A

SUMMER PROJECT REPORT

OF

“DUKE PLASTO TECHNIQUE PVT LTD.”

PREFACE As per the syllabus of B.TECH ELECTRICALENGINEERING in JODHAPUR NATIONAL UNIVERSITY& MECRC,every student is required to undergo industrial training for 30 days.The objective of the practical training is to develop amongthe student feeling industrial environment and business practicebase in them as a supplement to the theoretical study of themanagement.

Training and knowledge is very much important for engineering student. Especially training is important to see the position of the company.I have taken industrial training in “DUKE PLASTO TECHNIQUE PVT LTD.” Which is situated at PALANPUR in Gujarat.I got good information and knowledge about variousdepartment of this company. I have prepared this report onTECHNICAL ANALYSIS of this company.

SUTHAR VISHNU.H

Logo of Duke Plasto Technique Pvt Ltd:-

ACKNOWLEDGEMENTI am student of Centre for ,engineering student of JNU,JODHPUR. I has take Industrial Training in Duke Plato Technique Pvt. Ltd. at Badarpura nearbyPalanpur.When a good things comes to end, memories are left behind, in this regard, I amindebted to respected Chairman Prabhubhai Patel, Managing Director P.P.Patel,Marketing Manager S.N.Patel, Finance Director D.K.Patel and Purchase DirectorR.P.Patel for giving me this wonderful opportunity to do a project in an organization.I am highly obliged to Duke Plasto Technique Pvt. Ltd., Badarpura, where I havedone my summer training. I am thankful to Mr. R.M.PATEL(HR Manager) and Nareshbhai Parmar (Accounts head) for giving me permission for doing summer training.

MISSION

We are committed to manufacture products complying with the bestquality standards of the world.We strive to create an environment that nurtures youth andnourishes the experienced.On the bedrock of ethics, Duke is instituted by amalgamating thebest practices and technologies of the world.

VALUES

The values that guide us are trust, ethics, integrity, discipline andperformance.

COMPANY PROFILE

Duke Plasto Technique Pvt. Ltd.Name of Company :➢Duke Plasto Technique Pvt. Ltd.Location :➢Corporate Office :401, 4th floor, Ankit Building,Near Shilp, C.G.Road,Navarangpura, Ahmedabad-09Phone : +91 -79 -26405782Fax : +91 – 79 – 26403428➢Works :N.H.14, Deesa Highway,Opp. Hotel Green Wood,Badarpura, Palanpur – 385510(N.Gujarat, India.)Size of the Unit :➢Medium Scale IndustryForm of Organization :➢Partnership Firm

Name of the Product :

Duke Plasto Technique Pvt. Ltd.1. Submersible Pumps2. Motors3. Monoblock Pumps4. Centrifugal Pumps5.Pressure Booster Pumps

Existing Management Body :Designation Name➢ Managing DirectorMr. P.P.Patel➢ Executive DirectorMr. S.N.Patel➢ Executive DirectorMr. D.K.Patel➢ Executive DirectorMr. R.P.Patel➢ BankersBank of Baroda➢ HR ManagerMr. P.M. Dalwadi

1.6 Location chart

The Duke Plasto Technique is located on Deesa palanpur Highway and beside ofpaper mills , these companies development good and fastly. They developed goodafter omitting their partnership in Aroma Group. In the company ,there are two plant,PVC pipes and Submersible Motors. Company Located in 225000 Sqt. big offices,canteen, plant, godown etc..are having in this area.

CERTIFICATION

Duke Plasto Technique Pvt. Ltd.Recognized by the Best Certification

1. Duke Plato Technique Pvt. Ltd. has received ISI certification for IS 4985 in

the year 1999.

2. Received ISI certification for ISI 12818, and ISO 9001:2000 from ABS in the

year 2000.

