Summer Training Report

SUMMER TRAINING REPORT
Submitted in partial fulfillment for the award of Diploma in Mechanical Engineering
AT
NALKUP KHAND, MAHARAJGANJ (HEADQUARTER –FARENDA)
PROJECT TITLE
. Maintenance Department
SUBMITTED TO -
M T G B GOVERNMENT POLYTECHNIC SIDDHARTHNAGAR DUMARIAGANJ (UP)
DEPARTMENT OF MECHANICAL ENGINEERING
SUBMITTED BY -
NAME - IQUBAL HUSAIN
ENROLLMENT NO - E18444634300019
ROLL NO - 2163033435011
BRANCH - MECHANICAL ENGINEERING
TRAINING DURATION -
FROM: - 28/08/2020 TO: - 27/09/2020
NAME OF OFFICER: - MR. DINESH CHANDRA (JUNIOR ENGINEER)

ACKNOWLEDGEMENT
I would sincerely like to thank the employees and the officers of Nalkup Khand,
Maharajganj for their help and support during the vocational training despite
their busy schedules; they took time out for us and explained to us the various
aspects of the working of the plant from the production shops.
I would sincerely like to thank Mr. Dinesh Chandra (Junior Engineer) and Mr.
Arun Babu Gupta (Executive engineer), at ExEn No. Division Maharajganj for
providing me opportunities to undergo his able guidance and offering me a very
deep knowledge of practical aspects of industrial work culture.
IQUBAL HUSAIN

PREFACE
The objectives of the practical training are to learn something about industries
practically and to be familiar with the working style of a technical person to adjust
simply accounting to the industrial environment.
It is rightly said practical life is far away from theoretical one. We learn in
classroom can give the practical exposer real life experience no doubt they help in
improving the personality of the student, but the practical exposure in the field
will help the student in long run of life and will be able to implement the
theoretical knowledge.
As a part of academic syllabus of three year degree course in Mechanical
Engineering, every student is required to undergo a practical training I am student
of second year mechanical and this report is written on the basis of practical
knowledge acquired by me during the period of practical training taken at Nalkup,
Khand Maharajganj.

CONTENTS
[1]. Introduction to Nalkup khand…………………………………………………………..
[2]. Machine Shop…………………………………………………………………………………..
[3]. Welding Shop……………………………………………………………………………………
[4]. Hydraulic Suspension Unit Test Bench………………………………………………….
[5]. Maintenance of Submersible Motor (10HP -20HP)………………………….
[6]. Starter Repair………………………………………………………………………………….
[7]. Conclusion………………………………………………………………………………………
[8]. Bibliography …………………………………………………………………………………….

INTRODUCTION TO NALKUP KHAND
ABOUT DEPARTMENT:-
Description of water resources like wells, canals and dams could be seen at many places in
Vedas. In Rig-Veda description of wells, kavat could easily be seen at many places. Water from well,
used to be fetched from wheels made of stone, in which container is tied to rope. Wells were not only
used to fetch the water for daily use of humans and animals, but were also used for irrigation too. In Rig-
Veda word 'Awta' is also mentioned which is the symbol of Well. In other hymn word 'Kulya' is being
mentioned, which means 'Artificial Canal. In Yajurveda one can see the description of digging of canals.
Even Guru of Devas 'Brahaspati' had said that repairing and modification of dams and canals is a holy
practice and rich society of state should take its responsibility. Whole this history clears that irrigation
sources have always been an important part of civilization and livelihood.
Around 3150 B.C. many epics described the irrigation farming since the time of Mahabharat.
When Rishiraj Narad visited King Yudhisthir's state to meet him in this context, then he questioned him
about the condition of farmers in his state, that whether they are healthy or not? Are reservoirs large
and sufficient and do they have sufficient of water and does water is supplied to various parts of state?
All these questions and concerns shows that even in Mahabharat Era irrigation was one of the main
agenda for development of the society.
FOUNDED: - 1823
SLOGAN: - स िंचनेन मृधि भवति

