companies with its own pump testing setup, Milnars Pumps
provides pump testing services as well. Facilities and equipments in the factory are adequate. The
industry primarily focuses on industrial heavy duty pumps, although sometimes they manufacture
household pumps also. This report will discuss on the various departments for pump manufacturing, the
processes each parts of the pump goes through up to export, the production and facilities, the efficiency of
the workers and operators, the role played by the management, any possible ways of improvement, and an
overall picture of the current state of the industry.
History
Milnars Pumps started its journey as KSB Aktiengesellschaft in 1962 in the then East Pakistan. The
German company renamed itself to KSB Pumps Company Bangladesh Ltd after liberation in 1972. After
that the company slowly stopped their business and their license was bought by Aftab Group after some
time and renamed the company to Milnars Pumps Ltd in 1980.
Location
Milnars Pumps Ltd factory is situated at Tongi industrial area. The establishment, similar to many other
industries in the area, is close to Turag river. Local waste management system makes it easy for
processing and transporting factory waste. The nearby market area makes sure the small supplies are
always at hand.
As the factory deals mostly with industrial pumps, transportation of products to other local industries is
very easy and economical.
Being not very far from Dhaka outskirts, it is rather accessible for the people in the capital.
2
3. Pump Production
Pumps are obviously the company’s main product. The types of pumps Milnars produces are detailed as
follows:
i. Centrifugal Pumps: These pumps come with a single impeller to accelerate and pressurize the fluid
and a volute casing that increases pressure further, helping the fluid to gain greater delivery pressure.
The factory produces mostly centrifugal pumps. The motors to be paired are imported however. The
models produced are named proprietarily. E.g. : 40-20 AR (smallest, 2” delivery side diameter),
150-26 (largest, 8” delivery side diameter).
ii. Submersible Pumps: These pumps have no suction head and are staged. Most submersibles
produced are 3 phase induction motor coupled. Motors are imported. Some models are : 150QJ
(smallest, 3” diameter), 300QJ (largest, 6” diameter).
iii. Deep Well Turbine Pumps: Also known as DWT pumps, these are similar to submersible pumps
except for that the motor lies on the ground level, coupled by a vertical shaft. These pumps excel in
efficiency from the submersible pumps and operate at a deeper level. However, the amount of noise
generated make it less suitable for urban or suburb areas. Some models are : B6B (smallest), B12B
(largest).
iv. Multistage Centrifugal Pumps: Similar to centrifugal pumps except for that these have multiple
stages i.e. multiple impellers to build a huge pressure on the fluid. Each impeller builds up pressure
atop the previous and so these pumps are suitable for heavy fluid moving industry applications.
Milnars Pumps produces only two models of this pump, MOVI32 and MOVI40.
FIG : CENTRIFUGAL PUMP FIG : SUBMERSIBLE PUMP
3
4. Production Line
The various departments in the industry are which the pump parts go through during production. The
major 4 departments are:
i. Foundry Shop
ii. Machine Shop
iii. Assembly Section
iv. Test Bench
Each department is separate from one another in terms of equipments and function.
Foundry Shop
The foundry shop works with the primary part building by casting metal into molds. The method followed
here is conventional with apt equipments available for metal melting and casting for both mass and base
production. The operations in the foundry are by order of part manufacture are as followed:
i. Pattern Making: Patterns used are made of wood. Patterns are what give shape to the molds.
Patterns are of two types : Regular Patterns and Core Patterns. Regular patterns shape a solid part.
Core patterns sit within the Regular pattern to create a hollow space within a part. E.g. the volute
casing has a hollow part where water flows through. So that uses a core pattern alongside the regular
external pattern.
ii. Sand Preparation: Sand is prepared before mold can be made. Sands contain additives in order to
enhance their property. Two types of sand is prepared for different purposes. White sand or regular
sand is SiO2 with some additives for nominal bonding. This sand is cheap and not high heat
sustainable. The mold shape may break at high temperature. The costlier Red sand has more additives
added so bonding is very good and sustained at very high temperatures. This mold sustains shape very
FIG : DEEP WELL TURBINE PUMP FIG : MULTISTAGE CENTRIFUGAL PUMP
4
5. well at high temperatures. This sand is used when intricate shape is to be achieved. White sand is used
for rough surfaces.
