SIX WEEKS SUMMER TRAINING REPORT

On

(Industrial training)

Submitted by

VIVEK KUMAR SRIVASTAVA

Registration No-11304418

Section - M1313

Programme- B.tech Mechanical Engineering

Under the guidance of

Er. Manoj yadav

School of Mechanical Engineering

Lovely Professional University, Phagwara

(June-july, 2016)

DECLARATION

I hereby declare that I have completed my six weeks summer training at 55, 56- industrial area, Phagwara, OPAL ENGINEERING CORPORATION from 15/06/2015(start date) to

15/07/2015(end date) under the guidance of manoj kumar. I declare that I have worked with full dedication during these six weeks of training and my learning outcomes fulfill the requirements

of training for the award of training for the award of B.tech (ME) Lovely Professional University, phagwara.

(Signature of student)

Name of Student:Vivek kumar srivastava

Registration n0:11304418 Date: 05/08/2016

ACKNOWLEDGEMENT

It is a great pleasure for me to acknowledge the assistance and contributions of all the people who helped me to make my industrial training a success.

I would also like to thank and all officials for the assistance and guidelines they have given towards this program.

Finally I would like to thank every individual who gave me even the slightest support to make my Industrial training a success.

Thank you every one!

INDEX

1) company profile

2) Services provided by opex

3) Technology learnt (engine)

4) Trouble locating chart

5) conclusion

Company profile

The Opal group established in the year 1989 is technically guided and managed by Mr. O. P. Uppal, an engineering graduate and his dynamic son Mr. Prashant Uppal an engineer with MBA degree, specialization in marketing from U.K. The group is a perfect combination of youth and experience. This group with its emphasis on the quality has developed customers in different

countries all over the world.

OPAL ENGINEERING CORPORATION a 100% export unit(RECOGNIZED EXPORT HOUSE BY GOVERNMENT OF INDIA) is in the process of getting accreditation of ISO

9002.In a short span it acquired recognition in the world market as a Diesel Engine , Pumping Set and Exporter of light engineering goods.

The people at OPAL GROUP are committed to their work with innovation and growth being the guiding force.

ACHIEVEMENTS:-

The group has received the following prestigious awards:

National award for Outstanding Entrepreneurship from the president of India for the year 1993.

All India engineering Export Promotion Council Award on Regional and All India Basis from 1993 onwards.

State Export Excellence Award from 1993 onwards

Services provided

Diesel Engines Generators Pumps

Hand tools Pumping sets Spare parts

Pumping Sets

OPEX high speed vertical compression ignition, four cycle cold starting, water Cooled Diesel Engines are manufacturing within strict tolerance limits, which help us to providing quality product to our farmers. Water cooled Diesel Engine range from 4.5 H.P. to 24 H.P. in twin

cylinder category.

COMBUTION: For low fuel consumption and easy starting of the engine, there is an open type combustion chamber in an aluminum alloy piston in combination with long steam nozzle.

Hand tools

carpentry tools

Garage tools

Industrial tool

Measuring tools

pliers

pincers

spanners

wrenches

Technology Learnt

Measurement.It is an important part for an engineer to survive in industries, life is highly impossible

without having the knowledge of measuring instrument and various types of measurement. We can say in simple terms that growth is measured with measuring

instruments and if we do not have the knowledge then we can not decide how much we have grown in our life.

Threading is an important concept.We got the information about measuring type i.e Suth(hindi), an important measurement

on which threading of nut and bolts are measured.

1 suth =0.125 (1/8)

2 suth =0.250 (1/4)

3 suth =0.375 (3/8)

4 suth =0.500 (1/2) (all measurement in inches)

Engine assembly

(DIESEL ENGINE ASSEMBLY PROCEDURE)