Milestones of Irrigation Department, U.P.
 1817 Lord Hasting handed over the task of maintenance of canal originating from western
bank of Yamuna River to Lieutenant Blane of Engineering Core.
 1821 Operation of Western Yamuna Canal.
 1822 Lord Hasting handed over the task of maintenance of Doab canal originating from
Eastern bank of Yamuna River to Lieutenant Dibuied.
 1823 Establishment of first Irrigation Office in Saharanpur.
 1830 Operation of Eastern Yamuna Canal.
 1842 Construction started of Upper Ganga Canal By Colonel Proby Cautley.
 1854 Supply of water in Upper Ganga Canal.
 1855 Establishment of Central Public Works Department.
 1871 Approval to construction of Lower Ganga Canal.
o Construction of Agra Canal System started.
o Operation of Lower Ganga Canal started.
 1880 Recommendation of providing Irrigation facility in 40% land of total Culturable land in
Bundelkhand by Drought Commission.
 1885 Construction work of Betwa Canal completed.
 1886 Betwa Canal got operated for irrigation in Jalauna and Hamirpur districts.
 1898 Construction of Fatehpur Water Branch.
 1903 Formation of Second Drought Commission, in which it Reiterated to provide irrigation
facility as recommended by First Drought Commission.
 1906 Construction started of Lehchura Dam on Dhasan River.
 1907 Construction of Dhasan Canal.
 1909 Construction Started if Pahadi Dam on Dhasan River.
 1910 Construction completed of Lehchura dam on Dhasan River.
o Construction of Dhukva Dam.
 1912 Construction completed of Pahadi dam on Dhasan River.
 1913 Construction of Ghagra Canal.
 1915 Construction of Garai Canal.
o Construction of Gangau Dam on Ken River.
 1919 Construction started of Sharda Canal System.
 1928 Construction completed of Sharda Canal System.
 1952 Construction started of Matateela Dam.
 1954 Formation of PWD and Irrigation Department.
 1955 First flood work started by Irrigation Department.
 1956 Discharge of Yamuna canal is increased to 2500 cusec from 800 cusec.
 1957 Construction completed of Narayani Canal System.
 1961 Construction of Rihand dam.
Establishment of Irrigation Research Institution in Rurkee.

Setting up of Control Design Directorate at Lucknow.
 1964 Construction completed of Matateela Dam.
Technical Examination Wing established in Secretariat for Irrigation Department.
 1968 Sharda Sahayk Canal construction started.
 1972 Construction of Gandak Canal System.
 1973 Construction started of Rajghat canal.
 1974 Construction of Western Prayagraj Branch.
 1977 Commencement of Kanhar project.
 1978 Construction started of Bheemgauda dam.
Construction of Saryu canal.
 1984 Construction completed of Bheemgauda dam.
Construction of Parallel Lower Ganges Canal.
 1994 Construction of Gandak Canal System completed.
 1996 Beginning of Baan Sagar Project.
 2003 The Information System Organization establishes in Irrigation Department in July 2012
under Project Component C-I Consolidation and Enhancement of Irrigation Department reforms
Organization/department with activity UPID Modernization & Capacity Building In Uttar Pradesh
Water Sector Restructuring Phase-II. The Following works executed by ISO mainly using modern
Technology. ⇒ Establishment of SCADA System in Various Structure of Canal System for Real
Time Discharge. ⇒ Development of Mobile App for Flood Information System.
 2017 Application of Remote Sensing Technique in Flood Information System Application of
Web Based Technique in Monitoring Management System.

INTRODUCTION TO MACHINE SHOP
Machine shop work is generally understood to include all cold-metal work by which an operator, using
either power driven equipment or hand tools, removes a portion of the metal and shapes it to some
specified form or size. It does not include sheet metal work and coppersmithing. The function of all
machine tools is to produce metal parts by changing the shape, size, or finish of a piece of material. The
shape of a part made with a machine tool is limited by the types of motion the tool can apply.
Standard machine tools are grouped in six basic classes:
1. LATHES
2. DRILLING MACHINES
3. SHAPERS
4. PLANERS
5. MILLING MACHINES 6. GRINDING MACHINES
LATHE:-
The lathe is used for turning various metals against a cutting tool that shapes it to the desired product.
The engine lathe is a machine tool that produces a cutting action by rotating the work piece against the
cutting edge of the tool.

