HMC internship report

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UNIVERSITY OF SARGODHA
Internship Report Prepared by
Hafiz Zia-ur-Rahman
Submitted to
Mr. Mudasir Chaudhry
(Management Training Centre)
Incharge MTC
Mr. Ali Asghar
Dated: 29th August, 2017

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ACKNOWLEDGEMENT
All praise is to Almighty Allah, the Beneficent, and the Merciful. He showered his
great blessings upon us in the form of Holy Prophet, Hazrat Muhammad
(P.B.U.H).
With much effort and time spent, I thank God for being able to complete the
internship in HMC.
I wish to take this space and opportunity to express my thanks to all officials for
providing me helpful information and exchanging thought and HMC for
supporting us in doing this internship.
In performing my work at HMC, I had to take the help and guideline of some
respected persons, who deserve my greatest gratitude. The completion of this work
gives me much Pleasure. I would like to show my gratitude to the following
Persons
1. Mr. Ghulam Mustafa
(Incharge Machine shop)
2. Mr. QaiserNaeemButt
(Incharge Layout Section of Fabrication)
3. Mr. Mehran Ahmed
(Welding Engineer Fabrication Shop)
4. Mr. Shamshad Gill
(Incharge Machine shop)
I would also like to thanks all those who have directly and indirectly guided me
while doing my work at Heavy Mechanical Complex Texila, Punjab, Pakistan.

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Table of Contents
Sr. no Workshops & Labs Page no.
1. Introduction to HMC ………… 4
2. Production Planning & Control ……….. 6
3. Basic Machine Shop ………… 8
4. TTC & Heat Treatment ………… 23
5. Fabrication Shop ………… 27
6. NDT Lab ………… 34
7. Material Testing Lab ………… 37
8. Pattern Shop ………… 40
9. Forge shop-I&II ………… 43
10. Inspection ………… 44
11. Recommendations ………… 45

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1. INTRODUCTIONTOHMC
Heavy Mechanical Complex (Pvt) Limited is a leading engineering goods manufacturing
enterprise in Pakistan located at Taxila about 32 Kilometers north of capital Islamabad. It is a
professionally managed progressive organization with over 160,000 sq. meters covered facilities
and 1,100 employees.
HMC defines itself as “A technical institute in which all types of machines including Sugar
plants, Cement Plants, Road rollers, Over Head Cranes ranging from 0.5 to 50 tons Heat
Exchanger boilers, Special Defense parts (i.e., NDC works), Special Vibratory Rollers (which
can bear statistically 10 to 12 tons vibratory load) and Pakistan steel works. Some other
processes that are also done by HMC are Designing and manufacturing and assembling and
installation with the certification of ISO – 9001 and ASME Standards.
Heavy Mechanical Complex Ltd. (HMC), Taxila is a major heavy engineering subsidiary of the
State Engineering Corporation (SEC) under the Ministry of Industries & Production,
Government of Pakistan.
The Heavy Mechanical Complex (HMC), the biggest undertaking of its type in Pakistan, was
established in 1976 with Chinese assistance. The Heavy Forge Factory (HFF) at this complex has
proved crucial for Pakistan's defense production needs. HMC has the capability for designing,
engineering and manufacturing of industrial plants and machinery.
HMC manufactures equipment for hydro-electric power plants, thermal power plants, Sulphuric
acid plants, industrial alcohol plants, oil & gas processing plants, and chemical & petro-chemical
plants, etc. Boilers, cranes, construction machinery, material handling equipment, steel structure,
railway equipment, etc. are some of the other products which are produced on regular basis.
1.1Departments:
 Sales and Marketing Department
 Design and Engineering Department
 Production Planning and Control Department
 Production Shops (HMC1 & HMC2)
 Quality Assurance Department
 Project Management Department
 Human Resources Department
 Finance and Budgeting Department

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1.2 PRODUCTS:
Heavy machineries are being produced here like:
 Road rollers
 Overhead cranes
 Mobile crane
 Sugar plants
 Cement plants
 Oil refineries
 Power plants
 Pressure vessels
 Boilers 40 to 80 Ton
 Heavy duty machinery
 Hydral power plants
 Turbines
 Rod construction machinery
 Asphalt mixing plant etc.
First Boiler with Capacity of 140 Tons
ASME
ASME STAMPS
U: Pressure vessel according to ASME section VIII, Div. I
U2: Pressure vessel according to ASME section VIII, Div. II
S: Power Boilers
PP: Pressure Piping
1.3 Major Achievements:
 Pioneer in getting ISO 9001 certification and helped other local industries to acquire
 ISO 9001 certification
 Acquired Authorization from American Boiler Board to use ASME STAMPS for power
 boilers, pressure vessels and pressure pipes
 Attained capability to design, engineer, manufacture machinery for turn-key supply of
 higher module sugar and cement plants
 Pursue a dynamic marketing and engineering product diversification, policy as a
 consequence diversified into energy sector (Thermal and Hydral Power Plants) and oil
 & gas processing industry etc.

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2. Production,Planning& Control
The Production planning and control department has been organized with objective of improving
company performance. This department is responsible for production planning & control,
Dispatches of finished equipment’s and sales tax related activities. The department is headed by
General Manager PPC and comprise the following section
2.1Projectplanning:
 To ensure receipt of all drawings and documentation from design as per contract and
according to the schedule for production and procurement
 To issue ‘material purchase requirement to MMG’ for indenting
 To prepare and issue job orders
 To prepare data for ICR for survey by FBR
 To prepare necessary production documents for manufacturing i.e. casting and forging in
case of FFW
2.2 CorePlanning:
Core planning section has following works.
 Master schedule planning.
 Order Activity plans.
 Monitoring of all the schedules.
 Preparation of various periodic reports for MIS.
 Maintaining of balance order position.
 Maintaining sale and production report.
 Sale/production budget.
 Project review meeting and follow up.
 Data entry for DP list and updating of all files.
 Processing of all data and generation of reports.