DIESEL ENGINE ASSEMBLY BEING DONE IN TWO PARTS:-

1. SUB. ASSEMBLY

2. FINAL ASSEMBLY

SUB ASSEMBLY:-S.NO

DESCRIPTION COMPONENTS

1 CRANK SHAFT CRANK SHAFT, LUBRICATIN OIL PUMP, TAPPER ROLLER BEARING ARE HEATED TO FIT ON

CRANK SHAFT, BOLT 5/16” BSF X ½”2 CYLINDER HEAD

ASSEMBLYCYLINDER HEAD, INLET & EXHAUST VALVE

LAPPING IS DONE ON DRILL MACHINE, VALVE SPRING SET, VALVE CUP SET, 5/16” BSF STUD,

7/16” BSF STD3 ROCKER BOX

ASSEMBLYROCKER BOX, ROCKER SHAFT, ROCKER LINER

SET, DECOMPRESSURE SHAFT, DECOMPRESSURE SHAFT SPRING, ROCKER

SCREW, GRUB SCREW4 FUEL PUMP BRACKET

ASSEMBLYFUEL PUMP BRACKET, FUEL PUMP LINER, FUEL

PUMP LINER SPINDLE, 5/16” BSF STUD5 CAM GEAR ASSEMBLY CAM GEAR, CAM SHAFT ARE FITTED WITH

HYDRAULIC PRESSURE, CAM BUSH 2 PC, GOVERNER WEIGHT C.I, GOVERNER SPRING,

GOVERNER WEIGHT PIN, GOVERNER PUSH ROD WITH PLATE, GOVERNER PUSH ROD PLAIN,

STEEL BALLS6 MAIN BEARING

HOUSING ASSEMBLYMAIN BEARING HOUSING, TAPER ROLLER

BEARING 32211

FINAL ASSEMBLY:-

1. FIT ALL STUDS 5/16” BSF ON CRANK CASE AND TIGHT IT ON ENGINE BED WITH THE HELP OF IMPACT WRENCH.

2. PUNCH THE ENGINE NO. AND H.P ON TOP FACE.

3. FIT THE GEAR COVER PLATE, GOVERNER ASSEMBLY PLATE AND BODY PLUG.

4. FIT THE MAIN BEARING HOUSING ON ONE SIDE, FIT THE TAPPER RILLER BEARING 32211 ON OTHER SIDE ON CRANK CASE, FIT THE CRANK SHAFT AND TIGHT THIS WITH BEARING PLATE & BEARING SHIM, ADJUST THE

CRANK END PLAY WITH BEARING SHIM THEN TIGHT THE BALANCE WEIGHT WITH REQUIRED TORQUE.

5. TIGHT THE FULCRUM PIN BOLT/ FULCRUM PIN, FIT THE MOBILE OIL FILTER ON LUBRICATING OIL PUMP STRAP.

6. FIT THE VALVE TAPPET, CAM GEAR COMPLETE. LOCK THE CAM BUSH WITH CAM LOCK BOLT.

7. FIT THE CRANK GEAR, RETAINING CAP FIT WITH BOLT.

8. MATCH THE CAM GEAR TOOTH WITH THE CRANK GEAR TOOTH ON THE VALVE TIMING MARK.

9. FIT THE C.R BEARING IN BOTH CONNECTING ROD END & TIGHT THIS, TIGHT THE PISTON, PIN AND LOCK.

10. FIT THE CYLINDER LINER, LINER RUBBER RING, CYLINDER BLOCK, CHECK THE BUMPING CLEARENCE WITH THE LEAD, ADJUST THE CLEARENCE AS

PER STANDARD WITH BLOCK SHIM.

11. FIT THE PISTON RING..

12. ASSEMBLED THE CYLINDER HEAD COMPLETE THEN FIT THE ROCKER BOX, TIGHT CYLINDER HEAD WITH REQUIRED TORQUE.

13. FIT THE SIX HOLE PLATE, FUEL PUMP BRACKET AND GEAR COVER.

14. FIT THE FLY WHEEL KEY WHILE CHECKING THE RUNOUT OF THE WHEEL.

15. MARK THE TDC POINT ON FLY WHEEL, FUEL TIMING MARK ON FLY WHEEL.

16. FIT THE FUEL PIPES

Various steps in the assembly with their terminology.

Images of Assembly of diesel engines

DIESEL ENGINE SENT TO TESTING UNIT FOR FINAL TESTING.

Testing

(DIESEL ENGINE TESTING PROCEDURE AND MAINTANING OF ENGINE TESTING RECORD)

ENGINE TESTING PROCEDURE BEING DONE IN 3 PARTS:-

1. PREPARATION OF ENGINE FOR TESTING2. ENGINE TESTING

3. MAINTANING OF TESTING RECORD

1. PREPARATION OF ENGINE FOR TESTING:-

(I) FILL THE MOBILE OIL SAE 30/40, 3.5 LTR IN DIESEL ENGINE AND CHECK THE MOBILE OIL WITH OIL GAUGE

(II) FIT THE FUEL PUMP BODY ON FUEL PUMP PLATE ON 90 – 95MM BEFORE TDC.(III) TIGHT THE NOZZLE HOLDER ON CYLINDER HEAD, TIGHT THE HIGH PRESSURE PIPE

ON NOZZLE HOLDER.(IV) PUT THE DIESEL ENGINE ON TESTING BED, FIT THE FUEL PIPE ON FUEL PUMP BODY.

