eastern coalfields limited

Eastern Coalfields Ltd, Sanctoria,

Dishergarh,
Project report

NAME - TANMOY DAS, SAURISH DEY

ROLL NUMBER - 10800716031, 10800716074,

DEPARTMENT - MECHANICAL ENGINEERING

COLLEGE - ASANSOL ENGINEERING COLLEGE

TRAINING DURATION - 11 JAN 2019 to 31 JAN 2019

 PREFACE
This Project Report has been prepared in partial fulfillment of
the requirement for vocational training: Practical Studies of the
program B.TECH . in Mechanical Engineering (Sem.VI) in the
academic year 2018-2019. For preparing the Project Report, we
have visited the ECL Central workshop for the period of 21 days,
to avail the necessary information.
The rationale behind visiting the company and preparing the
Project Report is to have mechanical training for repairing
pumps winding, motor repairing, conveyor roller
making, roof bolt making, vehicle maintenance,
machining and welding processes. We have taken the
opportunity to explore the Mechanical department, its use,
necessity in workshop and making, maintenance and repairing
of various instruments which are used in ECL.
All the above mentioned topics will be presented in the
preceding pages of this report. The main aim to carry out this
training was to familiarize ourselves with the real industrial
scenario, so that we can relate what we study in our textbooks
and their practical applications.
NAME OF TRAINEES
TANMOY DAS
SAURISH DEY
 ACKNOWLEDGEMENT

We wish to express my gratitude to all those individuals with

whom, we interacted and gained knowledge, insight and
thoughts while preparing this project report.
First of all, we are grateful to the
General Manager (IED) and
General Manager (HRD) ECL, Santoria
for granting us the permission to do this project in the
organization.
At the same time we would like to thank the
CH.MANAGER(E&M) ,
Sr. Manager (Personnel) and
DY.Manager (E&M)
for their co-operation during the training period.
We would like to thank them for their able guidance and
encouragement while working on this project.
we also take this opportunity to thank the Superintending
Engineers of all the divisions of ECL for their co-operation while
we visited their respective divisions.
 CONTENTS

● INTRODUCTION
● HYDRAULIC DRILLING MACHINE.
● HYDRAULIC BORING MACHINE.
● HYDRAULIC PLATE CUTTING MACHINE.
● HYDRAULIC PRESSING MACHINE.
●COMPLETE CASTING PROCESS OF FEW
DAMAGED PUMP PARTS.
● MOTOR WINDING AND FITTING.
● PUMP REPAIRING.
● ROLLER MAKING.
● SUBMERGED ARC WELDING.
● STUDY ON AUTOMOBILE PARTS.
AND A BRIEF DESCRIPTION ABOUT ELECTRICITY
GENERATING ENGINES & LARGE DIESEL
ENGINES.
●AUTOMATIC LATHE MACHINES.
 INTRODUCTION
Eastern Coalfields Limited is a coal producer based company in
India, which was founded in 1975 after nationalisation of coal
mines in India. It is one of the fully owned subsidiaries of coal
India limited. The Company has its headquarters at Sanctoria, in
West Bengal.
Sodepur central workshop (ECL) is a well known and prominent
workshop. The whole workshop is divided into management
building , roller & maco shop, welding room, motor winding
and fitting shop, foundry shop, drilling and roof bolt section,
crane station, automobile repairing shop, storage section and
transformer
 Hydraulic Drilling Machine

Hydraulic machines are machinery and tools that

use liquid fluid power to do simple work, operated by the use
of hydraulics, where a liquid is the powering medium. In heavy
equipment and other types of machine, hydraulic fluid is
transmitted throughout the machine to various hydraulic
motors and hydraulic cylinders and becomes pressurised
according to the resistance present.
The popularity of hydraulic machinery is due to the very large
amount of power that can be transferred through small tubes
and flexible hoses. At sodepur workshop such drilling machine
is generally used for drilling in square iron plates, which plays a
role of washer (in roof bolt) .There is a continuous flow of
lubricating oil at the tip of drilling tool, which makes the job
more smoother and better for machine.
It is so powerful that at one time (hardly 4-5 min.) it can drill up
to 10 plates of each almost 2-3 cm . Really such machines are
boon for us which saves a great time and effort both which are
very important in an industrial life.

