COMPANY PROFILE

1.1 BIRTH OF THERMAX :

In the beginning there was fire. Then there was steam. Steam heated produced

mechanical movement. It could be used to produce electricity too. The use of steam rewrote

the history of human civilization. It was the driving force of industrial revolution, the

precursor of modern age, as we understand it. Even in this age of cybernetics, genetic

engineering and information superhighways, boilers that produce steam are critical on-line

equipment, across diverse industry segments – be it a small-scale unit, which needs a 600

kg/hr, or a fertilizer plant, which needs a 300-tones/hr high-pressure steam generator.

Years ago there was a small company in Bombay called National Steel Equipment

Company (Nat Steel), which made hospital sterilization equipment. It’s founder A.S.Bathena

(1908-1991) and his son Jamshed decided to go in for collaboration with a Brussels based

company Wansons for manufacturing of so called “Baby Boilers”. It was a case of David

joining hands with Goliath; Wanson was one of the largest manufacturers of coil type boilers

in Europe while Nat. Steel was 5000 Sq. Ft. asbestos go down in a corner of Mumbai.

Nevertheless, the new venture took off meeting a market need that the customers

not even aware of: while Indian industry in the mid-sixties was largely familiar with bulky

hand fired boilers, the Wanson India “Vaporax” boilers produced steam within two minutes

of cold start.

In two years the new company sold over a hundred boilers, while a market survey

predicted a turnover of RS.3 million in the third year, the company got in that year a single

order for that figure. The order was from L&T. Bathena was soon joined by Mr. Rohinton D.

Aga (1935-1996), a Cambridge educated economist by training and manager by profession.

A visionary, Aga laid down many of the fundamental principles and value systems that have

guided Thermax (as Wanson India was renamed in 1980). One of Aga’s favorite words was

“Synergy” and it was synergy that is at the core of Thermal’s diversification and growth.

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1.1.1 HISTORY:

The Wanson collaboration came to an end in 1978, and thus new name “THER-

MAX PVT. LTD. came to Existence in june1980. Now, Thermax is not only manufacturing

boilers, but also on its path to become a diversified growing business corporation.

Let’s share some highlighted features of ‘Thermax’ history:

In 1973, first water tube boiler called ‘Multitherm’ was manufactured.

In1975, water treatment plant was started.

In1976, chemical division came to existence.

In1977, Energy system division (ESD) was formed.

In1980, surface coating was started.

In1980, formation of Process Heat Division (PHD).

In1981, introduction of heat recovery division.

In1983, system and software division got started.

In1985, chemical and process division founded.

In1985-86, fluidized bed technology developed.

In1986, production of high temperature heater started.

In1987, liquid & vapour phase boilers manufactured

In1987, introduction to steam fired Vapour Absorption Chillers.

In1978, set-up of all India services franchisee network.

In 1988, manufacturing & marketing of painting guns & other equipments.

In1989, merger of energy division in a joint venture with ‘Babcock & Wilcox’.

In1996, acquired ISO 9002 (1994) membership.

In2000 became ISO14000 member.

In2001, formation of Boiler & Heater division (B&H).

In2002, to get ISO 9002 (2000) certification.

The above listed divisions are only a few of the various fields that Thermax has

ventured into. Thermax completed 25 years of its services to the industrial development of

the nation, in year 1991. And in 1995 after 30 years from its inception the company went

Public (limited).

1.1.2 REDEFINING IT’S BUSINESS:

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Many of Thermax’s early competitors, bigger and older companies, continue to

make boilers. Thermax, meanwhile, moved to become a multi-divisional multi-company

group with a strong presence in India and in selected overseas market. The substantial

difference vis-à-vis competition has been Thermax’s ability and agility in redefining its

business. Early in its history, Thermax redefined itself as a company that is not in the

business of making boilers, but in the business of generating and transmitting process heat.

Thermax: The process heat people. Then the business was redefined: conserving Energy and

Preventing Environment. This is the core competency of the group. It is the competency that

extends beyond mere products to full scale on site turnkey project solutions: from generation

of process heat to air pollution control. Waste heat recovery water recycling and effluent

treatment and on to co-generation of power and steam using a single fuel input. Today 60%

of Thermax’s turnover comes from its project business.

The commitment to energy conservation has led to the setting up of a pioneering

joint venture with Energy Performance Services, USA. The joint venture undertakes

comprehensive energy conservation programs, arranges funds and guarantees savings. In the

other core competency area of environmental engineering, Thermax offers solutions, which

enable industry to remain green and competitive.

1.1.3 GLOBAL THRUST:

Thermax today is a globalised group. One of the first inquiries came in the mid-

seventies when a visiting Soviet delegation spotted a Thermax hot air generator at an

exhibition in New Delhi. The Russians however wanted the equipment for drying paint.

Thermax took up the challenge and came up with a prototype in six months.

Seizing familiar opportunities and exploring niche markets, Thermax got on to the

globalization trail well before Indian industry was shaken by liberalization. On an average

20% of its turnover comes from exports. Today Thermax has a presence in many parts of the

world. Two Thermax V.A.M. s air-condition BBC’s studios and offices in London. A

number of Thermax steam generators are used to de-wax oil wells in Siberia. It’s Tulsion

brand of resins is best sellers in USA and is being increasingly accepted in Japan. A major

tire retreader in East Europe uses Thermax heating equipment. A paper and pulp

manufacturer in Thailand uses Thermax water treatment systems. Seven of the nine textile

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plants in the UAE use Thermax equipment. Thermax has set up integrated energy

conservation systems for Bali Nirvana, one of the biggest holiday resorts in Indonesia.

