1. INTERNSHIP REPORT
Heavy Mechanical Complex Taxila
18-Aug-14
HMC Taxila
SUBMITTED BY;- USAMA SHEIKH
REG # 11ABELT0442
Electronics Engineering
U.E.T PESHAWAR, ABBOTTABAD CAMPUS
SUBMITTED TO:-
MANAGEMENT TRAINING CENTER of HMC Taxila.

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ACKNOWLEDGEMENT
My experience of Internship has been successfully completed, thanks to the support staff of
many friends, colleagues & engineers with gratitude. I wish to acknowledge all of them.
However, I wish to make special mention of the following.
I am thankful to the Manager of Maintenance Department Engr. Amir Latif who
trusted on me while giving me this Internship so that I can involve in practical work & he
also encourage me in my internship era.
I am also thankful of my guide Contractor NISAR Ahmed under whose guideline I
was able to complete my internship. I am whole heartedly thankful to him for giving me his
value able time & attention & for providing me a systematic way for learning in my
internship time.

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INTRODUCTION:-
Internship:-
An internship is a method of on-the-job training for white-collar and professional
careers. Internships for professional careers are similar in some ways to apprenticeships for
trade and vocational jobs, but the lack of standardization and oversight leaves the term open
to broad interpretation. Interns may be college or university students, high school students, or
post-graduate adults. These positions may be paid or unpaid and are usually temporary.
Generally, an internship consists of an exchange of services for experience between
the student and an organization. Students can also use an internship to determine if they have
an interest in a particular career, create a network of contacts or gain school credit. Some
interns find permanent, paid employment with the organizations for which they worked. This
can be a significant benefit to the employer as experienced interns often need little or no
training when they begin regular employment. Unlike a trainee program, employment at the
completion of an internship is not guaranteed.
INTRODUCTION of HMC:-
Heavy Mechanical Complex (Private) Limited is a leading engineering goods
manufacturing enterprise in Pakistan located at Taxila about 30 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 have the resources to handle large projects with demanding delivery schedules.
Being the largest and most extensive fabrication and machining facility equipped
with state of the art technology. HMC provide manufacturing services both on our own or
customers design. HMC have gained rich experience in designing and
manufacturing of large projects through collaboration with internationally reputed
engineering organizations. All its processing facilities are in-house including Designing,
Fabrication, Machining, Iron and Steel Castings, Forgings, Heat Treatment,
Assembly, Sand Blasting, Painting and Galvanizing etc. HMC is ISO 9001 certified and is
authorized to use 4 ASME stamps U, U2, S & PP for equipment manufactured according to
ASME code. The manufacturing is backed by excellent quality control and testing
facilities to meet the product and customer quality requirements. 3rd party inspection
facilities are also available, where required. 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. 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 steelworks. Some other processes that are also
done by HMC are Designing and manufacturing and assembling and installation with
the certification of ISO – 9001.The Heavy Mechanical Complex (HMC), the biggest
undertaking of its type in Pakistan, was established in 1979 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 has the

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largest fabrication and machining facilities in the country equipped with
Computer Aided Designing (CAD) and can undertake a variety of fabrication /
machining jobs on sub-contracting basis. 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. The
company's capabilities include engineering and manufacturing of Sugar Mills
ranging between1,500 - 12,000 TCD (tons of cane crushing capacity per day),
Portland Cement Plants of 700-5,500 TPD (tons per day) module and White Cement
Plant of 50 - 1,000 TPD.
WORKINGSTAFF
HMC is a professionally managed progressive organization with 1,100
employees.HMC has a total covered area of 160,000 square feet.
FACTORIESATHEAVYMECHANICALCOMPLEX
 Heavy mechanical complex I (HMC I)
 Heavy forge and foundry works (HMC II)
 Heavy mechanical complex III (HMC III)
Of these the last one is directly under the ministry of defense while the former two are
governed by ministry of production.
QUALITYPOLICYOFHMC
HMC states its quality policy as follows: “Quality performance is
committed to excellence by each company employee. It is achieved by team
work and through a process of continuous improvement.” “We are dedicated to being seen as
an organization which provides quality products and services which meet or exceed
the expectations of our customers.”
FACILITIES AT HMC
There are several shops in HMC industry.
 Designdepartment
 Productionplanningandcontrol(PPC)
 Salesdepartment/(PMDi.e.ProjectManagementDepartment)
 AccountsFinanceandAdministration
 Machineshop
 Heattreatmentshop
 Fabricationshop
 Forgingshop
 Hydraulicpressshop
 Steelfoundry
 Castironfoundry
 Patternshop
 Maintenanceshop
 Qualitycontrol
PRODUCTIONCAPACITY
Machining capacity = 500ton *12 months
Fabrication and Machining capacity= 1000ton *12months