Hydraulic Boring Machine

A horizontal boring machine or horizontal boring mill is
a machine tool which bores holes in a horizontal direction.
There are three main types — table, planer and floor. The table
type is the most common and, as it is the most versatile, it is
also known as the universal type.
A horizontal boring machine has its work spindle parallel to the
ground and work table. Typically there are three linear axes in
which the tool head and part move. Convention dictates that
the main axis that drives the part towards the work spindle is
the Z axis, with a cross-traversing X axis and a vertically
traversing Y axis. The work spindle is referred to as the C axis
and, if a rotary table is incorporated, its centre line is the B axis.
It is incorporated at the workshop for making holes in the
cylinder for making rollers at roller shop and also used for
facing, internal flat cutting of pump machines and bearing
housing.
Hydraulic Plate Cutting Machine

The machine used is called a squaring shear, power shear,

or guillotine. The machine may be foot powered, less
commonly hand powered, or mechanically or hydraulically
powered. It works by first clamping the material with a ram. A
moving blade then comes down across a fixed blade to shear
the material. For larger shears the moving blade may be set on
an angle or "rocked" in order to shear the material
progressively from one side to the other; this angle is referred
to as the shear angle. Setting the blade on an angle decreases
the amount of force required, but increases the stroke. The
design of press tools is an engineering compromise. A sharp
edge, strength, and durability are ideal, but a sharp edge is not
very strong or durable, so blades for metal work tend to
be square-edged rather than knife-edged. Typical workpiece
materials include aluminium, brass, bronze, and mild
steel because of their outstanding shareability ratings. Stainless
steel is not sheared as often due to its tendencies to work-
harden.
It is employed in the workshop to cut the long iron sheets of 2-
3 cm thickness in the square plates to use that as a washer in
the roof bolt.
Its cutting velocity is very high which provides a high
momentum to the blades.
 Hydraulic pressing machine

A hydraulic press is
a machine press using
a hydraulic cylinder to
generate a compressive
force. It uses the
hydraulic equivalent of a
mechanical lever, and
was also known as
a Braham press after the
inventor, Joseph Braham,
of England. He invented
and was issued a patent
on this press in 1795. The hydraulic press depends on Pascal's
principle-the pressure throughout a closed system is constant.
One part of the system is a piston acting as a pump, with a
modest mechanical force acting on a small cross-sectional area;
the other part is a piston with a larger area which generates a
correspondingly large mechanical force. Only small-
diameter tubing (which more easily resists pressure) is needed
if the pump is separated from the press cylinder.
It has a vast of role in industrial applications, but in the
workshop it is mainly used for the purpose of punching, forging,
moulding and metal forming operations.
Sometimes, it is also used as to straight the square iron plates
(washer).

Casting Process

Casting is a manufacturing process in which a liquid material is

usually poured into a mould, which contains a hollow cavity of
the desired shape, and then allowed to solidify. The solidified
part is also known as a casting, which is ejected or broken out
of the mould to complete the process. Casting materials are
usually metals or various cold setting materials that cure after
mixing two or more components together; examples are
epoxy , concrete, plaster and clay. Casting is most often used
for making complex shapes that would be otherwise difficult or
uneconomical to make by other methods.
Casting is a 6000-year-old process. The oldest surviving casting
is a copper frog from 3200 BC.
In the foundry shop the metal (discarded copper wire) is mixed
with epoxy and heated at 900 ⁰C -1300 ⁰C for up to 2-3 hrs to
become liquid and is then poured into a mould. The mould is a
hollow cavity that includes the desired shape, but the mould
also includes runner and risers that enable the metal to fill the
mould. The mould and the metal are then cooled until the
metal solidifies. The solidified part (the casting) is then
recovered from the mould. Subsequent operations remove
excess material caused by the casting process.
The final mixture almost contains 88% cu, 10% tin & 2% Zn and
5-6% cu is drained out as sludge.
 Motor Winding & Fitting

In electrical engineering, electric machine is a general term

for machines using electromagnetic forces, such as electric
motors, electric generators, and others. They are
electromechanical energy converters: an electric motor
converts electricity to mechanical power while an electric
generator converts mechanical power to electricity. The moving
parts in a machine can be rotating (rotating machines) or linear
(linear machines). Besides motors and generators, a third
category often included is transformers, which although they
do not have any moving parts are also energy converters,
changing the voltage level of an alternating current.
In electrical engineering, coil winding is the manufacture
of electromagnetic coils. Coils are used as components of
circuits and to provide the magnetic field of electrical machines
such as motors and generators, and in the manufacture of
loudspeakers and microphones. The shape and dimensions of a
winding are designed to fulfil the particular purpose.
Parameters such as inductance, Q factor, insulation strength,
and strength of the desired magnetic field greatly influence the
design of coil windings. Coil winding can be structured into
several groups regarding the type and geometry of the wound
coil. Mass production of electromagnetic coils relies on
automated machinery.