iii. Mold Preparation: Sand is used accordingly to the required intricacy of the casting. For simple
shape where the exact shape retaining isn’t required, white sand is used as it is cheap. For parts
requiring retainment of shape, red sand is used. Most parts use mixture of both as they have uneven
construction. Mold is shaped either by using molding beds or frames. Conventional method is
followed when making molds.
iv. Metal Melting: The factory has 2 induction furnaces and 1 Cupola furnace. Induction furnaces have
capacities, 200 and 300kg. These are used for mostly base production. The furnace controller used
regulates 425V and 125A current supplied. A transformer is used to regulate the voltage as main line
sometimes fluctuates around 350-360V even. The electric controller is started beforehand to start up
the furnace and it slowly reaches the required voltage and amperage. The Cupola furnace is used
mainly for mass production with a capacity of 5 Tons. Fuel used for this one is mainly coal. Metals
melted are by majority of use:
i. Manganese Steel (Fe.Mn Scrap)
ii. Cast Iron
iii. Mild Steel (Steel rods)
iv. Stainless Steel
v. Aluminum
vi. Bronze
v. Casting: A hydraulic mechanism is used to lift and slant the furnace and load the molten metal charge
into a bucket. The bucket walls are coated with red sand in order to withstand the heat. A crane is
used to lift and unload the charge through the runner.
vi. Cleaning: After the molten metal cools down my natural air flow, the rough extrusions from the
runner and the riser are cut off and the surfaces are cleaned using a steel brush so that little to no sand
remains in the part.
vii. Quenching: For parts with intricate shape, quenching isn’t done. Parts with more or less rough
shapes are quenched with water. The stone crushing jaws that are produced are quenched after further
heating and hardening of the material in a large oven.
After cleaning, the parts are sent to the machine shop for machining and finishing.
The Foundry section of the industry is quite competent and has regular production going on. When pump
parts aren’t being produced, stone crusher jaws are produced. This is very economical for the company as
it’s using the available resources and making profit regularly and continuously. Quite impressive.
5
7. FIG : MOLD PREPARATION FIG : MOLD BED
FIG : IRON MANGANESE SCRAP FIG : STEEL SCRAP
FIG : CLEANING THE SAND FIG : METAL MELTING AND CASTING
7
8. Machine Shop
The machine shop is apt with equipments and supply. The machines available at large are:
• Engine Lathes
• Vertical Lathes
• Turret Lathes
• Drilling Machines
• Grinding Wheels
• Milling Machines
The machines are used to do various operations on the rugged parts. Finishing operation is common on all
parts. The operations done on each part are numbered according to the total number of operations for that
part. E.g. the volute casing goes through 5 operations in total. The operations are named, first operation,
second operation and so on. In brief detail these operations are:
i. 1st Operation: Turning is done outside the casing where the impeller will mesh
ii. 2nd Operation: Facing is done in the inner side for the impeller to sit
iii. 3rd Operation: Turning is done on the delivery side to get required diameter
iv. 4th Operation: Drilling is done on the flanges for bolting
v. 5th Operation: Finishing is done by grinding the remaining surfaces with a hand grinding tool
Most notable in the machine shop are the huge vertical lathes. These lathes are fitted with 5 tool turrets.
The turret axis is normal to the vertical motion of the lathe.
The shop is equipped with a good number of engine lathes which are operated most frequently for turning
and facing operations. The small parts are machined here. The lathes with longer bed sizes are used to
machine shafts and pipes. A hydraulic guiding equipments is fitted to the lathe for sizing the shafts as they
have varying diameters along the length.
For every small parts after machining, two separate go-gauge and no go-gauge is used to check the
accuracy of the dimensions. These gauges are of different shapes and sizes according to the part.
