A REPORT ON

INDUSTRIAL TRAINING
AT

THERMAX LIMITED
CHINCHWAD, PUNE-411 019

BY
1. SADAKATALI M. MULLA
2. ABHISHEK M. MORADE
3. PRAFULL G. JOGDAND
4. RAJVARDHAN D. MANE
5. MUKUND S. RAUT
6. ASHWINI S. PATIL
7. DEEPALI A. KAMBLE
8. UJAWALA N. PATIL

BE-MECHANICAL ENGINEERING

UNDER THE GUIDANCE OF

F. N MUJAWAR
DEPARTMENT OF HEATING PRODUCT ENGINEERING

SIGNATURE OF GUIDE

1
 ACKNOWLEGEMENT
We hereby take the opportunity to express our gratitude towards all those who
were instrumental in the successful completion of our training in Thermax
Ltd., Chinchwad, Pune.

We would like to thank whole-heartedly to Mr. F N MUJAWAR for his

constant guidance and co-operation.

We are also thankful to Mr. Ramchandra Tokekar, Mr. Sanjay Patil for
their co-operation during the training.

BE Mechanical

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CONTENT:
Table of figures…………………………………………………….4
Training summery…………………………………………………5
Chapter 1: Company profile………………………………………6
1.1 Thermax
Chapter 2: Practical Training…………………………………….10
2.1 Introduction of REOMAX
2.2 Shop floor
2.3 Welding process
2.4 Vendor visit
2.5 Project work

Chapter 3: Impact of Engineering and Learned skills in

training……………………………………………………………...16
Chapter 4: Conclusion…………………………………………….17

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Table of figures:
Process layout of Thermax……………………………………………………..9

REOMAX Boiler………………………………………………………………10

Specification of REOMAX…………………………………………………….11

Visit to COMBLOC……………………………………………………………12

Manufacturing process of Boiler………………………………………………13

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 TRAINING SUMMERY

 We have completed 15 days period of training at Thermax Ltd.

 Thermax Ltd is independent private entity which designs and
manufactures the various Boilers, Heaters and Chillers .
 The work data of this company is so sensitive that it must have strict
security procedures to protect its products from theft especially by
enemies i.e. competitors’. This strict procedure have large effect in
limiting available information to include in this report. Only available
information is included.
 Academic knowledge is also essential in training which is studied at
university.
 In electrical maintenance department, we captured the information about
various components of control panel.
 During training period we completed project related to changes in
electrical control panel and components.
 The purpose is to identify the changes in electrical component in control
panel of boiler when moving from one fuel to another fuel.
 The most important outcome from training in Thermax Ltd is acquiring
many useful skills of various types and developing some existing skills.
This skills are very valuable for futures.

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Chapter 1: COMPANY PROFILE

INTRODUCTION TO THERMAX:

 Thermax is a leading, global company specializing in the areas of

generation and conservation of energy and preservation of the
environment.
 The company provides integrated services and equipment in Boilers and
Heaters, Captive Power, Cooling, Water and Waste Solutions, Enviro and
Chemicals.
 It has joint ventures with Babcock & Wilcox and Energy Performance
Services.
 The company has a global reach, with 11 overseas offices and a domestic
network of 12 sales & service offices
 Thermax is an ISO9001: 2000 and ISO14001 certified company and its
energy efficient and eco-friendly solutions helps industry to achieve
better resource productivity with the twin benefit of improved bottom
lines and a clearer environment.
 Thermax also integrates its expertise to offer Combined Heating, Power
and Cooling (CHPC) solutions. Thermax supports its operations by
advanced facilities, which leads with effective R&D and manufactures to
international codes.

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BIRTH OF THERMAX:
 Years ago there was a small company in Bombay (now Mumbai) called
National Steel Equipment Company (Nat steel) which made hospital
sterilization equipment’s.
 Its founder A.S.Bathena (1908-1910) & his son Jamshed decided to go in
collaboration with Brussels based company Wanson 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
500 Sq. Ft. asbestos goes down in corner of Mumbai.
 Mr. Rohiton soon joined Bathena D. Aga (1935-1996), a Cambridge
educated economist by training & manager by profession. A visionary,
educated Aga laid down many fundamental principles and value systems
that have guided Thermax (as Wanson renamed in 1980).