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Total = 500*12 + 1000*12 = 6000 tons per annum
This production capacity can be increased time to time with the extension of man
power and other sources subjecting to sub-contractors.
HMCPRODUCTSRANGE
HMC specializes in Engineering, Designing, Manufacturing, Installation and
Commissioning of plants and machinery including;
CementPlantandSpares:
600-5000 TPD
SugarPlantandSpares:
500-12000 TCD
ProcessPlantEquipment:
Pressure Vessels, Columns, Heat Exchangers, Drums, Storage Tanks and
Kilns
Chemical&Petro-ChemicalPlants:
Sulphuric Acid Plant, Basic Chromium Sulphate Plant, Industrial Alcohol
distillery, Gas Dehydration, LPG/LNG, Gas Purification & Sulphur Recovery Plants.
IndustrialBoilers:
Fire tube Package units, water tube package units, heat recovery
boilers, bagasse fire boilers (capacity up to 200 T/hr).
ThermalPowerPlants:
Equipment for utility boilers, membrane wall, turbine/generator parts.
HydralPowerPlants:
Gates, penstocks, wicket gates, head covers, turbine/generator parts
Cranes:
Electric overhead travelling crane, portal & mobile cranes.
RoadConstructionMachinery:
Static & vibratory road rollers, asphalt mixing plant.
SteelStructures:
For thermal power plants, process plants etc.
RailwaysEquipment:
Railway axles, surface traverser, screw coupling & screw jack.
Castings:
Iron & steel castings as per specifications
Forgings:
Shafts, rings and others as per specifications
AutomotiveForging:
For tractors and other automobile
PRODUCTION PLANNING & CONTROL
The PPC department has been organized with the objective of improving company’s
performance. The department is headed by a Dy. GM incharge PPC and comprises
of the following sections:
 Core planning / Data processing
1) Project planning
i. Material management.
ii. Material management section (MMG).
2) General store
i. Production technology.
ii. Feasibility / quantitative detail.

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iii. Process planning.
3) Tool designing
i. Dispatch cell / Material handling.
ii. Material handling store (MHC).
4) Dispatch cell
i. Income tax custom rebate (ICR)
1.SALESORDERNUMBERINGSYSTEM
The sales order numbering system allocates a unique identification system to each
order acquired by the sales and marketing department. This sales order consists of
six digits. The first two of these numbers designate the product group
number of the products to be manufactured or services to be provided by the
organization. The next two digits specify the fiscal year in which the order is received and the
last two digits give the number of similar orders already received in the same fiscal year.
2.COREPLANNINGSECTION
 Master schedule planning
 Order activity planning
 Monitoring all schedules / shop scheduling
 Preparing various reports for MIS
 Maintenance of balance order position.
 Monthly sales and production reports
 Sales / production budget.
 Project review. Meeting and follow up.
 Data entry, loading data and processing data
3.PROJECTPLANNINGSECTION
 To ensure receipts of all drawings and documentation from design as per
contact and accelerate the schedule for production and procurement.
 To issue “material purchase requirement” to MMG.
 To prepare “bill of material” to be purchased.
 To coordinate with the production technology for preparation of necessary document
for production.
 To prepare and issue job orders and follow up.
 To suggest alternate materials from stock to design.
 To prepare data and reports for ICR and for survey by CBR.
4.MATERIALMANAGEMENTA. MMG Section:
 Material requirement planning.
 Indenting and follow up of indents.
 To keep update purchase status for all the project demands.
 Establish stock levels for general consumable items and raw materials.
 Issuance of materials to the appropriate job.
 To keep and maintain update levels for the store items.
 To look after stores and related things.
B. General Store:
 To receive, issue all the materials, and equipment in stotes as per
laid down procedure.
 Maintain detailed record of store movements.
 Maintain stock location system.
 Maintain daily submission of issue and receipt statement to concerned dept.to keep
store areas secure and organized.