DRILLING MACHINES:
The drilling machine is a machine tool that produces the necessary cutting action by the rotation of a
multiple edge cutting tool.
SHAPING AND PLANING MACHINES:
Both of these machines can machine flat surfaces with a single point reciprocating, motion is applied to
both the work piece and tool in these machines.
MILLING MACHINES:
A milling machine provides cutting action to a rotating tool. The vertical milling machine is used to cut,
shape, and finish metal objects.
GRINDING MACHINES:
A grinder differs from other machines in that it uses a tool made of emery, Carborundum, or similar
materials. The wheel, made up of many tiny cutting points, cuts with the entire surface area that comes
in contact with the material being ground. Grinders cut with a grinding action, removing material in the
form of tiny particles.
Drilling Machine

Grinding machine
SAFETY RULES FOR MACHINE TOOLS:
The following are general safety rules for any machine tool:
1. Gears, pulleys, belts, couplings, ends of shafts having keyways, and other revolving or reciprocating
parts should be guarded to a height of 6 feet above the floor. The guards should be removed only for
repairing or adjusting the machine and must be replaced before operating it.
2. Safety set screws should be used in collars and on all revolving or reciprocating members of the
machine tool or its equipment.
3. Do not operate any machine tool without proper lighting.
4. Never attempt to operate any machine tool until you fully understand how it works and know how to
stop it quickly.
5. Never wear loose or tom clothing and secure long hair, since these items can become caught in
revolving machine parts. Ties should be removed and shirt sleeves should be rolled up above the elbow.
6. Gloves should never be worn when operating machinery except when absolutely necessary.
7. Always stop the machine before cleaning it or taking measurements of the work piece.
8. Do not lubricate a machine while it is in motion. Injury to the operator and damage to the machine
may result from this practice.
9. Always wear safety glasses or goggles while operating machine tools. Also, wear respiratory
protection if operation creates hazardous dust. All persons in the area where power tools are being
operated should also we are safety eye protection and respirators as needed.

10. Know where tire extinguishers are located in the shop area and how to use them.
11. Never wear jewellery while working around machine tools. Rings, watches, or bracelets maybe
caught in a revolving part which could result in the hand being pulled into the machine
12. Avoid horseplay. Tools are very sharp and machines are made of hard steel. An accidental slip or fall
may cause a serious injury.
13. Never use compressed air without a safety nozzle to clean machines or clothing. It will blow sharp,
dangerous metal chips a long distance.
14. Never place tools or other materials on the machine table. Cluttering up a machine with tools or
materials creates unsafe working conditions. Use a bench or table near the machine for this purpose.
15. Always use a rag when handling sharp cutters such as
milling cutters and end mills.
INTRODUCTION TO WELDING SHOP

In the Nalkup Khand, there are basically three type of welding used.
1. Submerged arc welding
2. Manual metal arc welding
3. MIG welding
SUBMERGED ARC WELDING:
In submerged arc welding the welding process will be covered with the flux so that it will not react with
oxygen and nitrogen. Because of the versatility of the process and the simplicity of its equipment and
operation, shielded metal arc welding is one of the world's most popular welding processes.
It dominates other welding processes in the maintenance and repair industry and though flux-cored arc
welding is growing in popularity, SMAW continues to be used extensively in the construction of steel
structures and in industrial fabrication. The process is used primarily to weld iron and steels (including
stainless steel) but aluminum, nickel and copper alloys can also be welded with this method.
GMAW COMPONENTS:
1. DC or Direct Current power supply
2. Electrode or wire feed controller Submerged arc welding
3. Wire drive roller assembly
4. Shielding gas source (cylinder) & regulator
5. Manually held Gun & ground clamps
6. Wire reel

Submerged Arc Welding
Manual Metal Arc Welding
MANUAL METAL ARC WELDING INTRODUCTION
 The terms commonly used when referring to Manual Metal Arc welding are M.M.A, Arc welding
or Stick welding.
 Manual metal arc welding was first invented in Russia in 1888. It involved a bare metal rod with
no flux coating to give a protective gas shield
 The development of coated electrodes did not occur until the early 1900s when the Kjellberg
process was invented in Sweden and the Quasi-arc method was introduced in the UK.
 It is worth noting that coated electrodes were slow to be adopted because of their high cost.