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2.3MaterialManagement(MMG):
a) MMG Section:
 Material requirement planning.
 Intending and follow up of indent.
 To keep updated purchase status of all project documents.
 Establish stock levels for general consumable items and raw materials.
 Coding of store items.
 Insurance of material to appropriate job.
 To keep and maintain updated stock status of all store items.
 To look after stores and related functions.
b) GeneralStores:
 To receive and issue all the materials and equipments in stores as per laid down
procedure.
 Maintain detailed record of stock movement.
 Maintain stock location system.
 Ensure daily submission of issue and receipt statement to concerned department.
 Ensure that all the storage areas (open/covered) are kept properly secured and organized.
2.4ProductionTechnology:
a) Feasibility/Quantitative Detail:
 Feasibility study and quantitative details of client´s enquiries for cost estimates.
b) ProcessPlanning:
Preparation of following documents.
 Detail parts list.
 Route card (machining and fabrication) if required.
 Cutting plans.
 Time sheets.
c) Tooldesigning:
 Designing of all types of press tools, dies, templates, jigs and fixtures.
 To produce drawings for machinery components for maintenance.
 Cutting plans, cutting/marketing templates for shop.

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2.5 DispatchCell/MaterialHandling:
a) Materialhandling:
 To keep all the material handling equipment operation worthy.
 Provide material handling services to stores and dispatch cells and shops as and when
required.
 Keep the open yard tidy and organized.
 Receive materials from shops for surface preparation.
 Arrange sand blasting/paint as per contractual requirement.
 Receive raw materials from general stores for onward issuance to shops against job
orders.
b) DispatchCell:
 To receive finish goods from shops/material handling sections.
 To draw the standard items/equipment’s from stores for dispatch to costumer/sites.
 To organize preservation/packing.
 Maintain detailed dispatch records of finished goods, equipment’s, standard items against
each contract.
 Organize transportation.
 Ensure complete and accurate documentation along with each dispatch.
 To prepare the dispatch plans and ensure compliance.
3. BasicMachineShop
Machine shop is considered as one of the most important shops of Heavy Mechanical Complex
as it contributes a major part in the income of the industry. In this shop different type of actions
and works can be performed with the help of different machines each perform unique work
which is performed under the supervision of experienced workers having experience of decades
which definitely cannot be compared with the theoretical work of anyone else.
Machine shop engineers always try to complete job with minimum cost but at the same time
quality would also not be sacrificed so lots of factors are included in a shop which makes it
unique and compatible.
3.1 Sequence of operation:

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“It is defined as the plan through which workers and engineers have to complete the required job
according to availability of machines “
Explanation
The whole procedure of job making in machine shop may be summarize in an easy way that at
first the request of job is received by PPS department in machine shop they analyse it carefully
and make drawings that helps workers to understand their job along with the plan which makes
easy for them to accomplish goal within the time limit according to the availability of machines
in machine shop or other shops machines may also be used to fulfil the job. This job then
forwarded to incharge of section according to the size of the job so it’s the duty of Incharge and
engineers available there to assign the job to any experienced worker which can effectively
perform the job with minimum usage of material it does not only save material but also so many
other things like cost, time, electricity and man power required for that job.
3.2ToolsusedinMachineShop:
Tool is probably one of the most important component of any sort of machine. The ability and
durability of tool predicts the quality and nature of machining on the job.
There are lots of tools but few important tools we saw in machine shop are:
 Boring Tool
Used in the process of boring.
 High Speed Steel(HSS)
Used for different sort of purposes including threading. Mostly used in lathe machines.
 Tapping Tool
Used for internal threading.
 Broaching Tool
Used to produce splines.
 Turning Tool
Used for turning operation.
3.3Machines/EquipmentinstalledinMachineShop
Machine shop1 consist of various kinds of machines each having its unique identity and importance
in this sector. This kind may not only be classified as for functions only but the maximum capacity of
the machine may also be considered so according to the capacity of job and the availability of crane
the machine shop 1 is divided into three bays which are as follows
 Small bay
 Medium bay
 Heavy bay

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In the machine shop of Heavy mechanical Complex there are nearly 500 machines of different
sizes and capacities. The machine shop of HMC contains various types of machines.
Available machines:
 Lathe machine (three jaws and four jaws chucks, turret).
 Planer.
 Milling machine.
 Drilling machine.
 HDL (heavy duty lathe).
 BVT (boring vertical turret lathe machine).
 Gear hobbing machine.
 Gear shaper machine.
 Straight bevel machine.
 Horizontal lathe machine.
 Radial drilling machine.
 Slotting machine.
 Double housing planner.
 Face plate machine.
 Column drilling machine.
3.4MACHININGOPERATIONSANDMACHINETOOLS:
• Turning and Related Operations
• Drilling and Related Operations
• Milling
• Machining Centers and Turning Centers
• Other Machining Operations
• High Speed Machining
 Machining:

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• A material removal process in which a sharp cutting tool is used to mechanically cut
away material so that the desired part geometry remains
• Most common application: to shape metal parts
• Machining is the most versatile and accurate of all manufacturing processes in its
capability to produce a diversity of part geometries and geometric features (e.g. screw
threads, gear teeth, flat surfaces)
ClassificationofMachinedParts:
1. Rotational-cylindricalordisk-like shape.
Achieved by rotation motion of the work part. Ex. turning and boring
2. Nonrotational(alsocalledprismatic)-block-like orplate-like
Achieved by linear motion of the work part. Ex. Milling, shaping, planning and sawing
 Turning:
• A single point cutting tool removes material from a rotating work piece to generate a
cylindrical shape
• The tool is fed linearly in a direction parallel to the axis of rotation
• Performed on a machine tool called a lathe

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• Variations of turning that are performed on a lathe:
 Facing
 Contour turning
 Chamfering
 Cutoff
 Threading
Facing
Tool is fed radially inward to create a flat surface.
Chamfering
Cutting edge cuts an angle on the corner of the cylinder, forming a "chamfer".