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5.PRODUCTIONTECHNOLOGY
 Feasibility/Quantitative Detail:
 Feasibility study and quantitative details of clients’ requirements for cost estimate.
 ProcessPlanning:
 Prepare details per list, route cards, cutting plans, time sheets and process maps for all
the processes.
 Tool Designing:
 Designing of all types of press tools, dies, templates, jigs and fixtures.
 Prepare drawings for machinery components, cutting planes, marking templates
for shops etc.
6.DISPACHCELL:
 To receive finished jobs from shops.
 To draw standard items from store for dispatch to customer.
 To organize packing etc.
 To organize transportation.
 Ensure complete accurate documentation with each product.
______________________________________________
MACHINE SHOP
Machineshopat HMC has following machines:
 Gear shaper machine
 Straight bevel machine
 Gear hobbing machine
 Vertical turret lathe machine
 Horizontal lathe machine
 Horizontal vertical slope type boring and milling machine.
 Universal boring, milling, facing, threading, taping machine.
 Plano milling machine.
 Horizontal boring machine.
 Redial drilling machine.
 Column drilling machine.
 Gear shaper tool machine
 Slotting machine
 BVT boring vertical turret machine
 Face plat lathe machine.
 Double housing plane
 Vertical milling machine.
a. Gear Shaper
A gear shaper is a machine tool for cutting the teeth of internal or external
gears. The name shaper relates to the fact that the cutter engages the part on the
forward stroke and pulls away from the part on the return stroke, just like the
clapper box on a planer shaper. To cut external teeth, a different machine called a
hobbing machine can be used.
b. Spur Gears
They connect parallel shafts, have involute teeth that are parallel
to the shaft and can have internal or external teeth. They cause no external thrust
between gears. They are inexpensive to manufacture. They give lower but satisfactory
performance. They are used when shaft rotates in the same plane.

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c. Helical Gears
Helical gears connect parallel shifts but the involute teeth are cut
at an angle to the axis of rotation. Two mating helical gears must have equal
helix angle but opposite hand. They run smoother and more quietly. They have higher
load capacity, are more expensive to manufacture and create axial thrust. They have longer
and strong teeth. They can carry heavy load because of the greater surface contact
with the teeth. The efficiency is also reduced because of longer surface
contact. The gearing is quieter with less vibration.
d. Internal Gears
Internal gears are hollow. The properties and teeth shape is similar as of external
gears except that the internal gear had different addendum and duodenum values modified to
prevent interface in internal meshes. They are designed to accommodate a wide range of
equipment. These are ideal and cost effective. The teeth are cut into the inside
diameter while the outside diameter is smooth. These gears are available only in brass.
Internal gear offers low sliding and high stress loading. They are used in planetary gears to
produce large reduction ratios. When choosing a mating gear the difference between
the number of teeth of girth gear and the pinion should
not be less than 15. Their nonbinding tooth design ensures smooth,
quiet operation. They are used to transmit rotary motion between parallel shafts, the shaft
rotating in the same direction as the arrangement.
e. WormGears
The Worm gear is the heart of most mills and kiln drive system. They can't be used in
spare parts inventory. They are also used in steel industry, sugar industry, paper and pulp
industry. The girth gear has been preferred over the gearless drives due to their
lower initial cost, simplicity to install, operate and maintain.
f. Hobbing
Hobbing is a machining process for making gears, on a hobbing machine, which is a
special type of milling machine .The teeth or spines are progressively cut into the
workpiece by a series of cuts made by a cutting tools 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.
g. HEAT TREATMENT AND TTC (TECHNICALTRAINING CELL)
 HeatTreatment–TheProcesses
 Annealing
 Normalizing
 Hardening
 Surface
 Full
 Case
 Tempering
 Stress releasing
 Carburizing
 Gas
 Pack
 Phosphating