Thermax has also emerged as a reliable partner for Japanese Engineering, Procurement and

Construction companies.

1. Thermax-Babcock & Wilcox LTD.: -

For design and manufacturing of high pressure, high capacity water tube boilers

and merger of energy division with it.

2. Thermax-Energy Performance services LTD.: -

This collaboration was made to support energy division and also for research

works.

Now, Thermax LTD., a multi-product multidivisional company is a name to

reckon within engineering industrial world. Its dynamic group headed by able leadership is

heading towards its ultimate goal and soon will create a place for itself apart from others.

1.1.4 STEADY GROWTH:

When Thermax commenced its business cooperation as Wanson India limited in

1967-68, it had equity of Rs.300, 000, a factory of 5000 sq. ft. and a staff of around 50. The

first year of operation ended with an income of Rs.4 million. In 2000-01 the Thermax

group’s turnover was of Rs.5000 million. The figure is conservatively estimated to exceed to

Rs.7000 million by the year 2002. For the major part of its history, Thermax growth was

financed mainly out of retained earnings – without public or institutional participation – by

building on a strong sense of mission, market focused strategies, and an organizational

culture that encouraged entrepreneurship.

In February 1995, the flagship company Thermax Limited, went public with an

issue of 6.88 million equity shares of Rs.10 each at a premium of Rs.180 per share,

aggregating to Rs.1156 million chiefly to part finance expansion and technological up

gradation of various manufacturing facilities. The issue was over subscribed seven times,

despite the lukewarm capital market condition. The Thermax shares are listed on six stock

exchanges: Mumbai, Delhi, Calcutta, Ahmedabad, Pune, and the National Stock Exchange.

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1.1.5 MANUFACTURING FACILITIES:

Thermax’s manufacturing facilities are spread over 14 plants measuring 66,000

sq. meters over an area of 400,000 sq. meters at four locations. The main manufacturing

facilities are in the Pimpri-Chinchwad industrial belt near Pune. The chemical division’s state

of art resin plant is at Khopoli off Bombay-Pune highway.

The main manufacturing hub has extensive facilities for sophisticated processes

like tube plate drilling, MIG/MAG/TIG/Spot/SAW and other welding processes, CNC gas

cutting, Parkerizing, Vapor degreasing, Tube end flaring and spiraling, plate rolling, coil

winding and Stress relieving. The facilities confirm to national and international standards

such as the ‘American Society of Mechanical Engineers’ (ASME) ‘S’, ‘U’, ‘PP’ and ‘R’

stamps and other codes like ISO, DIN, GOST, BS, and ABS.

Adopting ‘supplier partnership’ as a preferred way of doing business, Thermax

has evolved reliable supply sources for components, structural and piping. The group also

sources globally for the best cost and quality advantage.

A group-wise TQM program was initiated in 1993 and Lloyd’s Register Quality

Assurance has certified that Thermax’s quality management system confirms to the ISO 9002

and ISO 14000 standards. The quality assurance system has also received the AD-Merkblatt

certification.

1.1.6 SALES AND SERVICES SPREAD:

Thermax has twelve sales and service centers across India. A strong network of

franchisees and dealers, who are an intrinsic part of organization, strengthens the customer

focus. They are also involved in business plans and strategy formulation. Many dealers are

former employees of the group. The company has over 200 sales and service representatives

spread over every part of the country. Uniquely for a capital goods manufacturer in India,

Thermax has a network of service franchisees. Over 40 of them all qualified technocrat

entrepreneurs provide localized maintenance and service support to the ever growing

population of Thermax boilers, heaters, chillers and water treatment plants..

1.1.7 OVERSEAS NETWORK:

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Thermax Babcock & Wilcox TBW, Thermax’s first joint venture brings to India

Babcock and Wilcox’s 125 years of expertise in boiler design and technology. With a

satellite link to b/w’s mainframe in Dallas, a fully equipped CAD center and in-house

proprietary programs for structural analysis, gas flow modeling, piping stress and

performances, TBW is a key player in the area of boilers designed for high efficiency

performance. It offers a range of boilers firing widely varying fuels such as oil, gas, coal,

bagasse, husk, lignite, and agro wastes to produce steam up to 300 TPH with minimum

design pressure of 130kg/cm² and temperature up to 540°C. Package water tube FM boilers

are available up to 80 TPH for firing gaseous and liquid fuels such as natural gas, blast

furnace gas, CO, FO, LSHS or HPS, independent or in combination. TBW is a key player in

trend setting technologies like life extension program of power plants, up-gradation of

recovery boilers in paper plants, retrofits for burners, superheaters and economizers and co-

generation packages. TBW’s expertise is acknowledged world over: it’s boilers are running

in the US, Saudi Arabia, Thailand, Philippines and several other countries. In India, TBW’s

engineers and technicians have used comprehensive inspection and testing techniques to

predict the remaining life of boiler parts in aging power plants of several state electricity

boards. TBW redesigned the problem components and specified necessary repairs and

replacements to ensure operating reliability for at least another twenty years.

1.1.8 THERMAX ENERGY PERFORMANCE SERVICES:

The TEPS was forged to offer joint expertise in energy management and

performance contracting to address industry needs. TEPS is poised to enter into long time

contracts with industries to help them reduce their costs. TEPS will conduct necessary energy

utilization studies and the plan and implement comprehensive power saving programs. It will

also identify sources from which customers can obtain funds. Energy cost reduction

guarantees will be provided and savings in energy costs will be applied to amortize the debt

incurred to finance the project. Surplus savings will be shared with the TEPS under a pre-

agreed formula.