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Threading
Pointed form tool is fed linearly across surface of rotating work part parallel to axis of rotation at
a large feed rate, thus creating threads.
LatheMachines
• Most lathe machines are horizontal but vertical lathe machines are also used for jobs with
large diameter relative to the length and for heavy work
• The size of the lathe is designated by swing and maximum distance between centers
• Swing is the maximum work part diameter that can be rotated in the spindle
• Maximum distance between centers indicate the maximum length of a work piece that
can be mounted between headstock and tailstock centers
• 350 mm x 1.2 m lathe means a swing of 350 mm and maximum distance between centers
of 1.2 m

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3.5 MethodsofHoldingtheWorkina Lathe:
There are four common methods used to hold work parts in turning-to grasp the work, center and
support it in position along the spindle axis, and rotate it:
• Holding the work between centers
• Chuck
• Collet
• Face plate

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Holding the Work
between Centers
3 jaw self-centered
Chuck
Collet
Face Plate

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 Boring:
• Boring is similar to turning. It uses a single-point tool against a rotating work part
• Difference between boring and turning:
 Boring is performed on the inside diameter of an existing hole
 Turning is performed on the outside diameter of an existing cylinder
• In effect, boring is an internal turning operation
• Machine tools used to perform boring operations are called boring machines
• Boring machines
 Horizontal or vertical - refers to the orientation of the axis of rotation of machine
spindle

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Vertical Boring Mill
• Figure - A vertical boring mill –for large, heavy work parts
• Usually the work part diameter is greater than its length
• Typical boring machine can position and feed several cutting tools simultaneously
Drilling
• Machining operation used to create a round hole in a work
part
• Contrasts with boring which can only enlarge an existing
hole
• Cutting tool called a drill or drill bit-a rotating cylindrical
tool which has two cutting edges on its working end
• Customarily performed on a drill press

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Radial Drill
• Large drill press designed for large parts
• Head can be positioned at significant distance from the column to accommodate large
work
 Milling:
• A machining operation in which work is fed past a rotating tool with multiple cutting
edges
• Axis of tool rotation is perpendicular to feed direction
• Creates a planar surface; other geometries possible either by cutter path or shape
• Owing to the variety of shapes possible and its high production rates, milling is one of the
most versatile and widely used machining operations
• Other factors and terms:
Milling is an interrupted cutting operation-the teeth of the milling cutter enter and
exit work during each revolution
Cutting tool called a milling cutter, cutting edges called "teeth"
Machine tool called a milling machine

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Basic Types of Milling Operations
Peripheral Milling vs. Face Milling
• Peripheral milling or plain milling:
Cutter axis is parallel to surface being machined
Cutting edges on outside periphery of cutter
• Face milling
Cutter axis is perpendicular to surface being milled
Cutting edges on both the end and outside periphery of the cutter
Types of Milling
• Peripheral Milling
Slab milling
(a) Peripheral milling (b) Face milling

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Slotting
Side milling
Straddle milling
• Face milling
Conventional face milling
Partial face milling
End milling
Profile milling
Pocket milling
Surface contouring
Milling Machines
• Milling machines must provide a rotating spindle for the cutter and a table for fastening,
positioning and feeding the work part
• Types:
 Knee-and-column milling machine
 Universal milling machine
 Ram mill
Bed type milling machine
Planer type
Tracer mills
Tracer mills
CNC milling machines

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Vertical knee-and-column milling machine
Suitable for face milling
Horizontal knee-and-columnmillingmachine
Suitable forperipheral milling

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Ram type knee-and-column machine; ram can
be adjusted in and out, and toolhead can be swiveled
Universal milling machine

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Simplex bed-type milling machine: rigid construction for mass production
Hobbing
Hobbing is a machining process for making gears, splines, and sprockets on a hobbing machine,
which is a special type of milling machine. The teeth or splines are progressively cut into the
work piece by a series of cuts made by a cutting tool called a hob. Compared to other gear
forming processes it is relatively inexpensive but still quite accurate, thus it is used for a broad
range of parts and quantities
It is the most widely used gear cutting process for creating spur and helical gears and more gears
are cut by hobbing than any other process since it is relatively quick and inexpensive.

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4. HeattreatmentShop
This Shop involves various heating and cooling procedures performed to effect micro-structural
changes in a material, which in turn affect its mechanical properties. Heat treatment operations
are performed in HMC at various times during its manufacturing sequences. In some cases, the
treatment is applied prior to shaping. In other cases, heat treatment is used to relieve the effects
of strain hardening that occur during forming, so that the material can be subjected to further
deformation. Heat treatment is also performed at or near the end of the sequence to achieve the
final strength and hardness required in the finished product.
Heat Treatment is process of heating a material to a specific temperature, then cooling at a
specific rate to achieve specific mechanical properties. Iron-Iron Carbide Phase Diagram (Iron
Carbon Phase Diagram) is an important guide for heat treatment of different types of plain
carbon steel.
Heat treatment techniques include