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h. Heat treatment
“Heat Treatment is the controlled heating and cooling of metals to alter their physical
and mechanical properties without changing the product shape.”
i. Annealing
Annealing, in metallurgy and materials science, is a heat treatment wherein a material
is altered, causing changes in its properties such as strength and hardness. It is a
process that produces conditions by heating to above the re-crystallization
temperature and maintaining a suitable temperature, and then cooling. Annealing
is used to induce ductility, soften material, relieve internal stresses, refine the
structure by making it homogeneous, and improve cold working properties.
j. Normalizing
Annealing, in metallurgy and materials science, is a heat treatment wherein a material
is altered, causing changes in its properties such as strength and hardness. It is a
process that produces conditions by heating to above the re-crystallization
temperature and maintaining a suitable temperature, and then cooling. Annealing
is used to induce ductility, soften material, relieve internal stresses, refine the
structure by making it homogeneous, and improve cold working properties. In the
cases of copper, steel, silver, and brass this process is performed by substantially heating the
material (generally until glowing) for a while and allowing it to cool slowly. In this fashion
the metal is softened and prepared for further work such as shaping, stamping, or forming.
k. Hardening Flame Hardening:
A high intensity oxy-acetylene flame is applied to the selective region. The
temperature is raised high. The "right" temperature is determined by the operator based on
experience by watching the color of the steel. The overall heat transfer is limited by
the torch and thus the interior never reaches the high temperature. The heated
region is quenched to achieve the desired hardness. Tempering can be done to
eliminate brittleness.
l. InductionHardening:
In Induction hardening, the steel part is placed inside a electrical coil which has
alternating current through it. This energizes the steel part and heats it up. Depending on the
frequency and amperage, the rate of heating as well as the depth of heating can be
controlled. Hence, this is well suited for surface heat treatment. The Induction and flame
hardening processes protect areas exposed to excessive wear. Items that we induction harden
include Spur Gears and Spur Pinions ,Helical Gears and Helical Pinions ,Sprockets ,Internal
Gears ,Bevel Gears ,Shafts and Pins ,Rails and Racks ,Wheels and Rollers Sheave Wheels
,Links ,Axle Boxes and Bushes.
m. Tempering:
Tempering is a heat treatment technique for metals, alloys and glass. In steels,
tempering is doneto "toughen" the metal by transforming brittle martensite into bainite or a
combination of ferrite and cementite. Precipitation hardening alloys, like many
grades of aluminum and super alloys, are
tempered to precipitate intermetallic particles which strengthen
the metal. Tempering is accomplished by a controlled reheating of the
work piece to a temperature below its lower critical temperature. The brittle
martensite becomes strong and ductile after it is tempered. Carbon
atoms were trapped in the austenite when it was rapidly cooled, typically by oil or water
quenching, forming the martensite. The martensite becomes strong after being tempered
because when reheated, the microstructure can rearrange and the carbon atoms can diffuse
out of the distorted BCT structure. After the carbon diffuses, the result is nearly pure ferrite.