8
10. Assembly Section
The assembly section is where all the parts come in machined and ready to put together. The steps
commonly followed for a centrifugal pump assembly is approximately as follows:
i. The volute casing is checked for leak by sealing up the suction and delivery by covers and filling it up
with water. A pressure testing setup is available for this purpose. If the water leaks, then the casing is
marked unusable and sent off to dismantle.
ii. A bearing heater is used to heat up the bearings up to almost 140ºC. This increases the internal
diameter of the bearing so that it easily slips into the shaft. Two bearings are fitted to each shaft to
stay in the bearing housing. Grease is applied to the bearing balls.
iii. The shaft bearing assembly is then rammed into the bearing housing. Lubricant is applied to the shaft
after the assembly is placed in properly.
iv. The volute casing is then bolted on the opposite side of the suction side to the bearing housing. The
other side of the housing is sealed off with a cover.
v. Impeller is inserted through the suction hole and fitted to the shaft using a standoff and an impeller
nut. The assembly section typically has 3 major sizes of impeller nuts for various pump sizes.
vi. Suction side cover is fitted and bolted. There are no leaks at this point as leak testing was done
beforehand.
vii. A coupling disc is fitted to the opposite side of the shaft where a T-slot is located. The disc is meshed
and then a bolt is screwed so the disc doesn’t fall off.
viii.The motor and the pump shaft axes are aligned and meshed via the coupling disc. This alignment is
done by the help of a crane.
ix. During the whole assembly process, lubricant is used abundantly whenever needed at every moving
contacts. Gaskets are used between flanges or any meshing where leak prevention was required.
The assembly section had good number of equipments. However, the whole process is manual and very
time consuming. During mass production the assembly section lags very much due to the slow process.
Absence of automated machinery hurts the production quite a bit.
After the assembly is done, the pump is good to go for testing. Even without the testing, the pump is a
work ready unit at this point. So the pump leaves the production site and for the test bench.
10
12.
12
FIG : ASSEMBLY OF A CENTRIFUGAL PUMP
FIG : ASSEMBLY SECTION TOOLS
FIG : ASSEMBLY OF A SUBMERSIBLE PUMP FIG : ASSEMBLY OF A SUBMERSIBLE PUMP
13. Test Bench
Performance testing of the pumps is done at the Test bench. A complete setup is available for testing of
pumps having discharge of up to 3 cusec. The flow is separated into an upper and a lower pipe setup. The
lower having a maximum flow capacity of 2 cusec and the upper of 1 cusec for a total of 3. The upper
piping is mainly for overflow, but heavy duty pumps are tested using that part anyway.
There are various equipments available which are used to calculate the Head and the Discharge of a given
pump. These values are used to further calculate efficiency and other related conditions. The discharge is
varied using a flow control valve and the according head is measured from other calculations.
A digital wattmeter is available which gives the readings of supplied current and voltage to the operating
motor. As the power line is a 3 phase line, details of all 3 phases appear on the wattmeter for easy
obtaining of data.
Bourdon pressure gauges are used to measure pressure on the delivery and the suction side (if available).
The velocity of flow can then be figured out.
The area of flow is a V-notch of known geometry. The height (372mm) of which can be used to obtain
area of flow and in turn these data are used to easily measure the flow rate.
The steps followed in the testing procedure for centrifugal pumps are as follows:
i. The pump is mounted on the base frame aligned with a suitable motor
ii. Suction and delivery pipes are fitted as per requirement to ensure proper suction from the pool the
delivery through the V-notch or orifice plate
iii. Valve is fitted on the delivery line to control the flow and pressure as required
iv. A suction gauge is fitted on the suction pipe near the suction flange of the pump
v. A delivery gauge is of suitable range is fitted on the delivery pipe before pressure control valve
vi. The motor is connected to the starter
vii. The motor is started and the readings at different pressures are taken and recorded in the pump test
data and calculation sheet
viii.Calculation is done to obtain the results
The steps followed in the testing procedure for submersible pumps are as follows:
i. The pump-motor is installed on the pool so the the pump is well below the water level
ii. A suitable delivery pressure gauge is fitted through a rubber pipe to read the pressure to the delivering
water at the taping at the middle of the column/rising pipe
iii. The motor is connected to the starter
iv. The motor is started and the readings at different pressures are taken and recorded in the pump test
data and calculation sheet
v. Calculation is done to obtain the results
13
14. A sample of how the calculations are done for a centrifugal pump is shown below:
Some numbers used in this calculation directly are due to adjustment of the setup, e.g. different placement
of the pump, custom equipments. Some values like 2.725 in the WHP comes from the equation P =
Q*γ*H, which simplifies by converting the units to the given equation. γ = 9810, Q in seconds means
dividing the term by 3600. So essentially, 9810/3600 = 2.725.