Thermax’s JV partner, Energy Performance Services (EPS) Inc. is a subsidiary of

PECO Energy Company, a $4 billion US electricity and Gas Company. Targeting industrial

energy users, EPS Inc. has implemented over $9 million worth of projects and achieved

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substantial savings through efficiency improvements in the manufacturing processes and fuel

sourcing.

1.1.9 THE THERMAX GROUP BUSINESS DIGEST:

1. Process Heat Equipment

1. Steam boilers: forced and natural circulation water tubes and smoke tubes on oil, gas,

lignite and husk.

2. Fluidized bed combustion packaged boilers on coal and low-grade fuels like husk and

bagasse.

3. Liquid and vapor phase thermic fluid heaters on oil gas and solid fuels.

4. Hot air / hot water generators on oil, gas and solid fuels.

5. Oil / gas burner systems for boilers, heaters and furnaces.

6. Steam based fluidized bed tea dryers.

7. Oil and gas production-processing equipment.

8. Mobile and containerized hot water generators.

9. Packaged water tube FM boilers (up to 80 TPH.)

2. Energy Systems and Services:

1. Co-generation system, using a variety of solid and liquid fuels.

2. Captive power plants incorporating energy balancing systems.

3. Multi fuel fired high-pressure bi-drum boilers for process steam and power generation

capacity up to 300 TPH.

4. High temperature thermic fluid heating systems.

5. Oil fired shell type boilers.

6. Fines circulating fluidized bed boilers.

7. Conversion of old boilers into high efficiency fluidized bed boilers.

8. Waste fuel and waste steam fired boilers on carbon monoxide, black liquor, gas turbine

Exhaust gas, process and smelter exhaust gas etc.

9. Heat recovery steam generators.

10. Exhaust gas boilers on DG sets, gas turbines and furnaces.

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11. Process integrated boilers for sulfuric acid, nitric acid, and caprolactum and sponge ion

Plants.

12. Fluid bed dryers for sand / slag.

13. Thermal desalination plants.

14. Site erection atmospheric fluidized bed combustion boilers for low-grade fuels.

3. Absorption Cooling

1. Vapor absorption machine fired on steam, hot water and oil / gas (direct) up to a capacity

of 1400 TR.

2. Modular range in 30-70 TR capacity range.

4. Waste Management:

Water and Waste Systems (WWS) was formed by integrating Waste Management

Division and Water Treatment Division

1. Disposal of toxic and non-toxic effluents in liquid, solid and sludge using chemical

Incineration, electrolysis, and effluent treatment technologies.

2. Value added technologies in effluent plants like air/steam stripping submerged aerated

fixed film reactor.

3. Refinery waste water treatment plants.

4. Volatile organic compound incinerators.

5. Water Treatment:

1. Integrated zero liquid effluent discharge systems.

2. Water softeners and de-mineralizers: standard and custom built.

3. Vacuum and forced de-aerators, degassers, dealkalisers.

4. Water treatment plants for ultra pure water.

5. Filters for removal of suspended solids, dissolved minerals and metals.

6. Reserve osmosis and electrolysis units for treatment of saline and brackish water.

7. Condensate polishing and waste water treatment plants using ion-exchange technology.

8. Colour removal systems.

9. Revamping of old water treatment plants.

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10. Water purification products and systems for commercial establishments and households.

6. Air Pollution Control (Enviro):

1. Rigid frame electrostatic precipitators for utility/industrial boilers, cement, steel and non-

ferrous industries.

2. Multi-clone and high efficiency cyclones.

3. Fabric filters: pulse jet, reverse air and insertable type.

4. High and low energy wet scrubbers for gas and particulate cleaning applications.

5. Industrial fans and blowers: standard and custom built.

6. Pneumatic conveying systems.

7. Gas cleaning plants.

8. Scrap preheaters, water-cooled panels fume extraction systems for electric arc furnaces.

7. Chemicals :

1. Ion exchange resins.

2. Polyelectrolytes.

3. Oil well chemicals: pour point depressant and deoilers.

4. Boiler fireside cleaning compounds.

5. Cooling water chemicals.

6. Boiler feed water treatment chemicals.

7. Fuels and water treatment chemicals.

8. Leak free plant program.

8. The Quality Policy :

Our quality policy starts and ends with the customer as focal point: understanding

the customer’s requirements, building systems and process in place to ensure quality at every

stage and achieving our commitments on delivery and service before and after sales. It is our

endeavor to create culture of total quality where continuous improvement of our people, our

process and our products has become a way of life.

9. The Energy Mission:

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To transfer heat at highest possible efficiency to recover heat wherever possible,

to extract and use heat from integrated industrial processes to replace power with direct

sources of heat energy to generate heat and power simultaneously wherever possible, to

innovate technologies to use alternative and renewable energy sources.

10. The Environment Mission:

To support a national effort at environmental protection and play a significant role

in it by developing or acquiring appropriate technologies and providing services to enable

industry to produce in an uninterrupted and pollution manner.

2. DIVISIONAL PROFILE:

The company ventured into formerly unknown paths in India like water treatment

waste management, absorption chilling, chemicals, environmental engineering to extend it’s

view as an multi-product organization. In order to fulfill quality requirements and facilitate

better management for multiple products the company went to became a multidivisional

industry; principal divisions amongst them are listed here.