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4.1 Heat Treatment Processes:
HMC has following Types of Furnace and facilities which are used in heat treatment section
 HTS-1 Electric carbon furnace
 Electric box type furnace
 Flame hardening machine for surface hardening
 Chamber type Cleaner
 Electric tempering oil bath
 High temperature salt bath
 Low temperature salt bath
 Medium temperature salt bath
 High frequency induction heat treatment lab
Heat treatment of metals and alloys
Metallic materials consist of a microstructure of small crystals called "grains" or crystallites. The
nature of the grains (i.e. grain size and composition) is one of the most effective factors that can
determine the overall mechanical behavior of the metal.
Heat Treatment provides an efficient way to manipulate the properties of the metal by controlling
rate of diffusion, and the rate of cooling within the microstructure.
Annealing
Annealing is the process of slowly raising the temperature about 50ºC (90ºF) above the Austenitic
temperature line or line ACM in the case of Hypo eutectoid steels (steels with < 0.77%Carbon), about
50ºC (90ºF) in case of eutectoid steel and 50ºC (90ºF) into the Austenite-Cementite region in the case
of Hypereutectoid steels (steels with > 0.77% Carbon). It is held at this temperature for sufficient
Annealing Hardening Tempering
Normalizing Carburizing

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time for all the material to transform into Austenite or Austenite-Cementite as the case may be. It
is then slowly cooled at the rate of about 20ºC/hr. (36 ºF/hr.) in a furnace to about 50 ºC (90 ºF)
into the Ferrite-Cementite range. At this point, it can be cooled in room temperature air with
natural convection. The grain structure has coarse Pearlite with ferrite or Cementite (depending
on whether hypo or hyper eutectoid). The steel becomes soft and ductile.
Normalizing
Normalizing is the process of raising the temperature to over 60 º C (108 ºF), above line A3 or
line ACM Fully into the Austenite range. It is held at this temperature to fully convert the
structure into Austenite, and then removed from the furnace and cooled at room temperature
under natural convection. This results in a grain structure of fine Pearlite with excess of Ferrite
or Cementite. The resulting material is soft; the degree of softness depends on the actual ambient
conditions of cooling.
This process is considerably cheaper than full annealing since there is not the added cost of
controlled furnace cooling. The main difference between full annealing and normalizing is that
fully annealed parts are uniform in softness (and machinability) throughout the entire part; since
the entire part is exposed to the controlled furnace cooling. In the case of the normalized part,
depending on the part geometry, the cooling is non-uniform resulting in non-uniform material
properties across the part. This may not be desirable if further machining is desired, since it
makes the machining job somewhat unpredictable. In such a case it is better to do full annealing.
Hardening and tempering (quenching and tempering)
It consists of heating the metal to a suitable temperature (upper critical temperature), holding at
that temperature for a certain time (soaking), and cooling rapidly. The cooling rate depends upon
the quenching medium and the rate of heat transfer within the steel work piece.
Various quenching media used in HMC are
 Brine – salt water
 Fresh water
 Still oil
Brine quenching is the fastest and air quenching is the slowest.
Tempering
It is a heat treatment technique for metals, alloys and glass. In steels, tempering is done to
"toughen" the metal by transforming brittle martensite into bainite or a combination of ferrite and
cementite.

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Untempered martensite, while very hard and strong, is too brittle to be useful for most
applications. A method for alleviating this problem is called tempering. Most applications
require that quenched parts be tempered (heat treated at a low temperature, often three hundred
degree Fahrenheit or one hundred fifty degrees Celsius) to impart some toughness. Higher
tempering temperatures (may be up to thirteen hundred degrees Fahrenheit or seven hundred
degrees Celsius, depending on alloy and application) are sometimes used to impart further
ductility, although some yield strength is lost.
Precipitationhardening
Some metals are classified as precipitation hardening metals. When a precipitation hardening
alloy is quenched, its alloying elements will be trapped in solution, resulting in a soft metal.
Aging a "solutionized" metal will allow the alloying elements to diffuse through the
microstructure and form intermetallic particles.
These intermetallic particles will nucleate and fall out of solution and act as a reinforcing phase,
thereby increasing the strength of the alloy. Alloys may age "naturally" meaning that the
precipitates form at room temperature, or they may age "artificially" when precipitates only form
at elevated temperatures. In some applications, naturally aging alloys may be stored in a freezer
to prevent hardening until after further operations - assembly of rivets, for example, may be
easier with a softer part.
Induction furnace
An induction furnace uses induction to heat metal to its melting point. Once molten, the high-
frequency magnetic field can also be used to stir the hot metal, which is useful in ensuring that
alloying additions are fully mixed into the melt. Most induction furnaces consist of a tube of
water-cooled copper rings surrounding a container of refractory material. Induction furnaces are
used in most modern foundries as a cleaner method of melting metals than a reverberatory.
Metals melted include iron and steel, copper, aluminum, and precious metals. Because it is a
clean and non-contact process it can be used in a vacuum or inert atmosphere. Vacuum furnaces
make use of induction heating for the production of specialty steels and other alloys that would
oxidize if heated in the presence of air.

