A SUMMER PROJECT REPORT OF DUKE PLASTO TECHNIQUE PVT LTD.

PREFACE
As per the syllabus of B.TECH ELECTRICAL ENGINEERING 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 among the student feeling industrial environment and business practice base in them as a supplement to the theoretical study of the management. 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 various department of this company. I have prepared this report on TECHNICAL ANALYSIS of this company.

SUTHAR VISHNU.H

Logo of Duke Plasto Technique Pvt Ltd:-

ACKNOWLEDGEMENT I 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 best quality standards of the world. We strive to create an environment that nurtures youth and nourishes the experienced. On the bedrock of ethics, Duke is instituted by amalgamating the best practices and technologies of the world. VALUES The values that guide us are trust, ethics, integrity, discipline and performance.

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-09 Phone : +91 -79 -26405782 Fax : +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 Industry Form of Organization : Partnership Firm

Name of the Product : Duke Plasto Technique Pvt. Ltd. 1. Submersible Pumps 2. Motors 3. Monoblock Pumps 4. Centrifugal Pumps 5.Pressure Booster Pumps

Existing Management Body : Designation Name Managing Director Mr. P.P.Patel Executive Director Mr. S.N.Patel Executive Director Mr. D.K.Patel Executive Director Mr. R.P.Patel Bankers Bank of Baroda HR Manager Mr. 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 ofCRISIL SE28 for high Performance Capability certification in year 2008.

11. 12.

Received ISI certification for IS 8034 in the year 2008. 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 protected to hard rubber or plastic insulation. In this type of pump the motors are 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 of the stamping is designed for depends upon the number of the slots. If the number of the slot value is high, the length of stamping is also high. Good quality of stamping is M-45. Silicon steel grade generally used. Thickness of the stamping is 0.5 mm. Filling process was done before set the winding in the slot. In the slot outer and inner diameter of stator core depends upon the design of motor. In the stamping they generally uses P.V.C. insulation use for slot insulation material. In stator the length of the design of motor. Design of motor is according to I.S. (Indian Standard). In this 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. WINDING According 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 Wire Winding process was done using former. This company generally used P.V.C. winding wire as per I.S. 8783. This company used finolex, unilex etc. for the winding. When the motor is not generally water-cooled. They use super enamel. Wire as per I.S. 4800 part 7 1970. Then after winding set in the water. Then they test the insulation resistance of the winding is near about 50 Megha ohms P.V.C. insulation wire size is show in the table.

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

Determination of temperature rise of windings by resistance method: The temperature rise (t2-t1) may be obtained from the ratio of the resistance 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 test Measured within 30 second after shut down. T1 = temp of the winding at the moment of the The initial resistance method. R1 = initial resistance of the winding. For the practical purpose the following alternative formula may be found convenient. T2-T1 = [(R2-R1)*(235+T1)/R1]+ (T1-T2). Where, T2 = temperature of the cooling medium at the end of the test. Earthing In this company generally used G.I. pipe earthing as per I.S. 3043; 1987 and power factor measured by two-watt meter method. ROTOR In this company, In3- motor Generally uses squirrel cage rotor. The Diameter of the bearing of the rotor is as per I.S. These companies makes rotor different method rotor stamping is design of 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 reseating procedure in this rod. Another hole the copper rod is include in with use of hand do the reseating. 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 coating machine, after keep the air pressure 2 to 3 km* km. Then after check the spray gun with use of the static charge at 6 to 8 KV. Then the rotor set in the cage of power spray then this rotorstamping move slowly. Clean the part of the slive then set the timer at two hour in surface at the temp of 200 Celsius /-10 Celsius. Check the coating of the rotor of outside.

(4) Vaccume Impression method : Apparatus: - vaccume impression equipment Procedure: In this company the drying of the winding with use of vaccume impression method. In this method use of dipping method. This method is very popular in the company. After takes out winding is dipping in the bowl. About few minutes keep the windings in the bowl. Then after different types of colour is used at 1 to 15kg/cm press use 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 1995 G.R. 04CR 13 CR 4CR 13 20 Cr 13 CABLE JOINING INSTRUCTION: Cable jointing kits consist of PVC insulating tape, rubber compound tape, butt connectors of an appropriate size (joint sleeve). The following procedure is to be adopted for making a cable joint: Strip the outer insulation of the motor cable and jointing cable and also cut the inner insulation of each leads as per as per I.S. Connect the leads as per red, yellow, blue in required connection with the help of butt connectors. And ensure all joints should be tightening by crimping pier as per I.S. While scrap the insulation of the cable, which leads to roughen surface over leads, clean the surface of leads by solvent such as naphtha thicker to prepare for a watertight joint. Start tapping as per figure 6 first apply single layer of PVC insulation tape in clockwise on joint the apply as per I.S. 6A single layer of rubber compound tape in clockwise follow the same tapping procedure on all the leads then makes all the together as per figure 6-B and apply single layer of rubber compound tape in

anticlockwise start from tape in cable insulation in such a way to cover all the leads to protect from inside water of cable then similarly apply PVC insulating tape in clockwise tape. Here is different motors for different cable wire size in mm*mm given below the table. For one-phase motors: Wire size of this cable is 1.5 mm*mm and for one phase motor has use 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*mm Three phase motor brushes is made from (LTB) leaded treen bronze material and its I.S. is 318 1981. EQUIPMENT AND TOOLS REQUIRED FOR INSTALLATION: Following equipments are required for installation. A crane or tripped with chain block and swiveled hook of 1 tones capacity for pump sets up to 4P to 10 H.P. and 3 to 5 tones capacity above 10 H.P. the Tripod should allow load hook to be raised to 3 to 4 meters and it should be reacted directly above the well axis. Two pairs of supporting clams are required to suit discharge pipe size. Good quality the reading compound available in the market will serve the purpose. Five parts of graphite with one part of read lead mixed 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 spanners etc. Sluice value and bend.