 However, it was inevitable that as the demand for sound welds grew, manual metal arc became
synonymous with coated electrodes.
 When an arc is struck between the metal rod (electrode) and the workpiece, both the rod and
workpiece surface melt to form a weld pool.
 The types of electrodes used will affect arc stability, depth of penetration, metal deposition rate
and positional capability and are greatly influenced by the chemical composition of the flux
coating on the electrode.
 Electrodes can be divided into three main groups: Cellulosic, Rutile, Basic.
 Cellulosic electrodes contain a high proportion of cellulose in the coating and are characterized
by a deeply penetrating arc and a rapid burn-off rate giving high welding speeds. Weld deposit
can be coarse and with fluid slag, deslagging can be difficult. These electrodes are easy to use in
any position and are noted for their use in the 'stovepipe' welding technique.
 Rutile electrodes contain a high proportion of titanium oxide (rutile) in the coating. Titanium
oxide promotes easy arc ignition, smooth arc operation and low spatter. These electrodes are
general purpose electrodes with good welding properties. They can be used with AC and DC
power sources and in all positions. The electrodes are especially suitable for welding fillet joints
in the horizontal/vertical (HN) position.
 Basic electrodes contain a high proportion of calcium carbonate (limestone) and calcium
fluoride (fluorspar) in the coating. This makes their slag coating more fluid than rutile coatings -
this is also fast-freezing which assists welding in the vertical and overhead position. These
electrodes are used for welding medium and heavy section fabrications where higher weld
quality, good mechanical properties and resistance to cracking (due to high restraint) are
required.
 M.M.A welding up until recently was the widest used welding process, with most manufactured
products being welded by M.M.A., this is no longer the case with M.I.G./M.A.G. taking over from
it.

MIG (Metal Inert Gas Welding)
Gas metal arc welding (GMAW), sometimes referred as metal inert gas (MIG) welding, is a welding
process in which an electric arc is formed between a consumable wire electrode and the workpiece
metal(s), which heats the workpiece metal(s), causing them to melt, and join.
Along with the wire electrode, a shielding gas is fed through the welding gun, which shields the process
from contaminants in the air.
A constant voltage, direct current power source is most commonly used with GMAW.
There are four primary methods of metal transfer in GMAW, called globular, short-circuiting, spray, and
pulsed-spray, each of which has distinct properties and corresponding advantages and limitations.
Wire feed mechanism
There are three basic forms of wire feeders: the 'push' system, the 'pull' system and the 'push-pull'
system.
As the name suggests, in the push system, the wire is pushed by the wire feed drive rolls along the
conduit to the welding torch. The pull system utilizes a set of wire rolls in the torch handle which pull
the wire from the wire reel.
This arrangement increases the weight of the torch and does not increase the distance over which the
wire can be fed, this still being limited to around 3.5m, although the consistency of the wire feed is
improved and wire diameters down to 0.8 mm can be used.
The push-pull system is a combination of the above two systems with a set of drive rolls at both
the wire reel feeder and in the torch.
Here welding is done by two types of machines
 Semiautomatic special purpose machine
 Robotic machines (automatic)
 We use wire feed range between 10-12M/min, and we use push type system for this purpose
Modes Of Metal Transfer

Modes of Metal Transfer
Metal transfer in MIG is done in four modes.
1. Dip/short circuit mode
2. Pulsed mode
3. Spray mode
4. Globular mode
Metal Inert Gas Welding