OPEN THE FUEL AND CHECK THE FUEL TIMING BY THE METHOD OF SPILL, IF THERE IS DIFFERENCE THEN ADJUSTTHE SHIMS TO CORRECT THIS. TIGHT THE HIGH PRESSURE

PIPE ON PUMP BODY.(V) FIT THE WATER INLET PIPE, WATER OUT LET PIPE, EXHAUST SILENCRE, AIR CLEANER.(VI) THEN START THE WATER SUPPLY, THEN CHECK THE WATER SUPPLY MUST BE OK TO

DIESEL ENGINE, START THE ENGINE.

2. TESTING OF ENGINE:- TESTING ALL ENGINES BEING DONE IN 2 PARTS

1. ROUTINE TEST ALL ENGINES2. PERFORMANCE TEST: - ONE ENGINE OUT OF 20 ENGINES

1. CHECK THE BHP MARKED ON ENGINE2. CHECK THE LOAD, SFC CHART BEFORE TESTING THE ENGINE.

LOAD APPLIED ON ENGINE: - 2.5 Kg X BHPSFC STANDARD: - 252 gm/kw/hr

3. ROUTINE TESTING OF DIESEL ENGINE BEING DONE OF ALL ENGINES.

S.NO LOAD RPM RUNING TIME SFC1. 0 % 1500 15 MIN SFC CHECKED OF ALL

2. 50 % 1500 15 MIN ENGINES AS PER3. 100 % 1500 15 MIN IS : 11170 - 19854. 110 % 1500 15 MIN 252 GM/KW/HR

4. AFTER THE RUNING OF ENGINE, ENGINE MUST BE CLOSED, DRAIN OUT THE MOBILE OIL FROM ENGINE, OPEN THE FUEL PIPE THEN ENGINE SENT BACK TO PAINT SECTION.

PERFORMANCE TEST:- AFTER 20 ENGINES OF ROUTINE TEST ONE ENGINE MUST BE CHECKED ON DYNAMOMETER TO CHECK PERFORMANCE TEST, GOVERNING TEST, FUEL CONSUMPTION

TEST.

TYPE OF TESTS:-

1. PERFORMANCE TEST 8 HRS2. FUEL CONSUMPTION TEST 4 HRS

PERFORMANCE TEST :- AS PER IS : 10000 PART VIIIS.NO LOAD RPM TIME OF RUN SFC

1. 0 % 1500 30 MIN AS PER IS: 11170 – 1985,2. 50 % 1500 30 MIN 252 GM/Kwh

3. 100 % 1500 7 HRS4. 110 % 1500 1 HRS

FUEL CONSUMPTION TEST:- FUEL CONSUMPTION TEST IS BEING DONE ON DYNAMOMETER AS PER GIVEN FOLLOWING AS PER IS : 10000 PART IV

S.NO LOAD RPM TIME OF RUN1. 0 % 1500 30 MIN2. 20% 1500 30 MIN3. 40 % 1500 30 MIN4. 60 % 1500 30 MIN5. 80 % 1500 30 MIN6. 100 % 1500 30 MIN7. 110 % 1500 30 MIN

GOVERNING TEST: - ALSO CHECKED ON DYNAMOMETER ON THE BASE OF NO LOAD, FULL LOAD PARAMETER AS PER IS: 1000 PART VII 1980

IF THERE IS ANY FAULT FOUND IN DIESEL ENGINE, ENGINE SENT BACK TO ENGINE SECTION TO CORRECT THE FAULT AND OK ENGINE SENT TO PAINT SECTION.

TESTING RECORD: - ALL THE TESTING RECORD MUST BE MAINTAINED ON SAME Day.

Operating Procedure Of Dynamometer

1. DIESEL ENGINE SET ON THE BASE.2. DYNAMOMETER ARM SET WITH THE ENGINE FLY WHEEL & TIGHT THE

ENGINE ON BASE.3. START THE ELECTRIC MOTOR.

4. START THE DIESEL ENGINE.5. THEN TEST THE DIESEL ENGINE AS PER FOLLOWING PARAMETER.

%AGE OF LOAD TIME ( IN MINUTE) LOAD AS PER CONSTANT

25 % 30 BHP = WN/100

50 % 30

100 % 60

110 % 30

6. AFTER TESTING STOP THE DIESEL ENGINE.7. OFF THE ELECTRIC MOTOR.

8. CLEAN THE DYNAMOMETER.

PRECAUTION:-

1. STOP THE ENGINE IF KNOCKING SOUND PRODUCE.2. STOP THE ENGINE IF TOO MUCH SMOKE PRODUCE.

3. ALWAYS WEAR A HELMET & SHOES DURING TESTING THE DIESEL ENGINE.

(DIESEL ENGINE TESTING PROCEDURE AND MAINTANING OF ENGINE TESTING RECORD)

ENGINE TESTING PROCEDURE BEING DONE IN 3 PARTS:-

4. PREPARATION OF ENGINE FOR TESTING5. ENGINE TESTING

6. MAINTANING OF TESTING RECORD

1. PREPARATION OF ENGINE FOR TESTING:-

(VII) FILL THE MOBILE OIL SAE 30/40, 3.5 LTR IN DIESEL ENGINE AND CHECK THE MOBILE OIL WITH OIL GAUGE

(VIII) FIT THE FUEL PUMP BODY ON FUEL PUMP PLATE ON 90 – 95MM BEFORE TDC.