2.1 Process Heat Division (PHD)

This is probably the oldest division in Thermax. Its existence can be traced to the birth of

company. Its Main area of concern is the design and production of boilers. The various

types of product it deals with are:

Steam boilers: forced and natural circulation, water and smoke tube working on oil, gas

and solid fuels

Fluidized bed combustion package boilers on coal and low –grade fuels like husk and

bagasse.

Liquid and thermal phase thermic fluid heaters on gas and solid fuels.

High efficiency coil type steam boilers and water heaters.

Steam based fluidized bed tea/dal drier.

Oil and gas production –processing equipments.

Packaged water tube F.M boilers (up to 80 TPH)

2.2 Absorption Cooling Division (ACD)

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Thermax perhaps was the first company to introduce the concept of absorption

cooling in India. While it is imperative that electrical energy be replaced by something else in

the industry, notably for heating and cooling application, Thermax now offers an energy

efficient alternative to conventional compression industrial refrigeration. Vapour absorption

machine manufactured by Thermax utilizes steam and waste heat; these vapour absorption

machines are having advantages of being environmental friendly and less on electricity

consumption index. This division is involved in the following products.

Vapour absorption machines, which are steam, fired, hot fired and direct fired up

tocapacityof1400TR & Modular range in 30-70 TR capacities.

L - series chillers in the range of 100-240 TR capacities.

LL - series chillers in the range of 300-550 TR capacities.

2.3 Energy System Division (ESD)

Waste heat utilization has become a very important sector of the industry, owing

to which the above division came into being in Thermax. As discussed earlier regarding

waste heat absorption, this division deals with the later part of the above statements i.e. Heat

Recovery Units (HRU). Operating on waste heat.

The products of this division include.

Exhaust gas waste heat boilers for PG sets, gas turbines and other industrial application.

Economizers: plain tubes, cast iron, extended surfaces, cast iron muffled.

Process integrated waste heat boilers.

Waste gas fired heaters & metal recuparators

Special purpose pressure vessels, heat exchangers, towers, columns radiation coils and

reactors for critical applications

2.4 Water Treatment Division

This division is bit new and products of this division are

Water softener and demineralization Unit -standard and custom make.

Vacuum and forced deaerators, degassers, and dealkalisers

Water treatment plants for ultra pure water.

Filters for the removal of suspended solids, dissolved minerals and metals.

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Reverse osmosis and electrolysis units for the treatment of saline and brackish Water.

Condensate polishing and waste water treatment plants using ion exchange theory.

2.5 Waste Management Division

The activities of this division cover,

Disposal of toxic and non-toxic effluents in liquids, solids and sludge form, using

chemicals incineration, electrolysis and effluents technologies.

Evaporation plants for distilleries and paper mills.

Refinery wastewater treatment plants.

Fluidized Bed dryers for cement and other industries.

2.6 Air Pollution Control Division

This division has the following range of products,

Multiclone and large diameter cyclones.

Fabric filters: pulse jet, reverse air and insertable type.

Rigid frame electrostatic precipitators for utility /industrial boilers, cement, steel and non-

ferrous.

High and low energy wet scrubbers for gas and particulate cleaning application.

Industrial fans and blowers: standard and custom built.

Air washer units and ventilation systems

Pneumatic conveyors & Zero leak dampers of various designs, expansion joints.

2.7 Chemical Division

This division is involved in processing of following products:

Water treatment and softener chemicals

Thermic fluid processing.

Anti scaling and rusting chemicals

3. DEPARTMENTAL PROFILE

For the proper & efficient working of an industry there always needs an able

management and proper departmental structure .A Company can stand only if, the

interdepartmental relationships is good and there is a perfect rhythm in their workability.

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Thermax is not is an exception for this statement its departments work with full potential and

with perfect co-operation of each other.

Following are some of them,

3.1 Production:

This department looks after the manufacturing of different products of the

company. All the production plants come under this department. This department may be

called as heart of the company. Its responsibility includes,

1} Manufacturing and assembly of a boiler unit.

2} Interplant loading and unloading of job accessories and spares.

3} Internal housekeeping in the plant.

4) Day to day planning of shop floor activities.

3.2 Maintenance:

This department looks after the proper working of machine, their

maintenance and their repair. It also looks for the maximum utilization of the currently used

machines.

3.3 Welding Engineering Department:

This department looks after the welding and related activities

1} To look after the Welding Training School (WTS).

2} To train newly recruited/apprentice welders.

3} To train present welders in new welding techniques.

4} To look after welding machine and shop floor welding activities.

5} To assist shop floor in complex welding designs and situations.

6} To introduce advanced welding technology with the help of MED & Maintenance.

3.4 Quality Control/Assurance Department (QC/QA) :

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This department performs the useful process of quality Control and its assurance,

from the customer as well as factory point of view

1} To audit, standardize, frame & implement ISO 9001(1994) quality standards procedures.

2} To inspect and test daily production (NON IBR jobs).

3} Take measure to improve current quality standards.

4} To meet customer’s quality requirements.

5} To train people regarding total quality philosophy.

3.5 Quality Control (IBR CELL):

Since boiler manufacturing is a specialized process, its necessary to follow strictly

IBR procedures for the production processes, designing, quality measures etc. Thermax has

taken care of them all and this cell works for the same purpose. Its duties are as follows,

1} To check and offer boiler quality plates layouts, components and accessories.

2} To check whether IBR procedures are followed or not.

3} To inspect critical welding areas and suggest changes/correction (if any).

4} To inspect whole boiler assembly and offer it to external IBR officers.

5} To get certified boiler design and testing capacities as per IBR acts.