PUMP REPAIRING
A pump is a device that moves fluids (liquids or gases), or
sometimes slurries, by mechanical action. Pumps can be
classified into three major groups according to the method they
use to move the fluid: direct lift, displacement,
and gravity pumps.
Pumps operate by some mechanism
(typically reciprocating or rotary), and consume energy to
perform mechanical work moving the fluid. Pumps operate via
many energy sources, including manual operation,
electricity, engines, or wind power, come in many sizes, from
microscopic for use in medical applications to large industrial
pumps.
In the shop first they used to diagnose the pump problems by
estimating water pressure, pressure control switch, pump
starting problems and many more such problems
Before changing a water pump or control, we need to know
why the water pressure or water flow is poor. Sometimes loss
of water pressure is also observed that the pressure with which
water enters a plumbing fixture has become too slow, or is
sometimes too slow or weak in water flow rate, or water flow
may stop entirely. The well pump, in turn, could have been
damaged or hastened to the end of its life by a bad water
pressure tank which has caused well pump short-cycling. Short
cycling of the pump motor can burn up the pump relay control.
So these are some pump repairing facts which is been observed
by me at the workshop.
 Roller making

Rollers are mainly used in conveyors, which are used to transfer

goods from one nearer place to another. Its mainly a shaft
connected to a cylinder with bearings in both ends by the help
of submerge arc welding.
For making a roller e have to cut a large cylindrical pipe in to
small length and then the connecters are connected by humans
fixing bearings at both ends. Then put that on the submerge arc
welding setup and run the machine.
There are many types of rollers some are shown in figure.

A bearing is a machine element that constrains relative motion

to only the desired motion, and
reduces friction between moving parts. The design of the
bearing may, for example, provide for free linear movement of
 the moving part or for free rotation
around a fixed axis; or, it may prevent a
motion by controlling
the vectors of normal forces that bear on
the moving parts. Most bearings facilitate
the desired motion by minimizing friction.
Bearings are classified broadly according
to the type of operation, the motions allowed, or to the
directions of the loads (forces) applied to the parts.
Rotary bearings hold rotating components such
as shafts or axles within mechanical system, Lubrication is often
used to reduce friction.
 Submerged arc welding

Submerged arc welding (SAW) is a common arc

welding process. The first patent on the submerged-arc welding
(SAW) process was taken out in 1935 and covered an electric
arc beneath a bed of granulated flux. The process requires a
continuously fed consumable solid or tubular (metal cored)
electrode. The molten weld and the arc zone are protected
from atmospheric contamination by being "submerged" under
a blanket of granular fusible flux consisting of lime, silica,
manganese oxide, calcium fluoride, and other compounds.
When molten, the flux becomes conductive, and provides a
current path between the electrode and the work. This thick
layer of flux completely covers the molten metal thus
preventing spatter and sparks as well as suppressing the
intense ultraviolet radiation and fumes that are a part of
the shielded metal arc welding (SMAW) process.
SAW is normally operated in the automatic or mechanized
mode, however, semi-automatic (hand-held) SAW guns with
pressurized or gravity flux feed delivery are available. The
process is normally limited to the flat or horizontal-fillet
welding positions (although horizontal groove position welds
have been done with a special arrangement to support the
flux). Deposition rates approaching 45 kg/h (100 lb/h) have
been reported — this compares to ~5 kg/h (10 lb/h) (max)
for shielded metal arc welding. Although currents ranging from
300 to 2000 A are commonly utilized, currents of up to 5000 A
have also been used (multiple arcs).
Single or multiple (2 to 5) electrode wire variations of the
process exist. SAW strip-cladding utilizes a flat strip electrode
(e.g. 60 mm wide x 0.5 mm thick). DC or AC power can be used,
and combinations of DC and AC are common on multiple
electrode systems. Constant voltage welding power
supplies are most commonly used; however, constant current
systems in combination with a voltage sensing wire-feeder are
available.
 Study on Auto-Mobile Parts
Auro mobile is a very useful transport for both Humans and
industrial materials. That’s why the maintainance of auto
mobile is very important. In the Sodepur Central Workshop
there is a auto-mobile repairing shop also.
In a auto mobile vehical there are many
many parts, in our training we have learnt
about the important parts of auto mobile
and their work, working procedure,
positioning etc.
The parts are like …
Engine System : It is the main part of a
automobile, which produces power,by the
combustion of fule using these parts.
 Spark plug. The spark plug supplies the spark that ignites the
air/fuel mixture so that combustion can occur. ...
 Valves. The intake and exhaust valves open at the proper time
to let in air and fuel and to let out exhaust. ...
 Piston. ...
 Piston Rings. ...
 Connecting rod. ...
 Crankshaft. ...
 Sump.
A Car engine is a IC engine, this type of engine performs intake,
compression, combustion and exhaust in a different part of the
housing.There Were Carborator in the Petrol engines and Fule
Injectors for Diesel engines.
By Running for a long time the engine gets heated to a high
temp. for that problem There is a cooling system for every
vehical having liquid coolent and radiator.
Then The Produced power comes under the Gear Box going
through Clutch and then delivered to the Rare Wheels.
For the unneccery up-downs the vehical get hamaraged in
many way so there are shock-Absorbers in a vehical. For heavy
loaded vehicals Leaf spring is used and for Cars Simple helical
spring is used.There The Steering, breaking system and Exhaust
are also very important parts for a vehical.