3. Approval from GWSSB, Gujarat in the year 2001.

4. Approval from UP Jal Nigam in the year 2002.

5. Approval from PHED, Rajasthan in the year 2003.

6. Supplied to UNISEF & WHO, South Africa in the year 2004.

7. Approval from Karnataka water Supply Board in the year 2005.

8. Received National Quality Award for Quality Product in 2006.

9. ISO 9001:2000 certification from TUV:SUD South Asia for quality Management System in 2008.

10. CE certification from TUV:SUD for Outsource/Export to European Countries.

10. NSIC-CRISIL rating of“CRISIL SE28” for high Performance Capability certification in year 2008.

11. Received ISI certification for IS 8034 in the year 2008.

12. Applied for BEE Star rating in the year 2008.

MAIN COMPONENTS OF SUBMERSIBLE PUMP SET Frame Pump bowl. Stator Winding Non return value Vertical Shaft Bearing Bearing bush. Impeller.

Motor is in the waters so these stator windings are protectedto hard rubber or plastic insulation. In this type of pump the motorsare arranged pipe so the motors diameter are talking small.

STATOR:-

In this company stator core was fabricated from the silicon steel and dynamo steel lamination and thickness variation of the lamination was0.53 mm to 0.5 mm according to design parameter.

The slots of motor are 24. Motor is design for two poles. Length ofthe stamping is designed for depends upon the number of the slots.If the number of the slot value is high, the length of stamping isalso high. Good quality of stamping is M-45. Silicon steel gradegenerally used. Thickness of the stamping is 0.5 mm. Fillingprocess was done before set the winding in the slot. In the slotouter and inner diameter of stator core depends upon the design ofmotor. In the stamping they generally uses P.V.C. insulation usefor slot insulation material. In stator the length of the design ofmotor. Design of motor is according to I.S. (Indian Standard). Inthis company stator casing grade is as per I.S. 210 1993 FG 200 grade. Its made with the use of carbon steel. Its I.S. is I.S. 70 part 5 1985.WINDINGAccording to rating of motor two types of winding wire for

the motors were used like.(1) P.V.C. Insulated Wire,(2) Polly Proper Insulated Wire.P.V.C. Insulation WireWinding process was done using former. This companygenerally used P.V.C. winding wire as per I.S. 8783. This companyused finolex, unilex etc. for the winding. When the motor is notgenerally water-cooled. They use super enamel. Wire as per I.S.4800 part 7 1970. Then after winding set in the water. Then theytest the insulation resistance of the winding is near about 50 Meghaohms P.V.C. insulation wire size is show in the table.

Performance of characteristic of 2 pole threephase submersible motors as per I.S.for bore

Determination of temperature rise of windings byresistance method:The temperature rise (t2-t1) may be obtained from theratio of the resistance by the formula(T2+235)/(T1+235) =(R2/R1).Where,T2 = temp of the winding at the end of thetest.R2 = resistance o the winding at the end ofthe testMeasured within 30 second after shut down.T1 = temp of the winding at the moment oftheThe initial resistance method.R1 = initial resistance of the winding.For the practical purpose the following alternative formula may befound convenient.T2-T1 = [(R2-R1)*(235+T1)/R1]+ (T1-T2).Where,T2 = temperature of the cooling medium at theend of the test.EarthingIn this company generally used G.I. pipe earthing as per I.S.3043; 1987 and power factor measured by two-watt meter method.ROTORIn this company, In3- motor Generally uses squirrel cagerotor. The Diameter of the bearing of the rotor is as per I.S. Thesecompanies makes rotor different method rotor stamping is designof as per I.S. 6B 1984(1) Balancing Method: -(2) Brazing Method: -(3) Power coating method: -(4) Vaccume Impregnation Method: -

(1) Balancing Method : -In this method the company makes a rotor in balancing condition then after they use filling process in the rotor.