6} To train people about IBR quality philosophy.

3.6 Production Services Group:

This group though not takes part in actual production but works for betterment of

industrial processes and relations. It includes,

a) Manufacturing Engineering Department (MED) :

This one assists manufacturing in their daily work and look after their daily needs for

proper working. Its working areas are

1} Providing shop-floor drawings and designs.

2} Designing fixtures, jigs, special purpose m/c, clamp etc as per requirement.

3} To look after and maintain self produced machines.

4} To check workability of presently used machines.

5} To help production department in their day to day activities.

6} To deal with vendor regarding externally designed and manufactured components.

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b) Industrial Engineering Department :

These concentrates on improving product layout, standardizing norms based on

improvements. The IED engineers are actively involved in Standard man-hour (SMH)

estimation for new jobs, manufacturing budgeting; identification of area for cost reduction,

preparation and conduction of shop and off

3.7 FACTORY MANAGEMENT GROUP (FMG):

Same as above, this group does not play role part in direct production but helps

production people to carry out their work in successful, safe and efficient manner. It includes

a) Civil Maintenance :

This department maintains the civil structures and amenities such as buildings,

Ponds, garden, water supply, electricity supply, waste handling and other factory civil works.

b) Industrial Safety :

This department takes care of safety procedures to be followed in plant, to

enhance accidents free environment, to identify and eliminate unsafe acts and conditions in

factory premises, to nurture total safety policy in each employee.

Waste Management Cell:

This department works for the disposal of non-performing assets and Factory

arising lots. It also works for the waste/scrap reduction and utilization.

c) ISO 14001 :

With a view to enhance perfect environmental conditions in the factory premises

this department was introduced in the company & its job is to frame and implement eco-

friendly atmosphere and to eliminate any kind of wastage and pollution creating elements.

d) Quality Management (Kaizen) :

This department works for the continuous improvement in the factory

related process and other task undertaken by them with the help of a Japanese technique

called ‘KAIZEN’. We’ll study later about this department in detail.

4 PLANT PROFILE:

4.1 Plant 1:

1] Burner and Oil Preheater Assembly Section: -

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This section is used for assembly of burner & OPH with boilers like REVOTHERM,

SHELLMAX, TWIN DRUM as per the engineering division .Since it’s just an assembly

area, there are no special purpose machine in this section.

2] Testing Section:-

In this section boilers like REVOMAX,AQUATHERM, THERMOPAC are tested for

firing with water &steam pressure. The regular firing sequence with control on is followed &

the outcoming temperature & pressure is measured for engineering standardization.

4.2 Plant 2/2A:

1] Plant 2: -

This plant is used for storage and dispatch of all solid fuel boilers.

2] Plant 2a: -

Responding to the oil crisis world wide THERMAX introduced fluidized bed concept to the

boiler business. In this plant fluidized bed combustion system for MULTITHERM boilers is

manufactured. Here the plates are bended in bending machine; the box so formed is used for

welding tube plates. After that, extensive drilling is carried out on these plates for insertion of

tubes and whole IBH & MBH ASSEMBLY is fabricated and thus header section for

fluidized bed is prepared .A high capacity 350 tons press, high efficiency radial drilling

machine and shapers are highlights of this plant.

4.3 Plant 3:

This plant was used for blower fan manufacturing and assembly. But just now is in closed

state.

4.4 Plant 4:

Newer to the academic concern coil type boilers such as RX, TP, AMW, DELTATHERM

are manufactured in this plant. This shop concern with complete production of the boiler

right from tube to tube welding, coiling, coil calibration, coil and shell setup and final

assembly with all accessories. Machine in this shop includes automated TIG & MIG units,

giant horizontal and vertical coiling machine, coil calibration m/c and above all a paint shop

for final dispatch of these boilers.

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4.5 Plant 5:

This shop is well known as drum shop and mainly undertakes project for ESD (Energy

System Division), Here ESD products such as drum, headers etc. for main HRU are

manufactured this plant follows activity of plate rolling, ‘L’ seam & ‘C’ seam setup –weld &

back gauging. Huge radial drilling m/c, header-drilling m/c, Himalaya rolling m/c, back

gauging rail, rotators & SAW units are used in this plant. This plant also has radiographic

enclosures for components produced.

4.6 Plant 6:

Same as like plant 4 here also coil type boiler’s components are manufactured &

assembled. Small capacity boilers up to max. Capacity of 20 T.P.H. is manufactured here.

Special thermic fluid heaters are also produced in this plant. This plant also has a hydro-

testing bay for coil type boilers.

4.7 Plant 7:

This is not in use just now, and is treated as godown for finished products.

4.8 Plant 8:

This plant is also called as S.M shop because here SHELLMAX i.e. shell type, 3

pass, oil or gas fired type boilers is manufactured. In This plant after ‘L’ seam welding, all

the process up to painting & handing over is done. The plant has two tilting fixtures for full

welding of boilers. A stress-reliving furnace to remove all concentrated stress that is

produced during welding is also located in this plant. Machine such as rotators, SAW units

and many other type of welding machines for MMAW, MAG, TIG, FCAW are used in this

shop.

4.9 Plant 9:

This plant is involved in following activities:

1) Shot blasting

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2) Painting of completed assembly with spray gun & anti –rusting coating.

In this plant shot blasting of shell type boilers is done. Due to impact of the shots, the

corroded layer is removed. Separate rail lining are provided for loading & unloading jobs &

process is carried out in enclosed shed with dust collection unit & re- circulation system.