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HISTORY OF THERMAX:

 The Wanson collaboration came to an end in 1978, & the new name
THERMAX PVT. LTD came into existence in JUNE 1980.
 Now Thermax not only manufactures boilers but is also on its path to
became diversified growing business corporation. Some highlighted
features of thermax’s history are as follows,
 In 1973, first water tube boiler called ‘Multitherm’ was manufactured.
 In 1975, water treatment plant was started.
 In 1976, Chemical division came to existence.
 In 1977, Energy system division came to existence.
 In 1980, Surface coating was started’
 In 1980, formation of Process Heat Division (PHD).
 In 1981, introduction of Heat Recovery Division.
 In 1983, system & software division got started.
 In 1985, chemical & process division formed.
 In 1985-86, fluidized bed technology developed.
 In 1987, Liquid & vapor phase boilers manufactured.
 In 1987, introduction to steam fired vapour absorption chillers.
 In 1988, set up of all India service franchisee network
 In 1989 , merger of energy division in a joint venture with ‘Babcock &
Wilcox’.
 In 1996, Acquired ISO 98002 (1994) membership.
 In 2000, became ISO 14000 member.
 In 2001, formation of Boiler & heater division (B&H).
 In 2002, got ISO 9002 (2000) certification.
 Thermax’s manufacturing facilities are spread in 15 plants measuring
66,000 Sq. meters at four locations.

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 PROCESS LAYOUT OF THERMAX

MARKETING
DEPATMENT

ORDER
FEEDBACK EXICUTIVE
DEPARTMENT

PLANNING
TECHNICAL
DEPARTMENT
SERVICES

DISPATCHING DESIGN
UNIT DEPARTMENT

PACKING
SHOP FLOOR
DEPARTMENT

QUALITY
DEPARTMENT

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Chapter 2: PRACTICAL TRAINING

INTRODUCTION ABOUT REVOMAX:

The REVOMAX is the latest oil and gas fired, coil type steam generator it is
non IBR type boiler. It is fully automatic packaged boiler with necessary
accessories mounted on common chassis .The three pass, reverse flue
membrane coil design is blend of proven techniques in combustion and Heat
Transfer technology.

REVOMAX BOILER

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 Specifications of REVOMAX:
RXA TYPE BOILER

RXA 02 – 200kg/hr, 10.54kg/cm2 (Fuel HSD, GAS, HSD-GAS)

RXA 03 – 300kg/hr, 10.54kg/cm2 (Fuel HSD, GAS, HSD-GAS)

RXA 04 – 400kg/hr, 10.54kg/cm2 (Fuel HSD, GAS, HSD-GAS)

RXA 05 – 500kg/hr, 10.54kg/cm2 (Fuel HSD, GAS, HSD-GAS)

RXA 06 – 600kg/hr, 10.54kg/cm2 (Fuel HSD, GAS, HSD-GAS)

RXD TYPE BOILER

RXD 04 – 400kg/hr, 10.54kg/cm2 (Fuel FO,HSD, GAS, HSD-GAS,FO-GAS)

RXD 06 – 600kg/hr, 10.54kg/cm2 (Fuel FO,HSD, GAS, HSD-GAS,FO-GAS)

RXD 850 – 850kg/hr, 10.54kg/cm2 (Fuel FO,HSD, GAS, HSD-GAS,FO-GAS)

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SHOP FLOOR:

The first we learned the detailed information about the different types of
boilers then we visited to shop floor for watching the actual working of boilers
and manufacturing of the boilers. In actual working of the boiler , we saw the
working of the Revomax , Combloc ,then in the manufacturing
process .Bending of the sheet ,rolling, welding of the sheet to make a boiler.