(2) Brazing Method : -Apparatus: -Gas Welding Equipment.Procedure: -First before the Brazing Method copper rod must be required.Four rod is press on hydraulic pressure and then includes reseatingprocedure in this rod.Another hole the copper rod is include in with use of hand do thereseating.During Brazing we use 2% brazing rod.The metal is added in slots with use of brazing rod.Below the size of torch and light

(3) Power coating method:-Apparatus: - Power coating, machinery.Procedure: -Check the density of the rotor power on this power coatingmachine, after keep the air pressure 2 to 3 km* km.Then after check the spray gun with use of the static charge at 6 to8 KV.Then the rotor set in the cage of power spray then this rotorstampingmove slowly.Clean the part of the slive then set the timer at two hour in surfaceat the temp of 200 Celsius /-10 Celsius.Check the coating of the rotor of outside.

(4) Vaccume Impression method : -Apparatus: - vaccume impression equipmentProcedure: -In this company the drying of the winding with use of vaccumeimpression method.In this method use of dipping method. This method is very popularin the company.After takes out winding is dipping in the bowl. About few minuteskeep the windings in the bowl.Then after different types of colour is used at 1 to 15kg/cm pressuse with help of spray gun.Motor shaft is becomes wruget steel and cormium steel.Material I.S.(1) Wruget steel - I.S. 61873 1961-40(2) Cormium steel - I.S. parts 1995G.R. – 04CR 13 CR 4CR 13 20 Cr 13

CABLE JOINING INSTRUCTION: -Cable jointing kits consist of PVC insulating tape, rubbercompound tape, butt connectors of an appropriate size (jointsleeve).The following procedure is to be adopted for making a cable joint:Strip the outer insulation of the motor cable and jointing cable andalso cut the inner insulation of each leads as per as per I.S.Connect the leads as per red, yellow, blue in required connectionwith the help of butt connectors. And ensure all joints should betightening by crimping pier as per I.S.While scrap the insulation of the cable, which leads to roughensurface over leads, clean the surface of leads by solvent such asnaphtha thicker to prepare for a watertight joint.Start tapping as per figure 6 first apply single layer of PVCinsulation tape in clockwise on joint the apply as per I.S. 6A singlelayer of rubber compound tape in clockwise follow the sametapping procedure on all the leads then makes all the together asper figure 6-B and apply single layer of rubber compound tape in

anticlockwise start from tape in cable insulation in such a way tocover all the leads to protect from inside water of cable thensimilarly apply PVC insulating tape in clockwise tape.Here is different motors for different cable wire size in mm*mmgiven below the table.For one-phase motors: -Wire size of this cable is 1.5 mm*mm and for one phase motor hasuse white cable for colour coding method.For three-phase motors: -(1) 2.5 mm*mm (2) 4 mm*mm(3) 6 mm*mm (4) 10 mm*mm(5) 16 mm*mm (6) 25 mm*mmThree phase motor brushes is made from (LTB) leadedtreen bronze material and its I.S. is 318 1981.

EQUIPMENT AND TOOLS REQUIRED FORINSTALLATION: -Following equipments are required for installation.A crane or tripped with chain block and swiveled hook of 1 tonescapacity for pump sets up to 4P to 10 H.P. and 3 to 5 tonescapacity above 10 H.P. the Tripod should allow load hook to beraised to 3 to 4 meters and it should be reacted directly above thewell axis.Two pairs of supporting clams are required to suit discharge pipesize.Good quality the reading compound available in the market willserve the purpose. Five parts of graphite with one part of read leadmixed with lubricating oil can serve the purpose.Chain spanner: - 2 numbers.Megger: - 0-500 V.Tools: -screw driver 200 mm to 300 mm long insulating spannersetc. Sluice value and bend.

TESTING : -In this company different types of test in three phase motors arebelow.Continuity test: -Insulation test: -High voltage test: -Rotation check: -Temperature test: -Continuity test: -Connect the two wires of megger between two phases of the motorit shows zero resistance. Take this test with all the phase one byone. It should show zero resistance.

