This document describes a semester training project at Cheema Boilers Limited from January to May 2018. It provides an introduction to the company and outlines their product range of different types of boilers. It then describes the processes involved in manufacturing process boilers, including shot blasting, marking, drilling, welding, and quality checking. The document proposes using an NC grinding machine to automate the grinding process for back chipping/gouging to reduce labor and increase productivity and precision. It presents the benefits of automating this process and concepts for the machine design.
2. INTRODUCTION
• CHEEMA BOILERS LIMITED IS A TRUSTED NAME IN THE FIELD OF INDIAN BOILER
INDUSTRY.
• ALTHOUGH CBL STANDS FOR CHEEMA BOILERS LIMITED, BUT WE DRAW
STRENGTHS FROM THESE WORDS IN OUR OWN WAY.
1. C FOR COMMITMENT
2. B FOR BRILLIANCE
3. L FOR LONG TERM RELATIONS
• CBL HAS GOT ITS OWN MANUFACTURING FACILITIES AT KURALI 25 KM FROM
CHANDIGARH, NEAR ROPAR AND CORPORATE OFFICE AT MOHALI, (CHANDIGARH).
3. PRESENT PRODUCT RANGE
• EFFYPAC
• EFFIPOWER
• HYPAC
• OILPAC
• ENERGY & ENERGYPAC PLUS
• INPAC
• STEAMMAX
11. PROJECT UNDERTAKEN
PRODUCTION MANAGEMENT OF PROCESS BOILERS
GUIDED BY:
MR. DAWINDER PADDA
(ASSISTANT MANAGER)
&
MR. PARDEEP SAINI
(ASSISTANT PRODUCTION ENGINEER)
PRESENTED BY
SAHIL RANA
11403026
MECHANICAL ENGINEERING
12. PROCESSES THAT TAKES PLACE WHILE
MANUFACTURING OF PROCESS BOILERS
(WWP)
• SHOT BLASTING OF TUBES AND
HEADERS
• IN THIS PROCESS CLEANING OF
HEADER IS DONE.
13. MARKING OF HEADERS AND CHECKING OF MARKING
• IN THIS PROCESS THE MARKING OF
HEADERS AND TUBES ARE DONE AS
PER DRAWING AND THEN CHECKED
BY QUALITY ENGINEER BEFORE
DRILLING OF HEADERS
14. DRILLING OF HEADERS
• IN THIS PROCESS HOLES ARE
DRILL ACCORDING TO THE
SIZE GIVEN IN DRAWINGS
USING AUTOMATIC DRILLING
MACHINE
15. CLEANING OF HEADERS AND PROFILE CUTTING
• IN THIS PROCESS EDGE PREPARATION OF HEADERS
IS DONE FOR EASE IN WELDING.
• GROOVE ANGLE OF 30 DEEGRE IS MADE
16. CUTTING AND BENDING OF TUBES
• BEND RADIUS OF TUBES IS DECIDED ACCORDING TO THE DEMAND OF
DRAWING
• ONLY COLD BENDING OF TUBE IS DONE
17. SETUP OF WATER WALL PANEL
• IN THIS PROCESS SETUP OF
WATER WALL PANEL IS DONE
WITH ONLY FOUR TUBES WITH
TOP AND BOTTOM HEADERS
• REST OF THE TUBES ARE FIT
AFTER THE EXAMINATION BY
QUALITY ENGINEER.
18. TACKING OF TUBES AND SUPPORTING CHANNEL
• TACKING OF ALL TUBES ARE
DONE AFTER BIENG EXAMINED
BY QUALITY ENGINEER
19. TACKING OF STRIPS
• FITUP OF STRIPS
WITH TUBES ARE
DONE IN THIS
STAGE WITH THE
HELP OF E-6013
ELECTRODES
20. WELDING OF TUBES AND STRIPS
• TUBES ARE WELDED USING SMAW • STRIPS ARE WELDED USING FCAW
21. HYDRO TEST
• HYDRO TEST OF SHELL AND WATER
WALL PANEL IS DONE BEFORE
ASSEMBLY
• HYDRO TEST ENSURES THAT THERE
IS NO LEAKAGE OF ANY TUBES AND
WELDING JOINTS.
• THE TESTING PRESSURE IS 1.5
TIMES THE WORKING PRESSURE OF
BOILERS.
Pressure
gauges
22. SETUP OF WATER WALL PANEL WITH SHELL
• FINALLY AFTER PERFORMING THE
HYDRO TEST OF WATER WALL AND
SHELL BOTH ARE FITTED TOGETHER
AND WELDED.
23.
24. ASSEMBLY OF VARIOUS PARTS WITH BOILER
• FIT-UP OF VARIOUS PARTS LIKE
STRUCTURE, ID AND FD FAN, APH,
WPH, DUCTING, CYCLONE ETC. ARE
WELDED WITH THE BOILER IF
REQUIRED AT SHOP.
25. QUALITY CHECKING OF FINAL PRODUCT
ALL READY PRODUCTS ARE EXAMINED BY QUALITY ENGINEER IN ORDER TO
ASSURE 100% SAFETY TO CUSTOMERS
28. DESIGN AND MODIFICATION OF GRINDING
PROCESS BY NC MACHINING
INTRODUCTION ABOUT THE PROJECT
GRINDING PROCESS IS MAINLY USED FOR THE PURPOSE OF BACK
CHIPPING/BACK GAUGING IN MULTITUBULAR SHELL AND FOR MANY OTHER
PURPOSES.
SKILLED LABOUR IS REQUIRED FOR THIS JOB TO BE DONE.
MANUAL PROCESS, SO MORE EFFORT IS REQUIRED AND IF IT WILL BE DONE
AUTOMATICALLY, IT THEREBY WILL INCREASE PRODUCTIVITY AND DECREASE
WORK FORCE REQUIRED.
29. OBJECTIVES
• REDUCTION OF WORKING TIME .
• COST REDUCTION- BY DECREASING WORK FORCE REQUIRED FOR THIS JOB.
• AS LONG SEAM AND CIRCULAR SEAM IS AN INEVITABLE PART OF EACH AND
EVERY BOILER SO OPTIMISATION OF PROCESS IS NEEDED.
• FOR MAKING PROPER GROOVES FOR THE WELDING TO BE SOUND WELD.
30. CONCEPTUAL DESIGN
INTRODUCING SOME SIMPLE MECHANISM
• INITIALLY BACK CHIPPING/BACK GOUGING IN MULTITUBULAR SHELL IS
DONE BY THE SKILLED LABOUR WITH THE HELP OF GRINDER.
• THIS SKILLED LABOUR CAN BE REPLACED BY NC MACHINE MOUNTED
ON A TRACTOR HAVING GRINDER OVER IT.
• THE MOVEMENT OF GRINDING WHEEL, FORWARD AND REVERSE
MOVEMENT OF TRACTOR CAN BE MANIPULATED BY NC MACHINE
• NO SKILLED LABOUR IS REQUIRED AND JOB WILL BE DONE WITH MORE
ACCURACY AND PRECISION.
33. KAIZEN BENEFITS
• EARLIER, THE MARKING OF TUBE PLATES ARE DONE MANUALLY BY HANDS
WHICH CONSUMES LOTS OF TIME AND EFFORTS.
• MARKING OF ALL TUBE PLATES ARE DONE NOW BY TRACING A 1:1 DRAWING OF
TUBE PLATE HOLES.
• RESULTS IN DECREASE IN MANUFACTURING LEAD TIME AND EFFORTS, AND
HENCE INCREASE IN PRODUCTIVITY OF AN ORGANISATION.