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n. Stress Releasing:
Stress releasing is used to reduce residual stresses in large castings,
welded parts and cold-formed parts. Such parts tend to have stresses due to
thermal cycling or work hardening. Parts are heated to temperatures of up to 600 - 650
ºC (1112 - 1202 ºF), and held for an extended time (about 1 hour or more) and then slowly
cooled in still air.
o. Carburizing:
Carburizing, also known as carburization, is a heat treatment process in
which iron or steel is heated in the presence of another material (but below the metal's
melting point) which liberates carbon as it decomposes. The outer surface or case
will have higher carbon content than the original material. When the iron or
steel is cooled rapidly by quenching, the higher carbon content on the outer
surface becomes hard, while the core remains soft and tough. This manufacturing process
can be characterized by the following key points: It is applied to low-carbon
workpieces; workpieces are in contact with a high-carbon gas, liquid or solid;
it produces a hard workpiece surface; workpiece cores largely retain their toughness and
ductility; and it produces case hardness depths of up to 0.25 inches (6.4 mm).
p. Phosphating:
Phosphate coatings are used on steel parts for corrosion resistance, lubricity, or as a
foundation for subsequent coatings or painting. It serves as a conversion coating in which a
dilute solution of phosphoric acid and phosphate salts is applied via spraying or immersion,
chemically reacts with the surface of the part being coated to form a layer of
insoluble, crystalline phosphates. Phosphate conversion coatings can also be used on
aluminium, zinc, cadmium, silver and tin. The main types of phosphate coatings are
manganese, iron and zinc. Manganese phosphates are used both for
corrosion resistance and lubricity
and are applied only by immersion. Iron phosphates are typically used
as a base for further coatings or painting and are applied by immersion
or by spraying. Zinc phosphates are used for rust proofing (P&O), a lubricant
base layer, and as a paint/coating base and can also be applied by immersion or spraying.
q. LIST OF APPARATUS
ElectricFurnaces:-
1. Carbottomfurnace
Max. temp = 950°C
Size = 900 x 700 x 1800
Plotter and temperature indicator is attached with it.
2. Boxtypeairfurnace
It is small and large.Max. temp = 950 °C
Size =600 x 500 x 1200
Max. temp = 950° C
Size =450 x 450 x 950
3. Pittypetemperingfurnace
Max. temp = 950°C
4. Saltbathfurnace
Small, medium, large Temp = 550-650°C
Size =300 x 400 x 500
Temp = 700-900°C
Size =300 x 400 x 800
Temp = 1050-1270°C

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Size =200 x 300 x 800
5. Flamequenchingplant
Vertical : φ1200 x 600
Horizontal : φ 450 x 2400
6. Highfrequencyinductionmachine
It is in isolated room, it uses 10,000 volts. It have a copper
ring that induct heat to the component’s external part, it have a mechanism of
movement of job and quenching. Room is provided with oil and water drum for the purpose
of quenching.
7. Cleaner
It is use to wash salt from metal surface after sand bathing.
8. ManualStraighteningPress
It is used to straight long and thin metallic sheets.
9. Electricgascarburizingfurnace
Temp = 950°C
Size =φ 300 x 600
10.Electrictemperingfurnace
Temp = 650°C
Size =φ950 x 1220
11.Saltbath
Size =2000 x 2000 x 1400
12.Waterquenchingtank
Size =1500 x 3000 x 3000
r. CTC Fabrication Shop
CTC stands for Central Technical Cell. Basically it is a drawing and
planning section of fabrication shop, in these 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 jobs of CTC
fabrication are
 Job feeding to shop
 Planning
 Material check
 Observation from manufacturing till sale.
 Job feeding to shop
 Planning
 Material check
 Observation from manufacturing till sale.
s. FABRICATION SHOP
Basically Fabrication Shop is divided into four sections:
 Heavy bay section,
 Medium bay section,
 Small bay section
 Marking and layout section
LISTOFAPPARATUSANDMACHINES
The machines in the fabrication shop and their capacities are given below:
SMALL BAY
 2.5 ton press
 5 ton bending machine