4.10 Plant 10 :

This plant may be called as heart of shell type boiler production, the reason

being manufacturing of shells & tube plate for boilers and cover plates for heat exchanger.

The plant is mainly involved in process of plate cutting (Note – these plates are special BQP

inspected by IBR officials), rolling these plates on rolling m/c then welding these rolled

shells (‘L’ seam & ‘C’ seam welding) and dispatching these shells as req. by other plants for

further processing. This plant owns highly advanced machines, to name a few are Versagraph

& Flo- Tech CNC plate cutting m/c, Himalaya rolling m/c, Pacific high tonnage press and

SAW units.

4.11 Plant 11:

This is an ACD shop and is involved in manufacturing of chillers, heat pumps,

and industrial cooling eqpt. This is the only plant that is own by ACD and works on the

principle of assembly line i.e. the whole chiller assembly is carried out in single production

line .A chiller is an air conditioning device that works on vapour absorption cycle rather than

vapour compression cycle for cooling .A chemical named Li Br is used

for this purpose. The chiller mainly consist of evaporator & absorber, water to be chilled is

passed through no. of tubes placed in vacuum in chiller body, chilled water so formed is

send through tubes to ducts with fans to provide room cooling.

This plant is equipped with modern m/c such as ‘Arboga’ CNC drilling m/c,

which can drill numerous holes with high accuracy &tolerances, also, the plant is having

highly modernize welding eqpt. & highly skilled worker. This plant is also having an

advanced chiller-testing bay, used to test newly made chillers.

Nowadays these chillers are gaining more markets than conventional air

conditioning. They also find their application in western countries as process cooling units.

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4.12 Plant 12:

This shop is mainly dealing with ESD projects and manufactures economizers;

superheaters waste heat boilers and many other kinds of HRU. Highly precise pipe bending

m/c, Projection welding m/c is used for the fabrication of fin tubes used in economizer, super

heaters.

4.13 Plant 13:

The main products of this plant are all solid fuel boilers (CP, CPF, HP, WP, CX,

CM, and MXP & MTFH) .All these boilers are manufactured in this plant. After completing

the fabrication of boiler .the hydro testing of complete boiler for pressure is done in this

plant. This plant has got two tilting fixture, rotators, welding machine, and lathe for flange

machining & hacksaw for pipe cutting.

4.14 Plant 14:

This shop is known as TD (Twin Drum Boilers) shop, named commercially as

COMBIMAX, this boiler is modification of SHELLMAX in the region of capacity &

efficiency. This plant is also involved on manufacturing of high capacity SHELLMAX &

Solid Fuel Boilers. This plant is equipped with biggest overhead crane of THERMAX

(120T(L)TONNAGE).Other thing special about this plant is it’s CORRUGATION

MACHINE, which is used, for corrugation of large furnace shell to provide it strength &

high heat transfer. This plant is also having a stress relieving furnace named ‘Modular

Furnace’ used for relieving stress formed during welding.

ASSIGNMENT NO.1

STUDY OF HANDLING AND STORING OF PLATES IN PLANT NO.10

1. INTRODUCTION:-

Study of material handling process for BQ plates from storage area to plant no 10.

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2. NEED FOR UNDERTAKING THE ASSIGNMENT:-

BQ plates handling always depend on material handling equipments such as forklift & mobile crane etc

BQ plates are not stored as per thickness.

Wooden blocks are not kept properly below each BQ plate while storing.

Plate get bend due to improper storage. Due to this BQ plates on Farley or Koike m/c which are kept on this m/c makes difficult to cut the plates.

Scraps are not removing on a regular basis to the scrap yard location.

3. BQ PLATE HANDLING & STORING PROCESS:-

Thermax makes boiler unit according to customer requirement. A boiler requires raw

material. So buyer is the Thermax person who’s contact to vendor. According to company

requirement buyer order BQ plates from the vendor. Vendor sends the material with test

certificate, all documents (LR) related to BQ plates.

3.1 VENDORS NAME:-

1. STEEL AUTHORITY OF INDIA LTD VEER SAWARKAR UDYOG BHAVAN

CONGRESS HOUSE ROAD, SHIVAJI NAGAR, MAHARASHTRA-INDIA

2. JINDAL STEEL & POWER LIMITED, SHAH BROTHERS ISPAT PVT. LTD.

406, GIRIRAJ SANT TUKARAM ROAD,CARNAC BUNDER,MAHARASHTRA-INDIA

BQ Plates comes on transporting vehicle truck lorry into company. Driver first take a

gate pass from security. Without gate pass driver not allowed into company. Gate pass show

to total logistics store office. After showing gate pass & plates documents (LR) they get the

weight with plates on truck lorry.

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3.2 PLATE SIZES:-

SR NO. PART NO. SIZE WEIGHT

    THK WIDTH LENGTH  1 RL11080003 8 2600 9000 14132 RL1108E001 8 2500 12000 18843 RL1208E001 8 2500 10000 15704 RL1208E002 8 2500 6300 989.15 RL1208H001 8 3000 5800 1092.726 RL1110E002 10 2500 12000 23557 RL1110E001 10 2500 8000 15708 RL11120002 12 2500 12500 2943.759 RL1112E002 12 2500 12500 2943.7510 RL1212E001 12 2500 12000 282611 RL1112E003 12 2500 9500 2237.2512 RL1112E001 12 2500 8000 188413 RL1114E001 14 2500 12500 3434.37514 RL1214E001 14 2500 12000 2901.3615 RL1114E002 14 2500 7000 1923.516 RL1116E002 16 2500 12000 376817 RL1116J001 16 3200 6400 2572.28818 RL1116E001 16 2500 8000 251219 RL1216E001 16 2500 10000 314020 RL1216G001 16 2800 5600 1969.40821 RL1118E001 18 2500 10000 3532.522 RL1118E004 18 2500 9300 3285.22523 RL1120E001 20 2500 12500 4906.25