Insulation test: -Apparatus: - megger 500/1000 V.Procedure: -Two terminals short of the megger instrument then check thereading of the megger when press button will be show be showzero.Keep the negative terminal of megger in water or land.Keep coil in water minimum 30 minutes then the connect the +Veterminal in the terminal of the coil.I.R. is show minimum 50-mega ohms resistance. If the insulation.resistance is indicating more than 200 mega ohms this reading notein order number (F); production (PD): 05 then this coil used forwinding.High voltage test: -In this company high voltage test is done by at 3000 volts of themotor. The one terminal of the high voltage in the water andanother terminal gives the windings for charging, then this terminaldischarge in the water.Rotation check: -To determine the correct rotation, connect the motor to the supply(Ensure that motor is filled with water). Check the rotation of themotor. It should coincide with the marked arrow.

Temp rise test of the winding : -The temperature rise (t2-t1) may be obtained from the ratio of theresistance by the formula(T2+235)/(T1+235) =(R2/R1).Where,T2 = temp of the winding at the end of the test.R2 = resistance o the winding at the end of the testMeasured within 30 second after shut down.T1 = temp of the winding at the moment ofThe initial resistance method.R1 = initial resistance of the winding.For the practical purpose the following alternative formula may befound convenient.T2-T1 = [(R2-R1)*(235+T1)/R1]+ (T1-T2).Where,T2 = temperature of the cooling medium at the end of the test.

PUMP LOSSES AND EFFICIENCIES

1) MECHANICAL EFFICIENCY: - There is mechanicalfriction in pump part such are packing bearings etc. so thereare mechanical losses.nm = rotor powershaft power2) HYDRAULIC EFFICIENCY :- the losses produce bythe traction and separation between the water and surface inwater how way are calculated in hydraulic efficiencynh = Actual head = HIdeal head H1

3) Volumetric Efficiency (nv) :- Some clearance is needbetween the pump causing and impeller so the dischargedwater from impeller is leaked from this space. This is occurbecause of pressure difference between suction anddischarged volume water, no in actually discharged water.Nv = Q Actual Discharge(Q+q) Theoretical DischargeWhere q= Leakage

4) Over all efficiency (no) :-no = nn + nv + nm= H + Q + Rotor PowerH1 (Q+q) Shaft Power

PUMP TROUBLE AND THEIR REASONS

1.VIBRATION: -1.Inadequate water level.2.Impeller or rotors are unbalanced.3.Shaft bent.4.Improper alignment.5.Bearings worn out.6.Air or gas in the water (defective base).7.Improper top face of tube well pipe.2. PUMPS TAKES TOO MUCH POWER: -1.Mechanical friction.2.Mis-alignment3.High specific gravity.4.Restricted speed.5.Duties different from the design.6.Low voltages.

3.LESS DISCHARGE: -1.Motor is running in reverse direction.2.Higher total head.3.Inadequate water level.4.Gas in water.5.Low voltage.6.Leakage in delivery parts.7.Wearing of hydraulic parts.

4.NO CHARGE: -1.Higher total head.2.Strainer / impeller choked.3.Coupling broken.4.Low speed.5.Lowest bowl not submerged in the water.

5.JAMMING: -1.Improper assembly.2.Mis-alignment.3.Dry running of pump.4.Failure of bearings.5.Sandy tube well.

6.PUMPS DOES NOT START: -1.Motor defective.2.Starting equipment defective.3.Overflow relay tripped.4.Low voltage.5.Jamming.6.Fuses blown off.

INSTALLATION AND OPERATION OFCONTROL PANELS GENERAL

Due to the case should be taken in installation andconnection of control panel to achieve trouble free service for longperiod. It should be protected against dust particularly. It should beclean from inside. The direct on line (DOL) control panels aresupplied up to 6 H.P. star delta type control panels up to 20 H.P. itconsists of: -Voltmeter.Ammeter.Direct on line or automatic star delta contactors with no volt coil(NVC) and over load relay.Phase indicating lamps.Actuating push buttons for starting and stopping the motors.Water level guard.Single phasing prevention.Above 20 H.P. autotransformer starting control panels aresupplied. Remove the hinged housing cover of control panels andcheck for loose and broken parts and connection in transits, theyshould be retightened / resoles us the case may be.