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5. FABRICATIONSHOP
Fabrication shop located in mechanical works HMC-1 is setup to create an interracial fault on
materials/work pieces in order to obtain any type of useful assembly or equipment. In HMC
(Heavy Mechanical Complex) Fabrication shop consists of five bays i.e., one heavy bay, two
medium bays and two small bays. Bays are divided as per the capacity of the cranes.
These bays are further splits up into different sections as per work requirement according to the
following arrangements
► Layout Section
► Fabrication Sections 1 to 9
► Machining Section
HMC fabrication shop has full capacity to fabricate every part which is used in boiler, gas tanks,
teem boiler, roar roller parts etc. HMC has following machine in fabrication shop.
 Parallel cutting machine.
 Trennjaeger circular saw.
 CNC cutting Machine
 Angle cutting machine
 Boom Column sub march welding machine
 Photo cell cutting machine
 Semi-automated machine
 Nonferrous steel cutting machine
Heavy bay
Crane capacity 50 ton
Medium bay
Light bay

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 Circular saw small size and large size.
 Straight rolling machine
 Rerolling machine
 Plasma cutting machine
 100ton press machine
 160ton brick press machine
 3000ton press machine
 Membrane water wall welding machine etc.
Fabrication is the process of forming, casting, machining and welding of metals.
Fabrication when used as an industrial term, applies to the building of machine, structures and
other equipment, by cutting, shaping and assembling components made from raw materials.
Small businesses that specialize in metal are called fabrication shop. Steel fabrication shops and
machine shops have overlapping capabilities, but fabrication shops generally concentrate on the
metal preparation, welding and assembly aspect while the machine shop is more concerned with
the machining of parts.
5.1FabricationTechniques:
Metal fabrication is a value added process that involves the construction of machines and
structures from various raw materials. A fabrication shop will bid on a job, usually based on the
engineering drawings.
Planning&
control
Marking &
layout
Cutting
processes
Forming &
pressing
Testing &
Inspection

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5.2 PlanningandControl(CTC):
CTC stands for Central Technical Cell. Basically it’s a planning and control section of
Fabrication, in this section different drawings are analyzed and then sent to different sections of
fabrication shop depending upon the job and capacity of the shop.
The main plans of CTC fabrication are as follows
 Job feeding to shop
 Planning
 Material check
 Observation from manufacturing till sale.
CTC
Job
Planning
Material
issued to
F.S
Make
cutting
plans
Design
Tool &
Dies
Check The
Work
Delivered
as per
route card

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Metalfabrication
Metal fabrication is a value added process that involves the construction of machines and
structures from various raw materials. A fabrication shop will bid on a job, usually based on the
engineering drawings.
Raw materials
Standard raw materials used by metal fabricators are
 plate metal
 welding wire
 co gas
 argon gas
 Cutting torches
 silica etc
The raw material has to be cut to size. This is done with a variety of tools.
Cutting
The raw material has to be cut to size. This is done with a variety of tools. The most common
way to cut material is by Shearing (metalworking); Special band saws designed for cutting metal
have hardened blades and a feed mechanism for even cutting. Abrasive cut-off saws, also known
as chop saws, are similar to miter saws but with a steel cutting abrasive disk. Cutting torches can
cut very large sections of steel with little effort.
Forming
Hydraulic brake presses with v-dies are the most common method of forming metal. The cut
plate is placed in the press and a v-shaped die is pressed a predetermined distance to bend the
plate to the desired angle. Tube bending machines have specially shaped dies and mandrels to
bend tubular sections without kinking them. Rolling machines are used to form plate steel into a
round section.
Machining
Fabrication shops will generally have a limited machining capability including; metal lathes,
mills, magnetic based drills along with other portable metal working tools.
Welding

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Welding is the main focus of steel fabrication. The formed and machined parts will be assembled
and tack welded into place then re-checked for accuracy. A fixture may be
Used to locate parts for welding if multiple weldments have been ordered. The welder then
completes welding per the engineering drawings, if welding is detailed or per his own judgment
if no welding details are provided.
Special precautions may be needed to prevent warping of the weldments due to heat. These may
include re-designing the weldments to use less weld, welding in a staggered fashion, using a
stout fixture, covering the weldments in sand during cooling, and straightening operations after
welding.
Straightening of warped steel weldments is done with an Oxy-acetylene torch and is somewhat
of an art. Heat is selectively applied to the steel in a slow, linear sweep. The steel will have a net
contraction, upon cooling, in the direction of the sweep. A highly skilled welder can remove
significant war page using this technique.
Final assembly
After the weldments have cooled it is generally sand blasted, primed and painted. Any additional
manufacturing specified by the customer is then completed. The finished product is then
inspected and shipped.
5.3 TYPEOFWELDINGS:
 Stick welding
 Tig welding
 Mig welding
Shielded Metal Arc Welding (SMAW) is frequently
referred to as stick or covered electrode welding. Stick
welding is among the most widely used welding
processes. The flux covering the electrode melts during
welding. This forms the gas and slag to shield the arc
and molten weld pool. The slag must be chipped off
the weld bead after welding. The flux also provides a
method of adding scavengers, deoxidizers, and alloying
elements to the weld metal.

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Gas tungsten arc welding (GTAW), also known as tungsten inert gas (TIG) welding, is an arc
welding process that uses a no consumable tungsten electrode to produce the weld. The weld
area is protected from atmospheric contamination by a shielding gas (usually an inert gas such as
argon), and a filler metal is normally used, though some welds, known as autogenously welds,
do not require it. A constant-current welding power supply produces energy which is conducted
across the arc through a column of highly ionized gas and metal vapors known as a plasma
Commonly used to weld thin sections of stainless steel and light metals such as aluminum,
magnesium, and copper alloys. The process grants the operator greater control over the weld than
competing procedures such as shielded metal arc welding and gas metal arc welding, allowing
for stronger, higher quality welds. However, GTAW is comparatively more complex and
difficult to master, and furthermore, it is significantly slower than most other welding techniques.
A related process, plasma arc welding, uses a slightly different welding torch to create a more
focused welding arc and as a result is often automated.
5.4BOILERFABRICATION:
In the energy sector HMC has supplied over 30,000 tons of fabricated equipment and parts to
different power plants. Major strength is HMC's capabilities for manufacturing utility boilers
pressure parts. For this purpose some of the major machines are:
 3 roller bending machines for making drums
 Booster pipe bending machine for making super heater
 Reheated and economizer coils
 Specialized machine for machining and welding of headers and complete train of
machines for manufacture of membrane walls in panel and bent form
HMC has the capability to manufacture following type of boilers:
 Natural circulation steam generators
 Heat recovery steam generators
 Fluidized bed combustion boilers
Besides Boiler Island, HMC have also capabilities and expertise for manufacture of balance of
plant equipment / parts such as:
 Condensers
 L.P. heater
 H.P. heater parts
 Water treatment plant
 Desecrator and feed water tank
 Pressure vessels
 Oil storage tanks
 Cooling water system
 Heat exchangers

