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
“THERMAX 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

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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:

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

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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
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

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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.

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

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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:

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

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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
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.

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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.
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.

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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.
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

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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:

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.

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  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)

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

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  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.
 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

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  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.
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

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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) :

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:

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 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.

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.

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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: -
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.

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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.

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:

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 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
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

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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.

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 &

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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.

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:-

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 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.

VENDOR SEND BQ PLATES

ON TRUCK LORRY

3.2 PLATE SIZES:-

SR
NO. PART NO. SIZE WEIGHT
THK WIDTH LENGTH
1 RL11080003 8 2600 9000 1413
2 RL1108E001 8 2500 12000 1884
3 RL1208E001 8 2500 10000 1570
4 RL1208E002 8 2500 6300 989.1

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 5 RL1208H001 8 3000 5800 1092.72
6 RL1110E002 10 2500 12000 2355
7 RL1110E001 10 2500 8000 1570
8 RL11120002 12 2500 12500 2943.75
9 RL1112E002 12 2500 12500 2943.75
10 RL1212E001 12 2500 12000 2826
11 RL1112E003 12 2500 9500 2237.25
12 RL1112E001 12 2500 8000 1884
13 RL1114E001 14 2500 12500 3434.375
14 RL1214E001 14 2500 12000 2901.36
15 RL1114E002 14 2500 7000 1923.5
16 RL1116E002 16 2500 12000 3768
17 RL1116J001 16 3200 6400 2572.288
18 RL1116E001 16 2500 8000 2512
19 RL1216E001 16 2500 10000 3140
20 RL1216G001 16 2800 5600 1969.408
21 RL1118E001 18 2500 10000 3532.5
22 RL1118E004 18 2500 9300 3285.225
23 RL1120E001 20 2500 12500 4906.25
24 RL1220E002 20 2500 12000 4710
25 RL1122E004 22 2500 11500 4965.125
26 RL1222E001 22 2500 12000 5181
27 RL1322E003 22 2500 9300 4015.275
28 RL1125E002 25 2500 12000 5887.5
29 RL1128E003 28 2500 12000 6594
30 RL1140E001 40 2500 8250 6476.25
31 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.

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

QC STORE AREA

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.

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

PLATES MOVE FROM QC

STORE TO PLANT NO.10

BQ PLATE STORAGE AREA

PLANT NO:-10

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

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

GUSSETS & TUBE PLATES

OFFCUT STORAGE AREA

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6. CUT PLATES SHIFT FOR ROLLING OPERATION:-

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:-

BQ PLATES
NOT KEPT PROPERLY SCRAP BOX KEPT ON
WOODEN BLOCKS

SCRAPS MATERIAL SPREAD IN STORAGE

AREA

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 TRUCK STAND ON BQ PLATES

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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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.
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.

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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.
ASSIGNMENT NO.3
STUDY OF MILKRUN DELIVERY

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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.
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.

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 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

CONCLUSION

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 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.

REFERENCES

Reference to web sites:

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[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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