HYDRAULIC SUSPENSION UNIT TEST BENCH

INTRODUCTION:-
 The "HSU TEST BENCH” is developed for testing the strength and leaks of HYDRO-PNEUMATIC
SUSPENSION SYSTEM. This test involves mounting the integrated suspension unit over the hsu
bench. The high performance Servo-hydraulic actuator is used for static and dynamic
mechanical testing of Hydro-pneumatic suspension units in highly accurate displacement control
mode.
 As per the specification there is LH unit and RH unit both to be mounted on the same test
bench. So provision of mounting the suspension unit (LH AND RH) is provided.
STATIC AND MECHANICAL BOTH KIND OF TEST CAN BE PERFORMED ON THE HSU TEST BENCH

SPRING CHARACTERSTIC TEST ON HSU TEST BENCH:
This test checks the static load bearing capacity of the suspension unit. This test is required to analyze
the static load capacity (because of tank weight) with the help of actuator.
 Max static Load: 16 ton
 Stoke of actuator for static stage: 375 mm
DYNAMIC TEST ON HSU TEST BENCH:
During dynamic testing all test performed gives the same condition which might be incur the real life
condition for the tank. It simulates the no. of test condition.
 Dynamic Load: 16 ton
 Max Stroke Length: 0-300 mm
 Frequency: continuously variable

Working of the System:-
This system consist two Parts.
[1]. HSU POWER PACK:
 Tank of 1000 liter is used as the storage for the servo oil. Equipped with limit switch,
temperature transmitter, and temperature gauge on the tank top. Inlets of the system have
manual ball valve with limit switch feedback to it. PARKER PV plus axial piston pump is used to
generate 250 bar of max pressure. To overcome shock, BELLOW is used in combination with
anti-vibration pad in combination at outlet oil is filtered by in-line filter of 6 micron and 3 micron
respectively. At junction manifold, pressure regulator is placed to set the limit of pressure.
 A separate circuit for the filtration and cooling of oil is provided including air cooled oil cooler
with separate motor pump arrangement. A tank top filter is also provided of 6 micron to filter oil
regularly.
[2]. HSU TEST BENCH:
 Further filtration is provided with in line 3 micron filter before going to Servo valve. Accumulator
with safety shut off block is provided to give constant pressure to actuator. Main Actuator
assembly mounted with loadcell (50,000 lbs) apply load on the test unit.

 Actuator motion is controlled by automatic servo valve at a constant speed of 15 20 mm/sec. for
3 cycles. Test beds have Tank of 1000 liter With Pressure transmitter to give output to DAQ
Panel.
MAINTENANCE & TROUBLESHOOTING
 T1. Power pack supply is not ON.
 S1: Make sure the main supply to the power pack is ON. Check for Internal connection in the
panel.
 T2. Motor is not getting ON from the DAQ panel.
 S2: Make sure the Local/DAQ knob is on DAQ only.
 T3. Pump is not making pressure.
 S3: Make sure pressure regulator is not altered, or set the desire pressure from the regulator.
 T4. Analog Input is not coming in the DAQ system. S4: Make sure the MCB of the DAQ panel is
ON.
 T5. Load value is not coming.
 S5: check for load cell connection. Or get the load cell checked
 T6. Filter is chocked (filter clogged light is ON).
 S6: Check the Filter Code, and contact Neometrx to arrange for the filter element. (Warning: Do
not operate the test bench without checking every filter, or else it will affect the Servo valve
performance and might cause permanent damage).
 T7. Leakage from fitting and hose connections.
 S7: Properly tighten the fitting from where the leakage is there. Check for the hose.

Maintenance of Submersible Motor (10HP -20HP)
>In 1928 Russian engineer and inventor Armais Arutunoff successfully installed the first submersible oil
pump.
> In the mid 1960s the first fully submersible deep-well water pump was developed.
Inventor of the electric submersible pump.
 In his design, the motor was ingeniously installed below the pump to cool the motor with flow
moving up the oil well casing, and the entire unit was suspended in the well on the discharge
pipe.
 A vertical type centrifugal pump close coupled to a small-diameter submersible motor is termed
as a submersible pump.
 It is diffuser type vertical centrifugal pump.
 Specially adapted to pumping water from tube wells.