INSTALLATION: -Mount the control on a vertical wall free vibration. Ensure thatcable entry is made completely dust proof by using cable glands.Connect the supply leads, motor leads and electrode exactlyaccording to the connection diagram given inside of the panel box.Tighten all the screw.Connect the ear thing wire to the terminal so marked. It isrecommended that ear thing connection should also be given todelivery pipe of the pump. Incoming switch fuse unit should benear the control panel so as to enable the operator to operate withboth the switch fuse unit and control panel from one place.

OPERATION: -Put the incoming switch fuse to “ON” position.Now phase indicating lamps will glow observe that all use glowingwith about the same intensity, otherwise do not start the panel.Voltmeter indicates supply voltage. If the voltage indicated isbelow the rated do not started the panel.Start the pump by pressing green button. Observe the steadyammeter reading. It should not exceed rated current.Incase of star-delta stator it is necessary to set the timer used forchange over from star to delta. First set the timer to its maximumvalue. Start the timer to its maximum value. Start the motor in startand measure the time taken for the motor to reach nearly ratedspeed. Stop the motor and set the timer.Do not start the pump in case if single phasing.

MAINTENANCE OF SUBMERSSIBLE PUMPSAND DIFFERENT MOTORS AS DIFFERENTI.S.: -

MAINTENANCE : -Practically no maintenance is required if the control panel isinstalled and commissioned properly. However following pointsshould be noted as preventive measures to ensure long trouble freeservice.Contacts blanched by deposits of silver oxide. It is good conductorof electrically. Do not dress the contact with file or emery paper.Filling of contact will remove the material and reduce the contactlife. At the most should be cleaned with white petrol or carbontetrachloride.If contactors hum, clean pole types with soft cloth.Keep the interior parts clean and free from dust.Tighten the terminal screws from time to time.Keep the silica tube crystals inside the control panels to avoiddamping of contact from moisture.Bimetal relay and timer do not require any maintenance. Hence they should not be tempered.

Different I.S. of Different motors : -Sr. No. Motor I.S.1 For one phase A.C.and universal motorfor submersible.I.S. 996, 19792 Generally inductionmotorI.S. 7583, 19963 Mono set pump forclear and cold waterI.S. 9079, 20024 I.S. of total verticalpump set.I.S. 8034, 20025 Test for agriculturaland water supplypumps code ofacceptant.I.S. 11346Characteristics of clear cold fresh water: -Turbidity 50 PPM (silica scale).Chlorides 500 PPM max.Total solids 3000 PPM, max.PH 6.5 to 8.5.Temperature 33 Celsius.Specific gravity 1.004 max.

Advantage of using submersible pump1. It is easily installment and no need for foundation.2. There is no problem in suction because it is arranged in the deepin water.3. There is less maintenance needed in it.4. The unit are work less noise.5. The overall efficiency is high of the pump.6. The power consumption are less.7. Its operation cost are lessPrecaution for pumps1. To fill the qualified grade lubricating oil at the right time inpump bearings.2. Pump is rotating according to the arrow draw on pumpcausing.3. Do priming until the flow of the whole water are not comingback from the pump causing.4. The pump has started at the same time after priming.5. The discharge valve is opened slowly after the pump hasstarted.

Difference b/w vertical turbine pump &Submersible pump1. The motor of submersible pump are costly than verticalturbine pump.2. The long shaft or vertical turbine pump are costly andits arranging are also costly.3. Experienced pump mechanic is needed for installmentof vertical turbine pump. Because there is accuratealignment between vertical pipe and shaft. Theinstallment of vertical turbine pump take two or threedays while submersible pump installment take in halfday.4. The motor and pump of vertical turbine pump are muchincreased efficiency than submersible pump.5. The constant voltage supply is needed for submersiblepump motor because it is very deep so there is voltagedrop in cable.6. In the vertical turbine pump long shaft and bearing etcare mechanical loaded so there are break down andrepair comes.7. The reliability of submersibles pump are more thanvertical turbine pump.8. Vertical turbine pump is low speed machine (1450 rpm)while submersible pump are high speed machine (3000rpm.)