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VENDOR SEND BQ PLATES ON TRUCK LORRY

24 RL1220E002 20 2500 12000 471025 RL1122E004 22 2500 11500 4965.12526 RL1222E001 22 2500 12000 518127 RL1322E003 22 2500 9300 4015.27528 RL1125E002 25 2500 12000 5887.529 RL1128E003 28 2500 12000 659430 RL1140E001 40 2500 8250 6476.2531 RL1140E002 40 2500 12000 9420

Table 1.3.2

Thermax receipt QC used alpha numerical method. BQ plates come from vendor,

Thermax give specific part no. on every plate thickness so it’s easy to find a plate in a stag.

BQ Plates unload from truck to QC store area. Receipt QC Check thickness, width, &

length of every plate by using Measure tape & digital vernier caliper. QC do not check the

diagonal, straightness & UT of plate. After inspection QC mark silver painted. Thermax

part number on each plate according to thickness. According to thickness, heat no, cast no &

grade registered in booklet. These plates are stored according to thickness.

.

If any defect or bend shown at inspection time, QC rejects BQ plates

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After unloading of plate empty truck weight was noted. Total logistics store office find

out the net weight of the plates. After getting the net weight total logistics store people give

the weight slip carbon copy to truck driver & acknowledgement stamp on it.

4. PLATES MOVE FROM QC STORE TO PLANT NO.10

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QC STORE AREA

5. SCRAP FROM BQ PLATES MOVE TO SCRAP AREA BY EOT CRANE

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PLANT NO:-10 BQ PLATE STORAGE AREA

PLATES MOVE FROM QC STORE TO PLANT NO.10

SCRAPS

By using safe working load (SWL crane 15T) & other material handling equipment

temporary workers unload cut component from m/c to finish component storage area.

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CUT COMPONENT STORAGE AREA

6. CUT PLATES SHIFT FOR ROLLING OPERATION:-

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OFFCUT STORAGE AREA

GUSSETS & TUBE PLATES

After unloading the finish (cut) components punching is done for identification. Model

number, heat number; cast number & dimension details

Is punch on different BQ plates? Punching is done manually as well as automatically by

entering data in the automatic punching machine.

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7. IMPROVEMENT REQUIRED IN PLANT NO 10 BQ PLATE STORAGE AREAS:-

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WOODEN BLOCKS NOT KEPT PROPERLY

SCRAP BOX KEPT ON BQ PLATES

SCRAPS MATERIAL SPREAD IN STORAGE AREA

Truck is been parked on to the plates so it was difficult to move the plates when required

until the truck is not moved. Wooden Blocks were not kept properly and scrap box is used to

be on the plates and it was not arranged properly.

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TRUCK STAND ON BQ PLATES

8. REQUIRE PLANT LAYOUT FOR STORAGE OF BQ PLATES:-

Fig 1.8.1

9. STEPS TO BE TAKEN:-

Scrap required to be removed on a regular basis & move to scrap yard location.

A layout plan for the plant 10 BQ plate storage area needs to be defining as per the

plate requirement schedule of the plant.

Plate requirement schedule is to be given to store one day before, so that material

handling equipments are to be arranged.

Plates are required to place according to thickness so it’s easy to identify & save

searching time. It will improve output from FARLEY & KOIKE CNC CUTTING

MACHINE.

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ASSIGNMENT NO.2

YARD STORAGE SPACE (TKS- C and H)

1. GOAL:

To reduce the storage area in the yard by 50% and arrangement of the components in such a

way so as to reduce inward and outward time and also time for searching the component in

the yard.

2. STORED ITEMS:

1. Pipes or Tubes.

2. Fire Doors.

3. Cable trays.

4. Feed Pipes.

5. Ladders.

6. Steam Header.

7. Ash Roaming.

8. Small Components (required daily).

9. Burner Ducts.

10. Refractory’s.

11. Centrifugal Fans.

12. Coil set.

13. Brackets.

14. Scrap Material.

3. NEED FOR UNDERTAKING THE ASSIGNMENT:

The items mentioned above are stored in the yard haphazardly reducing the usable space

drastically. The storage place on the racks is also not used efficiently. Due to this inefficient

use of space, more space is required for other items to be stored in the yard. This increases

the time required to find a particular component in the yard and also the inward and outward

time of the component. Also, there is no space for the crane to move freely in the yard.

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4. DIMENSIONS OF RACKS:

Rack No. Rack Size (L*B) (m)

1 5.44*2

2 5.44*2

3 3*1.6

4 2*2

5 2*2

6 4.3*1.2

7 5.44*2

8 1.1*1.1

9 3*1.6

Table 2.4.1

5. DIMENSIONS OF CENTRIFUGAL FANS (Diam.*L):

1. 88cm*80cm

2. 80cm*70cm

3. 85cm*60cm

4. 70cm*55cm

6. DIMENSIONS OF REFACTORY’S (Diam.):

1. 75cm

2. 70cm

7. SUGGESTIONS:

For the fans and refractory’s:

1. Fabricate pallets for the fans and refractory’s for specific dimensions so that they can

be accommodated on the forklift.