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MEDIUM BAY
 Shaft cutting Circular saw Cutting Dia 1350mm
 Shaft welding machine Height of beam 450 mm
HEAVY BAY
 3000 ton press
 1000 ton rolling machine
 50 ton capacity cranes
t. MARKING LAYOUT AND CUTTING SECTION
 Photo cell cutting machine Electromagnetic or paper templates are used
 CNC cutting machine A German CNC cutting machine is used for cutting accurate
and complex parts
 Plasma arc cutting machine for non-ferrous metals
 Semi-automatic cutting machine
 Oxygen and natural gas are used for cutting
 Mechanical cutting machine(shearing machine)
 Parallel cutting machine
 Trennjaeger machine
 Nine roller
 Straightening machine
u. Welding
Mainly welding is done in all bays of fabrication shop. The type
of welding used in fabrication shop is as follows:
1. Arc Welding:
Arc welding uses a welding power supply to create an electric arc between an
electrode and the base material to melt the metals at the welding point. They can use either
direct (DC) or alternating (AC) current, and consumable or non-consumable electrodes. The
welding region is sometimes protected by some type of inert or semi-inert gas,
known as a shielding gas, and/or an evaporating filler material. The process of arc
welding is widely used because of its low capital and running costs.
2. Shielded Metal Arc Welding (SMW):
Shielded metal arc welding (SMAW), also known as manual metal arc (MMA) welding
or informally as stick welding, is a manual arc welding process that uses a consumable
electrode coated in flux to lay the weld. An electric current, in the form of either alternating
current or direct current from a welding power supply, is used to form an electric arc between
the electrode and the metals to be joined. As the weld is laid, the flux coating of the electrode
is integrates, giving off vapors that serve as a shielding gas and providing a layer
of slag, both of which protect the weld area from atmospheric contamination. Because of
the versatility of the process and the simplicity of its equipment and operation,
shielded metal arc welding is one of the world’s
most p o p u l a r w e l d i n g p r o c e s s e s . I t dominates other welding processes in the
maintenance and repair industry, and though flux-cored arc welding is growing in
popularity, SMAW continues to be used extensively in the construction of steel
structures and in industrial fabrication. The process is used primarily to weld iron and
steels (including stainless steel) but aluminum, nickel and copper alloys can also
be welded with this method.
3. TungstenInertGasWelding:
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

13. 12
welds, known as auto genous 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 plasma. GTAW is most 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.
4. Metal Inert Gas Welding:
Gas metal arc welding (GMAW), sometimes referred to by its subtypes
metal inert gas(MIG) welding or metal active gas (MAG) welding, is a semi-
automatic or automatic arc welding process in which a continuous and
consumable wire electrode and a shielding gas are fed through a welding
gun. A constant voltage, direct current power source is most commonly
used with GMAW, but constant current systems, as well as alternating current,
can be used. There are four primary methods of metal transfer in GMAW, called
globular, short-circuiting, spray, and pulsed spray, each of which has distinct
properties and corresponding advantages and limitations.
v. WELDINGDEFECTS
Defect found in the welding are
o Cracks Blow holes
o Crack Spatter
o Lack of penetration Undercut
o Pipes Tungsten inclusion
o Porosity Restart of welding
o Lack of fusion
o Slag inclusions
w. NON DESTRUCTIVE TESTING LAB
Non-destructive test is used to identify the defects in welding joints in the NDT lab of
HMC NON DESTRUCTIVE EXAMINATION FACILITIES
o x-ray radiography
o Gamma ray radiography
o Ultrasonic
o Magnetic particle
o Liquid penetrant
o Eddy current
o Spectroscopy
x. RADIOGRAPHY TECHNIQUES
Following Radiography techniques are possible, but only three type
of radiography are used mostly X-ray, ultrasonic, and gamma ray radiography because
other radiography are expensive. A list of available radiographic methods is given below:
o X-ray Radiography
o Gamma Ray Radiography
o Neutron Radiography
o Proton Radiography
o Xero Radiography
o Fluoroscopy
o Micro Radiography