(IX) TIGHT THE NOZZLE HOLDER ON CYLINDER HEAD, TIGHT THE HIGH PRESSURE PIPE ON NOZZLE HOLDER.

(X) PUT THE DIESEL ENGINE ON TESTING BED, FIT THE FUEL PIPE ON FUEL PUMP BODY. OPEN THE FUEL AND CHECK THE FUEL TIMING BY THE

METHOD OF SPILL, IF THERE IS DIFFERENCE THEN ADJUSTTHE SHIMS TO CORRECT THIS. TIGHT THE HIGH PRESSURE PIPE ON PUMP BODY.

(XI) FIT THE WATER INLET PIPE, WATER OUT LET PIPE, EXHAUST SILENCRE, AIR CLEANER.

(XII) THEN START THE WATER SUPPLY, THEN CHECK THE WATER SUPPLY MUST BE OK TO DIESEL ENGINE, START THE ENGINE.

2. TESTING OF ENGINE:- TESTING ALL ENGINES BEING DONE IN 2 PARTS

1. ROUTINE TEST ALL ENGINES2. PERFORMANCE TEST: - ONE ENGINE OUT OF 20 ENGINES

5. CHECK THE BHP MARKED ON ENGINE6. CHECK THE LOAD, SFC CHART BEFORE TESTING THE ENGINE.

LOAD APPLIED ON ENGINE: - 2.5 Kg X BHPSFC STANDARD: - 252 gm/kw/hr

7. ROUTINE TESTING OF DIESEL ENGINE BEING DONE OF ALL ENGINES.

S.NO LOAD RPM RUNING TIME SFC

1. 0 % 1500 15 MIN SFC CHECKED OF ALL

2. 50 % 1500 15 MIN ENGINES AS PER3. 100 % 1500 15 MIN IS : 11170 - 19854. 110 % 1500 15 MIN 252 GM/KW/HR

8. AFTER THE RUNING OF ENGINE, ENGINE MUST BE CLOSED, DRAIN OUT THE MOBILE OIL FROM ENGINE, OPEN THE FUEL PIPE THEN ENGINE SENT

BACK TO PAINT SECTION.

PERFORMANCE TEST:- AFTER 20 ENGINES OF ROUTINE TEST ONE ENGINE MUST BE CHECKED ON DYNAMOMETER TO CHECK PERFORMANCE TEST, GOVERNING

TEST, FUEL CONSUMPTION TEST.

TYPE OF TESTS:-

3. PERFORMANCE TEST 8 HRS4. FUEL CONSUMPTION TEST 4 HRS

PERFORMANCE TEST :- AS PER IS : 10000 PART VIIIS.NO LOAD RPM TIME OF RUN SFC

1. 0 % 1500 30 MIN AS PER IS: 11170 – 1985,2. 50 % 1500 30 MIN 252 GM/Kwh

3. 100 % 1500 7 HRS4. 110 % 1500 1 HRS

FUEL CONSUMPTION TEST:- FUEL CONSUMPTION TEST IS BEING DONE ON DYNAMOMETER AS PER GIVEN FOLLOWING AS PER IS : 10000 PART IV

S.NO LOAD RPM TIME OF RUN1. 0 % 1500 30 MIN2. 20% 1500 30 MIN3. 40 % 1500 30 MIN4. 60 % 1500 30 MIN5. 80 % 1500 30 MIN6. 100 % 1500 30 MIN7. 110 % 1500 30 MIN

GOVERNING TEST: - ALSO CHECKED ON DYNAMOMETER ON THE BASE OF NO LOAD, FULL LOAD PARAMETER AS PER IS: 1000 PART VII 1980

IF THERE IS ANY FAULT FOUND IN DIESEL ENGINE, ENGINE SENT BACK TO ENGINE SECTION TO CORRECT THE FAULT AND OK ENGINE SENT TO PAINT

SECTION.

TESTING RECORD: - ALL THE TESTING RECORD MUST BE MAINTAINED ON SAME DAY

Routine testing image

Performance testing image.

Trouble locating chart

Export

Machine is ready for export

Packaging material for the engine

During loadig and unloading of goods

conclusion

It was an wonderful experience. We learnt various things by having exposed ourselves to industries and visualizing the things practically.