TESTING : In this company different types of test in three phase motors are below. Continuity test: Insulation test: High voltage test: Rotation check: Temperature test: Continuity test: Connect the two wires of megger between two phases of the motor it shows zero resistance. Take this test with all the phase one by one. It should show zero resistance. Insulation test: Apparatus: - megger 500/1000 V. Procedure: Two terminals short of the megger instrument then check the reading of the megger when press button will be show be show zero.Keep the negative terminal of megger in water or land. Keep coil in water minimum 30 minutes then the connect the +Ve terminal 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 note in order number (F); production (PD): 05 then this coil used for winding. High voltage test: In this company high voltage test is done by at 3000 volts of the motor. The one terminal of the high voltage in the water and another terminal gives the windings for charging, then this terminal discharge 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 the motor. 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 the resistance 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 test Measured within 30 second after shut down. T1 = temp of the winding at the moment of The initial resistance method. R1 = initial resistance of the winding. For the practical purpose the following alternative formula may be found 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 mechanical friction in pump part such are packing bearings etc. so there are mechanical losses. nm = rotor power shaft power 2) HYDRAULIC EFFICIENCY :- the losses produce by the traction and separation between the water and surface in water how way are calculated in hydraulic efficiency nh = Actual head = H Ideal head H1

3) Volumetric Efficiency (nv) :- Some clearance is need between the pump causing and impeller so the discharged water from impeller is leaked from this space. This is occur because of pressure difference between suction and discharged volume water, no in actually discharged water. Nv = Q Actual Discharge (Q+q) Theoretical Discharge Where q= Leakage 4) Over all efficiency (no) :no = nn + nv + nm = H + Q + Rotor Power H1 (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-alignment 3.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 OF CONTROL PANELS GENERAL Due to the case should be taken in installation and connection of control panel to achieve trouble free service for long period. It should be protected against dust particularly. It should be clean from inside. The direct on line (DOL) control panels are supplied up to 6 H.P. star delta type control panels up to 20 H.P. it consists 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 are supplied. Remove the hinged housing cover of control panels and check for loose and broken parts and connection in transits, they should be retightened / resoles us the case may be. INSTALLATION: Mount the control on a vertical wall free vibration. Ensure that cable entry is made completely dust proof by using cable glands. Connect the supply leads, motor leads and electrode exactly according 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 is recommended that ear thing connection should also be given to delivery pipe of the pump. Incoming switch fuse unit should be near the control panel so as to enable the operator to operate with both 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 glowing with about the same intensity, otherwise do not start the panel. Voltmeter indicates supply voltage. If the voltage indicated is below the rated do not started the panel. Start the pump by pressing green button. Observe the steady ammeter reading. It should not exceed rated current. Incase of star-delta stator it is necessary to set the timer used for change over from star to delta. First set the timer to its maximum value. Start the timer to its maximum value. Start the motor in start and measure the time taken for the motor to reach nearly rated speed. Stop the motor and set the timer. Do not start the pump in case if single phasing. MAINTENANCE OF SUBMERSSIBLE PUMPS AND DIFFERENT MOTORS AS DIFFERENT I.S.: MAINTENANCE : Practically no maintenance is required if the control panel is installed and commissioned properly. However following points should be noted as preventive measures to ensure long trouble free service. Contacts blanched by deposits of silver oxide. It is good conductor of electrically. Do not dress the contact with file or emery paper. Filling of contact will remove the material and reduce the contact life. At the most should be cleaned with white petrol or carbon tetrachloride.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 avoid damping 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 motor for submersible. I.S. 996, 1979 2 Generally induction motor I.S. 7583, 1996 3 Mono set pump for clear and cold water I.S. 9079, 2002 4 I.S. of total vertical pump set. I.S. 8034, 2002 5 Test for agricultural and water supply pumps code of acceptant. I.S. 11346 Characteristics 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 pump 1. It is easily installment and no need for foundation. 2. There is no problem in suction because it is arranged in the deep in 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 less Precaution for pumps 1. To fill the qualified grade lubricating oil at the right time in pump bearings. 2. Pump is rotating according to the arrow draw on pump causing. 3. Do priming until the flow of the whole water are not coming back 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 has started.

Difference b/w vertical turbine pump & Submersible pump 1. The motor of submersible pump are costly than vertical turbine pump. 2. The long shaft or vertical turbine pump are costly and its arranging are also costly. 3. Experienced pump mechanic is needed for installment of vertical turbine pump. Because there is accurate alignment between vertical pipe and shaft. The installment of vertical turbine pump take two or three days while submersible pump installment take in half day. 4. The motor and pump of vertical turbine pump are much increased efficiency than submersible pump. 5. The constant voltage supply is needed for submersible pump motor because it is very deep so there is voltage drop in cable. 6. In the vertical turbine pump long shaft and bearing etc are mechanical loaded so there are break down and repair comes. 7. The reliability of submersibles pump are more than vertical turbine pump. 8. Vertical turbine pump is low speed machine (1450 rpm) while submersible pump are high speed machine (3000 rpm.)