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 Steel structure
 Elevator hoist and cranes
 Piping
 Other misc. items
With a team of well experienced engineers and technicians, HMC is well prepared to carry out
all site construction work which includes:
 Site fabrication
 Erection / installation and commissioning
 Civil works (if part of complete construction work, package)
HMC is also providing services for repair / maintenance and BMR of existing power plant for its
boilers, turbines, condensers, heaters and other equipment.
BOILER COMPONENTS
Super Heaters
One of the most important accessories of a boiler is a superheated. It affects
improvement and economy in the following ways.
 The superheated increases the capacity of the plant.
 Eliminates corrosion of the steam turbine.
Reduces steam consumption of the steam turbine.
ECONOMISERS
This is feed-water heaters in which the heat from waste gases is
recovered to raise the temperature of feed-water supplied to the
boiler. They offer the following advantages:
 Fuel economy
 Longer life of the boiler
 Increase in steaming capacity
 Finned Tube Economizers
 C.I. Gilled Tube Economizers
 Plain Tube Coil Economizers
SteamGenerating Tubes
These are tubes in the Boiler where water is evaporated to steam and are
also called Steam Generating Tubes. These Tubes also form the Walls of
the Boiler and are hence called Water Walls or Water Wall Panels. These

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Tubes have very complicated shapes to allow Inspection openings and burner throats and
fabrication require bending Machines.
6. NONDESTRUCTIVEVETESTING(NDT)
The other facility of material testing provided by HMC is the non-destructive testing of the
material which means such methods of testing in which the breakage or damage of the material is
not involved. An example of this testing is the use of X-ray technology to locate the defects
internally. We can say that it undertakes X-ray, ultrasonic, die penetrant and magnetic particles
testing for surface cracks, voids, blow holes, porosity and cavity etc. in welds, castings and
forgings.
IT INCLUDE DIFFERENT OPEREATIONS
 INDICATION
 INTERPRETATION
 FALSE
 RELEVENT
 NON RELEVENT
 EVALUATION
 ACCEPT
 REJECT
6.1NONDESTRUCTIVEEVALUATIONFACILITIES:
1- X-ray radiography
2- Gamma rays radiography
3- Ultrasonic
4- Magnetic particle inspection

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5- Liquid penetrant method
6- Eddy current spectroscopy
7- Dye-Penetrant test
RADIOGRAPHY TESTING METHOD:
Radiography testing is most universally used NDT method for the detection of gas porosity in
weldments. The radiographic image of a round porosity will appear as oval shaped spots with
smooth edges, while elongated porosity will appear as oval shaped spots with the major axis
sometimes several times longer than the minor axis. Foreign material such as loose scale flux or
splatter will affect validity of test results.
ULTSONIC TESTING:
Ultrasonic testing (UT) is a family of non-destructive testing techniques based on the propagation of
ultrasonic waves in the object or material tested.
A typical UT inspection system consists of several functional units, such as the pulser/receiver,
transducer, and display devices. A pulser/receiver is an electronic device that can produce high
voltage electrical pulses. Driven by the pulser, the transducer generates high frequency ultrasonic
energy. The sound energy is introduced and propagates through the materials in the form of waves.
When there is a discontinuity (such as a crack) in the wave path, part of the energy will be reflected
back from the flaw surface. The reflected wave signal is transformed into an electrical signal by the
transducer and is displayed on a screen. The reflected signal strength is displayed versus the time
from signal generation to when an echo was received. Signal travel time can be directly related to the
distance that the signal travelled. From the signal, information about the reflector location, size,
orientation and other features can sometimes be gained.
Probe types
Normal Beam Probes: radiate their sound wave perpendicular to specimen surface.
TR Probes: separate crystal for receiving and transmitting waves
Angle Beam Probes: probes that radiate their sound wave at an angle.
EDDY CURRENT TESTING METHOD:
Continuous wave eddy current testing is one of several non-destructive testing methods that use
the electromagnetism principle. Conventional eddy current testing utilizes electromagnetic
induction to detect discontinuities in conductive materials.

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A specially designed coil energized with alternating current is placed in proximity to the test
surface generating changing magnetic-field which interacts with the test-part producing eddy
current in the vicinity.
Universal Crack Depth MeterX-RT-705
The crack depth meter X-RT 705 is in a fringe area of ultrasonic application. It can detect the
position, depth and angle of inclination of cracks in the surfaces of metallic materials rapidly and
accurately. As it operates on DC that’s why it is suitable for all the metals.
LIQUID PENETRANTTESTINGMETHOD:
Normally confined to in process control of ferrous and non ferrous welds
Liquid penetrant testing like magnetic particle is restricted to surface evaluation
Extreme caution must be exercised to prevent any cleaning material and liquid penetrant
materials from becoming entrapped and contaminating the rewelding operation
MAGNETIC PARTICLE TESTING METHOD:
Not normally used to detect gas porosity. Only surface porosity would be evident. Near surface
porosity would not be clearly defined since indications are neither strong nor pronounced.
Dye Penetrating Test (DPT)
Penetrant testing (PT), is a widely applied and low-cost inspection method used to locate
surface-breaking defects in all non-porous materials (metals, plastics, or ceramics).
Principle
DPI is based upon capillary action, where fluid having low surface tension penetrates into clean
and dry surface-breaking discontinuities. Penetrant may be applied to the test component by
dipping, spraying, or brushing. After adequate penetration time has been allowed, the excess
penetrant is removed and a developer is applied. The developer helps to draw penetrant out of
the flaw so that an invisible indication becomes visible to the inspector. Inspection is performed
under ultraviolet or white light, depending on the type of dye used - fluorescent or no fluorescent
(visible).
Inspection steps
 Pre-cleaning
 Application of Penetrant
 Excess Penetrant Removal
 Application of Developer
 Inspection