Electricity Generating Engines.

Now a days Electricity

generating engines are
very common in Every
Workshop for
Emergency Wokrs ,
These are also known
as diesel generator is
the combination of a diesel engine with an electric
generator (often an alternator) to generate electrical energy.
This is a specific case of engine-generator. A diesel
compression-ignition engine is usually designed to run on diesel
fuel, but some types are adapted for other liquid fuels
or natural gas.
Diesel generating sets are used in places without connection to
a power grid, or as emergency power-supply if the grid fails, as
well as for more complex applications such as peak-lopping,
grid support and export to the power grid.
Proper sizing of diesel generators is critical to avoid low-load or
a shortage of power. Sizing is complicated by the characteristics
of modern electronics, specifically non-linear loads. In size
ranges around 50 MW and above, an open cycle gas turbine is
more efficient at full load than an array of diesel engines, and
far more compact, with comparable capital costs; but for
regular part-loading, even at these power levels, diesel arrays
are sometimes preferred to open cycle gas turbines, due to
their superior efficiencies.

Automatic Lathe Machine

An automatic lathe is a lathe (usually a metalworking lathe)
whose actions are controlled automatically. Although all
electronically controlled (CNC) lathes are automatic. The first
kinds of automatic lathes were mechanically automated ones,
from the 1870s until the advent of NC and CNC in the 1950s
and 1960s. CNC has not yet entirely displaced mechanically
automated machines. The latter type of machine tool is no
longer being newly built, but many existing examples remain in
service.
An automatic lathe may have a single spindle or multiple
spindles. Each spindle contains a bar or blank of material that is
being machined simultaneously. A common configuration is six
spindles. The cage that holds these six bars of
material indexes after each machining operation is complete.
The indexing is reminiscent of a Gatling gun.
Each station may have multiple tools that cut the material in
sequence. The tools are usually arranged in several axes, such
as turret (rotary indexing), horizontal slide (linear indexing), and
vertical slide (linear indexing). The linear groups are called
"gangs". The operation of all these tools is similar to that on a
turret lathe.
By way of example: a bar of material is fed forward through the
spindle. The face of the bar is machined (facing operation). The
outside of the bar is machined to shape (turning operation).
 The bar is drilled or bored, and finally, the part is cut off
(parting operation).
Operations
Form tools
For the machining of complex shapes, it is common to use form
tools. This contrasts with the cutting that is performed on an
engine lathe where the cutting tool is usually a single point tool.
A form tool has the form or contour of the final part but in
reverse, so it cuts the material leaving the desired component
shape. This contrasts to a single-point tool, which cuts on one
point at a time and the shape of the component is dictated by
the motion of the tool rather than its shape.
Threading
Unlike on a lathe, single point threading is rarely if ever
performed; it is too time-consuming for the short cycle times
that are typical of screw machines. A self-releasing die head can
rapidly cut or roll-form threads on outside diameters. A non-
releasing tap holder with a tap can quickly cut inside diameters
but it requires single spindle machines to reverse into high
speed in order for the tap to be removed from the work.
Threading and tapping speed (low speed) is typically 1/5 the
high speed.
Rotary broaching
Rotary broaching is another common operation. The broach
holder is mounted stationary while its internal live spindle and
end cutting broach tool are driven by the work piece. As the
broach is fed into or around the work piece, the broach's
contact points are constantly changing, easily creating the
desired form. The most common form made this way is a
hexagonal Socket in the end of a cap screw.