After the testing is done and the pump is rated, it is officially ready for customer handover. The pump is
dried off and packaged with a suitable motor.
Suction gauge reading = Ps in-Hg = Ps x 0.346 m of water
Delivery gauge reading = Pd kg/cm2 = Pd x 10.01 m of water
V notch height = 372mm
Water surface distance from top point of V notch = V mm
Watt meter reading = Wm kW
Total Available Head, " m
Discharge, m3/hr
Working Horse Power, " hp
Input Horse Power, " hp
Combined Efficiency, " %
H = Ps * 0.346 + Pd * 10.21 + 0.34
Q =
(
372 − V
304.8 )
2.47
* 2.52 * 102
WHP =
H * Q * 2.725
746
IHP =
Wm
0.746
η =
WHP
IHP
* 100
H Q WHP IHP Efficiency
1 51.01 70.95 13.22 24.53 53.89
2 61.22 62.55 13.99 24.80 56.41
14
16. Factory Facilities
Milnars Pumps Ltd is a small sized factory but it has a good number of facilities that an industry should
have and sometimes more even. The facilities are primarily, power supply and gas supply.
Power Supply
Gas Supply
Production Rate
The factory doesn’t do very well in pump production. Most of the time, mass production equipments are
turned off. So production mostly depends on customer demand. During the time of the industry visit, an
average of up to 10 pumps per week was assembled. Up to 5 pumps are tested at the test bench daily.
However, despite the low pump production, not all equipments sit idle. The factory produces stone
crusher jaws for stone crushing machines. This machine part has quite a high demand and as per this item
has a production of almost 20 - 100 units per week.
Other small machine parts are also manufactured in the factory.
Supplier : PDB
Connection Type : Industrial 380V 3P
Annual Consumption : 20000-25000 Units (approx.)
Load Factor : N/A
Internal Power Plant : N/A
Backup Supply : 2 Diesel Generators (100KVA, 250KVA)
Supplier : Titas Gas
Connection Type : Natural Gas
Annual Consumption : Data Unavailable
Internal Power Plant : N/A
16
17. Comments
From the industry visit we got an overall picture of the state of the industry during that period. The
factory on basis of equipments and facilities is quite remarkable. Since it was a German company and
most equipments from then are still available, and those are very good quality machines. Also additional
equipments have been added over time.
The test bench is a strong suit to the industry as it is one of the rare industries to have one. Many pump
companies rely on Milnars to get their pumps tested.
The most notable negative side to the factory system is bad top level management. Investment in the
current state is negligible. Whereas modern factories are using automated technologies to speed up and
make more efficient their production processes, Milnars sits way behind the competition. Poor investment
and lack of future proof management hurt the overall production of the factory greatly. As we will see,
this is the problem that spreads and causes most other problems of the industry.
The lowest level management also somewhat lacks in hiring skillful workers. Most workers don’t have
proper knowledge of the machines they operate in the machine shop, and just follow steps. This results in
incompetent workflow and a barricade to new ideas being generated from the workers. Also, the machines
aren’t operated efficiently which results in higher depreciation and maintenance cost to the industry.
The assembly section is the weakest section of the factory. Every assembly is done manually. No
automated tools are used even in case of bolting the screws. This process eventually becomes very time
consuming. Even though enough pump parts come in through the machine shop, the assembly section
chokes the production noticeably.
The casting material quality is kept at an acceptable level. The material is tested manually by a chemist.
But if we look at the competing pump factories, they can offer far better material and production pretty
easily due to modern components.
Seeing all the negatives boil down to poor management, we can get a clear picture of how very important
the management sector is to an industry. A strong management can almost always turn the tables for any
business. Our suggestion will be to analyze the current pump market and make heavy investments on
automated technologies all over the factory.
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