Visit to Combloc Boiler

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 MANUFACTURING PROCESS OF BOILER

Raw Raw material

material for tubes

Cutting of
raw material Welding and
bending of
tubes

Rolling of
metal sheet
Hydraulic
cutting
Bending of
metal sheet

Welding

NDT test for Assembly of

welding Boiler

Sand
Blasting

Painting

Hydraulic
Testing

Dispatch

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WELDING PROCESS:

1) Arc Welding-
2) Resistance welding-
3) Brazing-
4) Soldering-
5) Solid state welding-
6) Oxyfuel gas welding-

Other welding process

VENDOR VISIT:

We visited at SCREW TECH & EFFICIENT which are suppliers of

Thermax .submerged ash conveyors , screw feeder ,rotary drum are provided
by SCREW TECH to Thermax. This type of ash conveyor used in COMBLOC
type of boiler in Thermax. Screw feeder is used for transferring the solid fuels.

After that ,we visited to EFFICIENT supplier .At the, we saw the pollution
control devices .apart from this we saw OPH & damper regulating
assemblies .The OPH is used to preheat the Fo oil &damper is used for
controlling the flow of fuel and air to the oil/gas fired burners.

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 PROJECT WORK
We learned different types of boiler according to their capacity,
shape ,size ,fuel used .Generally Coil type and Shell type boilers are made in
this plant. Different types of boilers used for different purposes:

 Revomax is used in process industry .

 Aquaerotherm boiler used in Tea industry for drying of leafs.
 Thermopac used for heating of plywood & textile industries.

Various types of boiler like HSD, GAS, HSD-GAS, FO, FO-GAS compared
with each other and differentiate their component with proper way in Excel
Sheet.

The main Aim of this Project is,

To reduce the time required for selection of change in component of electrical

control panel as per the fuel requirement. Guidelines to various sites / internal
conversions of control panels.

STEPS FOR PROJECT:

1) Collect the data:

Guider gives us various documents, manuals,
pdf ,electrical circuit related control panel.
2) Analyzing the data:
Study on the given data.
3) Simplify the data:
After analyzing simplify it proper way.
4) Comparing the data And Tabulated in Excel sheet:

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 Chapter: 3 IMPACT OF ENGINEERING AND
LEARNED SKILLS IN TRAINING
The training in Thermax Ltd. was very usful to us to acquiring new
Engineering skills that we had not learned before. This learned skills prove very
valuable by signifinig an impact in solving problems.It is very well known that
Engineering skills have vital importance in design problems specifically. Some
of the areas, problems and difficulties in which the Engineering skills that we
learned signified an impact in solving problems are the following:

 The work of technicians in Engineering in Thermax Ltd. Is not limited to

designing industrial application. The also provides chillers for the home
appliances as well as industrial application.
 Skills of teamwork and planning are universally desired since they
increase the efficiency of any project in terms of time and money.
 Getting about the detailed information about the control panel box and
different boiler that helps to add the more information of our knowledge
about the boilers and electrical (control panel box).
 Increasing our ability to work as a member in a team .Actually this had
been a problem of ours; we did not believe much in teamwork .now after
the training .We can say that our belief in the benefits of teamwork ,
when the team is concerned ,has increased a lot.

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 Chapter 4: CONCLUSION
In conclusion ,We are well satisfied with our training .We have learned
many new technical concepts ,acquired a number of new technical skill and
improved another group of existing skills, other than those gained at university
laboratories. However, this does not mean that we have learned little new things
in our training. We may count the technical skill that we learned or improved at
the training site, other than gained at university laboratories, in the following
point:
 Recognizing new types of Boilers and learning about them.
 Improvement in our knowledge about Boiler ant their component
 Learning about the procedure of manufacturing of Boiler.
 Recognizing the changes in control panel and their component.
 Learning about testing of welding.
 Training about safety majors.
 Learned about How to read P and I diagram.
 Improving our skill in Excel.
It is very good to acquire such large number skills few days of
training period. So, training at Thermax Limited can be said to be very valuable.

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