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Mostly cleaner for the penetrant which used are solvent and water emulsifier.
Recommendations
The recommendations for the material testing facilities in HMC are:
 The testing techniques are although sufficient enough yet they are old fashioned and
needed to replace by the modern techniques and equipment.
 The allocation of area for the labs is not sufficient enough according to their requirement
 One does not go to the dark room without permission
 There should be protective clothing for Gamma and X-ray radiations
 Gamma radiations leaks from open roof surface which effect the workers after
reflecting back from the ceiling.
7. MATERIALTESTINGLAB
For all the materials from which the jobs are to be made are subjected to some sort of testing
methods before the actual processing and working on it from raw material to the final and
finished jobs. The basic purpose of testing the material is to ensure adequate and the proper
composition of elements in required percentages in the material under testing so that there will
be a minimum chance of failure of job during overloading or excessive use of the job.
There are two basic types of material testing methods:
 Destructive Testing
 Non-Destructive Testing
In destructive testing methods the forces are applied to the material until it brakes. And by the
force, extension and respective values of stress and strain the qualities and properties are
determined e.g. impact testing and surface hardness testing.
While on the contrary the non-destructive testing includes methods which do not involve the
breakage of materials. i.e. Radiography and x-ray analysis.
In HMC the following two testing laboratories are present and working efficiently for testing of
almost all type of the materials and jobs being made in HMC; they are:
 Material Testing Laboratory
 Non Destructive Testing Laboratory
7.1Threesectionsofthelab:

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1- Chemical section
2- Metallographic
3- Mechanical
4- Quick Analysis
CHEMICAL SECTION:
The chemical section lies in the steel foundry. So, it mainly concerns with the determination of
the chemical composition of steel. However, samples from cast iron foundry are also brought
here to determine the chemical composition.
EMISSION SPECTROMETER:
In emission spectrometer, a 2”*2” sample is used. Arc is produced by using a tungsten electrode.
Argon gas is used for shielding. The atoms got excited. When they return to their ground state,
they emit radiations. Each element emits radiations of some specific wavelength. So, from the
wavelength element and its percentage can be calculated.
WET ANALYSIS:
The chemical composition can also be determined by wet analysis. Different chemicals are used
in different proportions. The color achieved at the end is a measure of element and its
percentage.
Other facilities include;
 Spectrophotometer
 Carbon apparatus
MECHANICAL SECTION
HMC has a capability to test for metal mechanical properties like hardness, strength, shearing,
crushing, impact bend test etc.
HMC mechanical testing lab has following facilities…
FACILITIES:
 30 ton universal testing machine (UTM)

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 60 ton UTM
 10 ton UTM
 100 ton UTM
 Charpy impact testing machine
 Brinell hardness tester 2 pieces
 Rockwell hardness tester 2 pieces
 Vickers hardness tester TESTS:
 Tensile
 Bend
 Shear
 Compression/crushing
METALLOGRAPHY:
Metallography is the process which involves the testing of materials using the microscopes and
other optical devices and then their internal structure is compared with the desired material’s
intermolecular structure.
The important uses of the metallographic study are following:
 Process control
 Presence and identity of defects
 Inclusion identification and determination of their density
 Examination of cracks, fractures and other failure mechanisms
 Evaluation of effects of corrosion and chemical attacks
 Identification of microstructure
 Grain or particle size
In metallographic section we studied and observed the microstructure of grey cast iron sample
which includes the graphite flakes with the simple microscope at 40 magnifications whereas its
magnification is up to 450. Also we observed the structure of M.S sample by digital microscope
in which a digital camera is placed and the photograph of the structure is obtained and its
magnification is up to 5000.
Magnifications such as;
 100 X

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 450 X
 1000 X
 2000 X
 A hardness tester with 450 X
Quick analysis
Quick analysis section is located in steel foundry and is further divided into two sections. One of
them is testing by emission spectrometer and other is determination of composition by chemical
testing methods.
In spectrometer section; firstly, a sample of the molten steel is brought out in form of a cube and
solidified after which it is brought into quick analysis section in which its surfaces are polished
on grinders to make the surfaces shiny which is very necessary to make it balanced on the
spectrometer surface otherwise the high pressure argon gas will cause any serious issues. At that
time the intensity of blow holes and pores or other surface defects are also inspected visually.
After this the sample is forwarded to spectrometer room and placed below a tungsten electrode
(it is used because of its highly refractory properties) and burned while the percentages of all the
components or the elements of the material is obtained on a computer screen processed by a
prescribed computer program. According to this result the desired percentages can be achieved
by adding desired components into molten steel in case the results are not satisfactory.
8. PATTERNSHOP
In this shop, the very first step for the casting is done. Patterns are made for moulds to be for
casting purposes. All this work is performed under the supervision of Shop in charge. The
process is performed following various steps which explained with terms as below
 Drawing study of the job.
 Add appropriate allowances to the casting material on paper work.
 Making layout of the pattern according to the drawing on the layout board.
 Margining the material to be used in the pattern.
 Cutting and carving the margined parts using machines and tools.
 Prepare core boxes for the core prints.
 Paint according to casting parts required.
 Assembling the pattern parts using glues, nails and tools.