2. Remove the 2nd shelf from the bottom from racks 1 and 2 so as to make room for

storing the fans and the refractory’s on the bottom shelf. The refractories may be

stored in stacks of 3 to 4 one on top of the other to make optimum use of the available

space.

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3. Using this arrangement can fit up to 12 fans (4 rows 3 columns) and 18 to 24

refractory’s (3 rows and 2 columns) on each shelf.

8. FOR OTHER COMPONENTS:

1. All the components having considerable length (Tubes or pipes) should be placed in

one direction (parallel placement).

2. Fire Doors should be placed in boxes.

3. Presently, feed pipes are placed in the racks, which are taking too much space and are

also heavy. If feed pipes may be placed in open boxes according to their dimensions

or may be hung on a stand made for the same purpose, much space can be freed in

racks, where we can put the smaller components which are frequently required.

4. The cable trays may also be placed in the racks on the free shelves in stacks. The

trays may be packed or kept open.

5. Steam Header and ash roaming should be placed in open boxes.

6. If space permits, the coil sets placed outside in the open may also be placed in the

bottom shelves in stacks of 4 or 5 by removing the shelf above it.

7. For scrap materials, a trolley may be placed, to transport the scrap material directly to

the scrap yard.

8. There must be proper crane road for lifting the heavier components.

9. Proper nameplates or tags with details must be stuck to the particular section of

components.

10. If required, yard area can be divided between movable components and immovable

components.

9. STEPS ALREADY TAKEN:

1. Separate racks fabricated for keeping the ladders, which are not to be discarded, after

approval of the design.

2. Open boxes to be kept one on top of the others have been fabricated for storing after

the approval.

3. Bracket to be made in the yard for hanging the ladders for the boilers like PSPMT

10066, 10065, 10064, etc. designed and given for approval.

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ASSIGNMENT NO.3

STUDY OF MILKRUN DELIVERY

1. GOAL:

To implement the Milk run system in the company to facilitate the JIT (Just In Time)

technique so as to reduce transportation and storage cost by reducing the inventory level by

ordering the materials only when required.

2. NEED FOR UNDERTAKING THE ASSIGNMENT:

The inventory stored in the company is very high and thus, the space availability in the

storage spaces is low. The high level of inventory also increases the costs incurred by the

company. The JIT technique cannot be used effectively due to the inventory level. In the

Milk run system, the truck collects the required materials as per a pre- decided route. The

implementation of the Milk run system can drastically reduce the inventory levels and also

the costs.

3. IMPLEMENTATION OF MILKRUN DELIVERY IN THERMAX

To implement the Milk run Delivery in company so that we can achieve JIT(Just In Time)

technique so as to reduce transportation and storage cost by reducing inventory level by

“First in First Out” process.

Need of Milk run Delivery arises when it seems that high inventory stored in company

increasing its handling cost. Need arises when company requires one component from vendor

its product manufacturing but vendor is sending more components than required by

company. To reduce vendor transportation cost, as a result company has to pay more for the

components and which are not required instantly and parallel the inventory handling cost is

increased. So JIT technique is essentially required for the company so that they can reduce

inventory as well as cost, and which can be only achieved by the Milkrun Delivery.

4. STEPS TO BE TAKEN FOR IMPLEMENTATION:

1. Mapping of various vendors who supply materials to the company.

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2. Finding the distances of those vendors from the company.

3. Calculate the longest possible route that may be traversed by the transportation

vehicle.

4. Offer a transportation contract to a reliable transporter.

5. Calculate the necessary frequency of the transportation vehicle.

6. Involve Quality Control.

7. Hold a supplier and transporter meeting.

8. Amend the PO (Purchase Order).

9. Scheduling the run.

10. Fixing the open truck size or weight capacity.

5. ISSUES:

1. Information about the required order before 4pm the previous day.

2. Readiness of the PO.

3. TDC mismatch.

4. Rate contract.

5. MO (Move Order) delay.

6. Alignment with the vendor

7. No unscheduled items to be made inward by the vendor

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CONCLUSION

This training gave me the opportunity to get first hand experience in the industry.

Whatever little I have learnt through the syllabus until now. I was able to actually see it and

have an interface with. Apart from theoretical Knowledge I got the golden opportunity to

understand the technique of communicating new ideas, improvements solving problems.

Developing relations with other departments and workers. Was also able to learn different

problems that the company faces and their solution.

THERMAX, being a heavy engineering company. Welding is a key process in

fabrication of boilers and chillers. I learnt that the application of welding is so varied and

extensive that each branch of engineering makes use of welding in one form or the other.

Thermax has separate welding cell to train the workers in proving the Quality of welding in

Thermax.

The assignment helped me to apply my technical fundamentals & gave me a practical insight

into the factory activities. They developed my ability to think innovative which brought variety

and depth in my knowledge. They put forward the truth that every manufacturing activity needs a

through blend of right inputs and capabilities.

All in all it was a wonderful experience top is a part of the industry and I whole

heartedly thankfully and obliged to my college and professors & also the company who

provided this golden opportunity.

I believed I have gained practical aspects of being an engineer and I looked forward

for my next phase opportunities in Thermax.

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REFERENCES

Reference to web sites:

[1] http://www.thermaxindia.com/ (as on 26-06-10)

[2] http://www.businessdictionary.com/definition/milk-run.html (as on 26-06-10)

Reference from Company:

[3] Plant Layout from MED (Manufacturing Engineering Dept.)

[4] Dimensions for rack and components from SCM (Supply Chain Department)

[5] Plant NO. 10 construction layout, Thermax.

.

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