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o Flash Radiography
o Auto Radiography
o Electron transmit Radiography
y. NDT METHDS APPLICATION AND LIMITATIONS
 RadiographytestingMethod:
1. Radiography is the most universally used NDT method for detection of gas porosityin
the weldments.
2. The radiography image of a “Round Porosity” will appear as oval shaped spots with
smooth edges, while “elongated porosity” will appear as oval shaped spots
with major axis. Sometimes several time longer then minor axis.
3. Foreign material such as loose scale, flux or splatter will affect validity of test results.
 UltrasonicTestingMethod
1. Ultrasonic testing equipments are highly sensitive, capable of
detecting micro separations.
2. Surface finishing and grain size will affect the validity of the test.
 EddycurrentTestingMethod
1. Normally confined to thin wall welded pipes and tube.
2. Penetration restricts testing to a depth of more than one quarter inch.
 LiquidPenetrantTestingMethod
a. Normally confined to in processes control of ferrous and non-ferrous welds.
b. Liquid penetrant testing is like magnetic particle is restricted to
surface evaluation.
c. Extreme condition must be exercised to prevent any cleaning material
andliquid penetrant materials from becoming entrapped &
contaminating the re-welding operation.
 MagneticparticleTestingMethod
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.
_________________________________________•
FORGING SHOP
“Forging is the term for shaping metal by using localized compressive forces.” Cold
forging is done at room temperature or near room temperature. Hot forging is
done at a high temperature, which makes metal easier to shape and less likely to fracture.
Warm forging is
done at intermediate temperature between room temperature and hot
forging temperatures. Forged parts can range in weight from less than a
kilogram to 170 metric tons. Forged parts usually require further processing to achieve
a finished part.
PROCESSESOFFORGING
i. Open-die drop-hammer forging
ii. Impression-die drop-hammer forging
iii. Press forging
iv. Upset forging
v. Automatic hot forging
vi. Net-shape and near-net-shape forging
vii. Induction forging
Of these the first three methods are commonly used in HMC

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FUNCTIONSOFFORGESHOP
i. Production of large and medium size forgings.
ii. Mostly forged parts include railway axles, draw hooks, screw couplings, cement
and sugar plant parts, boiler components, road rollers parts, cranes and drop tank
equipment’s.
iii. Its annual production is 4500 tons.
FORGING EQUIPMENT
HAMMERS:
i. 150kg pneumatic hammer
ii. 400kg pneumatic hammer
iii. 750kg pneumatic hammer
HYDRAULIC PRESSES:
i. 800 ton drawdown type press along with pump, accumulator station and
forging manipulator.
DIEFORGINGPRESSES:
i. 60 ton power press
ii. 160 ton friction press
iii. 400 ton power press
iv. 1250 ton friction press.
CRANES:
i. 1 ton stationary stewing crane
ii. 5 ton quenching overhead crane
iii. 12.5 ton overhead crane
iv. 20.5 ton forging crane
OTHERAPPLIANCESL
i. Shot blasting machine
ii. Pedestal grinder
iii. Quenching tanks_____ 2 oil and water (5m* 3m* 5m each)
FURNACES
i. Heating furnaces ________ 104.84m* 2.08m* 1.5mMax temp 1300 degree
Celsius
ii. Heat treatment furnace ________ 515m* 4m* 6mMax temp 1050 degree Celsius
PATTERN SHOP
The purpose of pattern shop is to make wooden or metallic components for casting process.
TYPESOFPATTERN
a) One piece or solid pattern
b) Two piece or split pattern
c) Three piece pattern
d) Loose piece pattern.
e) Self-core pattern.
f) Sweep pattern.
g) Skeleton pattern.
h) Match plate pattern.
i) Connecting pattern.
j) Master pattern
TYPESOFCOREPRINTS
a) Top print.
b) Bottom print.
c) Side print.