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 Weighing them and noting all the dimensions.
 Check and clearance by quality control authority in the shop.
 Load and sending it to the desired foundry for casting processes.
 Prepare for the next job.
8.1DrawingStudy
Drawing study means the study of the paper work in the shop before making the pattern in shop.
This step is basic step of this shop as the job depends upon it all the time. Drawing shows, us the
pattern to be made and what its dimensions are.
Drawing is actually the paper work of any job either for pattern or casted product. It can be in
two angle projections as
 1st angle projection
 3rd angle projection
Both angle of projection can be implemented in this shop but mostly 3rd angle of projection is
being implemented here as we follow the metric system in Pakistan mostly.
Difference between first and third is as below
For the study of drawing one must know which angle of projection is being used in the drawing.
 In first angle the object is in between the eye and drawing plane whereas in third angle of
projection, drawing plane is in between the eye the object.
 On drawing sheet, in first angle of projection, the front view is on the top left corner of
sheet and top view is on the bottom left corner of the sheet whereas for third angle
projection these views are inverted.
 British units indicate the drawing to be 1st whereas metric system indicated of 3rd angle
of projection.
8.2 AllowanceApproximation
Adding appropriate allowances which are given on the drawing and usually there are three types
of allowances in the sheet as:
 Working allowance
 Shrinkage allowance
 Moulding allowance
 Casting allowance
 Fabrication allowance
The purpose of pattern shop is to make wooden or metallic components for casting process.
8.3 TYPESOFPATTERN:
 One piece or solid pattern

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 Two piece or split pattern
 Three piece pattern
 Loose piece pattern.
 Self core pattern.
 Sweep pattern.
 Skeleton pattern.
 Match plate pattern.
 Connecting pattern.
 Master pattern
8.4TYPESOFCOREPRINTS:
 Top print.
 Bottom print.
 Side print.
 Tail print.
 Hang print.
 Balancing print.
8.5 TYPESOFCOREBOX:
 Box type core box.
 Shake out type core box.
 Gang type core box
8.6MACHINESINPATTERNSHOP:

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 Band saw.
 Joint planner.
 Thickness planner.
 Disc and spindle sander.
 Wooden lathe machine.
 Wooden milling machine.
9. ForgingShop
Forging is a deformation process in which the work is compressed between two dies using either
impact or gradual pressure to form the part.”
It is the oldest of metal forming operations dating back to about 5000 B.C. In the modern era,
forging is an important industrial process used to make a variety of high strength components for
automotive, aerospace, defence and other applications. These components include engine
crankshafts and connecting rods, gears, aircraft structural components, jet engine turbine parts
etc. In addition, steel and other basic metal industries use the forging process to establish the
basic form of large components that are subsequently machined to final shape and dimensions.
Forging shop I:
In this shop die forging is done.
Die forging:
In this type of forging method specific dies are used to produce the specific job
for this allowance is very low.
Requirements:
For die forging we need:
 Furnace
 Hammers
 In HMC forging shop 1 has following facilities:
 150kg hammering machine

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 800 ton hydraulic press with 3 ton manipulator
 25 to counter blow
 Trimming press
 Crew presser
 63 ton power press
 400 ton press
 1250 ton press
 Swelling crane of 1 ton capacity
Forging shop II
In this shop free forging is done. Free forging is method of producing jobs without using
dies. In free forging large allowance is present.
HMC have following facilities in this shop:
 1 ton hammer
 2 ton hammer
 3 ton hammer
Forge:
It is the ability of the material to undergo deformation under compression without rapture.
Any material or alloy which can be brought to plastic stage through heating can be forged the
extent to which the material can be forged is governed by its compositions as well as
temperature of the forging. Selection of the forging material depend upon certain mechanical
prosperities inherent in the material like strength, malleability, resistance to fatigue ,
durability, shock or bending machinability . Some forgeable materials are listed below:
 Pure aluminum
 Pure magnesium
 Pure copper
 Aluminum alloys
 Magnesium alloys
 Copper alloys
 Carbon and low alloy steels
 Stainless steel
 Nickel alloys

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10. INSPECTION
QUALITY INSPECTION
It is one of the most responsible and sensible department of the complex. If some part fails
outside in the field, it is not the mistake of the production department but of quality inspector
who passed it. So, the repute of any industry depends to a great extent on this department. This
department checks each and every material which comes in or goes out of the factory, i.e. from
the raw material to the final product. There is at least one quality inspector always present in a
shop for the stage inspection and the final inspection. If something exceeds the tolerance, they
have the right to reject it. They have different tools with them for the measurements. Some of
them are;
 Inside micrometer
 Outside micrometer
 Mercer gage
 Vernier caliper
 Bevel protector etc.
Recommendations
We would like to give some recommendations to improve the quality of work and save time
along the health of the workers because during our visit we observed that the workers are not
playing with their own lives which are a great loss of man power. To eradicate it we recommend
following things:
 Safetyshouldbe made necessaryforeachandeveryone especiallyforthe fabricationshop
 There shouldbe checkand balance of these safetysteps
 Trainedlabormusthave junioror freshlaborbecause inthe future theycan take theirseats.
 Environmentshouldbe made cleanandhealthybyplantingplantsandkeepingthe surface clean
 To increase the rate of workthe repeatedjobsshouldbe giventothatpersonwhohadworkedonit
but thisshouldbe made necessaryforthatpersonthat he will conveyhisknowledge tohissub-
ordinates.

HMC internship report

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