16. 15
d) Tail print.
e) Hang print.
f) Balancing print.
TYPESOFCOREBOX
a) Box type core box.
b) Shake out type core box.
c) Gang type core box
MACHINESINPATTERNSHOP
a) Band saw.
b) Joint planner.
c) Thickness planner.
d) Disc and spindle sander.
e) Wooden lathe machine.
f) Wooden milling machine.
MATERIAL TESTING LABORATORY
The objective of material testing laboratory is to check the chemical
composition of different alloys of iron, copper as well as other non-metallic elements.
The facility contains the following laboratories:
a) Quick response section.
b) Mechanical testing section
c) Heat treatment section
d) Microscope section
e) Wet test laboratory
QUICKRESPONSESECTION
The quick response section is situated near the steel foundry and it helps the foundry
men to melt different alloys in exact element ratios to get specific allows. It has
the facility to inspect the molten metal from the furnace at intervals and provide
the feedback within a few minutes. The facility has the following apparatus:
a) Emission spectrometer.
b) Spectrophotometer.
c) Carbon furnace.
d) Titration apparatus.
EMISSIONSPECTROMETER
This instrument vaporizes the metal by producing an electric
spark and then analyses the spectrum of the resulting vapors to identify the
percentage of 26 different metals in the given alloy. It has the capability to detect both
iron based and copper based metals. The elements that are detected by it include the
following: Carbon, silicon, manganese, phosphorus, sulphur, chromium, molybdenum,
aluminum, copper, cobalt, titanium, vanadium, tungsten, lead, boron, tin, zinc,
arsenic, bismuth, calcium, cesium, zirconium, and iron.
MECHANICALTESTINGSECTION
This testing section includes the following machines:
a) Universal testing machine
b) Impact test machine
c) Brinnel hardness testing machine
d) Rockwell hardness tester and Vickers
e) Wear testing machine
WET TEST LABORATORY
In the wet test laboratory, we use the element analysis to measure the moisture
contents in any material or a specimen or element.

17. 16
WINDING SHOP:-
Motor:
A Motor is a device that creates motion. It usually refers to an engine of some kind. It
may also specifically refer to:
 Electric motor, a machine that converts electricity into a mechanical motion
 AC motor, an electric motor that is driven by alternating current
 Synchronous motor, an alternating current motor distinguished by a rotor spinning
with coils passing magnets at the same rate as the alternating current and resulting
magnetic field which drives it
 Induction motor, also called a squirrel-cage motor, a type of asynchronous
alternating current motor where power is supplied to the rotating device by means of
electromagnetic induction
 DC motor, an electric motor that runs on direct current electricity
 Brushed DC electric motor, an internally commutated electric motor designed to be
run from a direct current power source
 Brushless DC motor, a synchronous electric motor which is powered by direct
current electricity and has an electronically controlled commutation system, instead of
a mechanical commutation system based on brushes
 Electrostatic motor, a type of electric motor based on the attraction and repulsion of
electric charge
 Engines, which are very commonly called "motors"
 Servo motor, an electric motor that operates a servo, commonly used in robotics
 Starter motor, for starting an internal-combustion engine of a vehicle.
 Stepper motor, a type of electric motor capable of rotating its output shaft in equally
spaced fractions of a full rotation, known as steps
 Internal fan-cooled electric motor, an electric motor that is self-cooled by a fan,
typically used for motors with a high energy density
 Actuator, a mechanical device for moving or controlling a mechanism or system
 Hydraulic motor, a machine that converts the energy of pressurized liquid flow into
mechanical motion
 Rocket motor, usually refers to solid rocket engines
 Molecular motor, the agents of movement in living organisms
 Synthetic molecular motor, molecular machines capable of rotation under energy
input
 Nanomotor, a molecular device capable of converting energy into movement
 Pneumatic motor, a machine that converts the energy of compressed air into
mechanical motion
 "Motor Car" or "Motor", alternate terms for an automobile

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INDUCTION MOTOR:-
An induction or asynchronous motor is an AC electric motor in which the electric
current in the rotor needed to produce torque is obtained by electromagnetic induction from
the magnetic field of the stator winding. An induction motor therefore does not require
mechanical commutation, separate-excitation or self-excitation for all or part of the energy
transferred from stator to rotor, as in universal, DC and large synchronous motors. An
induction motor's rotor can be either wound type or squirrel-cage type.
Three-phase squirrel-cage induction motors are widely used in industrial drives because
they are rugged, reliable and economical. Single-phase induction motors are used extensively
for smaller loads, such as household appliances like fans. Although traditionally used
in fixed-speed service, induction motors are increasingly being used with variable-frequency
drives (VFDs) in variable-speed service. VFDs offer especially important
energy savings opportunities for existing and prospective induction motors in variable-torque
centrifugal fan, pump and compressor load applications. Squirrel cage induction motors are
very widely used in both fixed-speed and VFD applications.
THANK YOU
Regards : USAMA SHEIKH