Constructional Details:
It consists of
 Pump bowl
 Motor assembly
 Discharge column
 Head assembly
 Water proof cable to conduct current to the submerged motor. Constructional Details:
Pump Element:
 Pumps with radial flow impellers- low capacities and high heads.
 Mixed flow impellers-for medium capacity and medium heads.

 Before starting the pump the direction of rotation should be checked.
 The direction which gives more pressure is chosen.
 Permissible limit of sand-25 grains/cubic meter of water.
 The shutdown period of pump should not exceed more than 2 weeks.
DO'S:
 Always suspend the pump set at least 3 meters above the bottom of the bore.
 The pumps must be installed 1meter below the water level surface.
 Check the water quality before filling in the motor.
 Always check the cable joints and vertical play after coupling the pump set.
 Always use a good quality control panel.
 Bending of cable must be avoided.
DON' T:
Don't run the pump if any of the following defects is observed.
 Water is sandy or acidic.
 If there is no water.
 If the problem of single phasing arises.
 Don't pull the motor with the help of cable.
 Minimum interval between the start and stop of the motor must be 1 minute.
o The capacity of the submersible pump is determined by the width of the impeller and diffuser.
 The pressure is determined by the diameter of the impeller, the speed and the number of
impellers.
ADVANTAGES:
 Can be used in very deep wells where a long shaft is not practical
 Unaffected by deviations in vertical alignment of well.
 More efficient than jet pumps.
 It can be used in places where above the ground housing is inconvenient.
 It can be used in wells of diameter as small as 15 cm.
 Less noise.

Disadvantages:
 Affected by seasonal fluctuations in water level.
 It can run only on electric motor not on an I.C. engine.
 Maintenance is difficult.
 Higher initial costs
 Problem of corrosion.
TUBEWELL

Starter Repair
12 HP SUBMERSIBLE PUMP STARTER
Necessity of starter
 At starting the speed of motor is zero so that the back e.m.f. In the armature is zero.
 Armature resistance is so low, if it is connected to power supply directly; huge current will pass
thru armature.
 The huge current may damage the machine, major heat, very high speed in case of DC series
motor.
 la = V/Ra
Function of starter
 Start and stop the motor.
 Limit inrush current where necessary.
 Permit automatic control when required.
 Protect motor and other connected equipments from over voltage, no voltage, under voltage,
single phasing etc.

Motor Starter Features.
 Rated by current (amperes) or power (horsepower)
 Remote ON/OFF control
 Motor overload protection
 Starting and stopping (electrical life)
 Plugging and jogging (rapid making and breaking current)
Type of starter
For DC Motor
 Two point starter for DC series motor
 Three point starter for shunt motor
 Four point starter for compound motor
For AC Motor
 DOL Starter
 Star-Delta
 Auto-transformer
 Variable Frequency drive
BCH Direct-on-Line (DOL) Starters & Star Delta Starters are highly reliable & time tested
starters & suitable for wide range of agriculture & industrial applications.
BCH Starters
BCH Starters have suitable rating contactors to operate the motor & best in class overload relays to
protect the motor from faults.
BCH Submersible Pump Starters
 Suitable rating Rugged & Proven Contactors (having encapsulated coil)
 Best in class & reliable overload relays
 ON-OFF push Button
 Auto Switch (with ON delay) cum Single phasing preventer
 Ammeter with suppresed scale (to withstand high and very high motor starting currents)
 Voltmeter (with Voltmeter selector switch)

 Motor "ON" & "Trip" LED indications
 Selector Switch (3 position) - Auto-Manual-Manual SPP
 Selector Switch (2 position) - Auto-Manual
 Available Phase indications "R" "Y""B" (in premium version)
 Short Circuit Protection - MCB/MCCB (in premium version)
 Rugged termination board (T.B.) of suitable rating
Protections
 Overload protection
 Single phase protection
 Phase Reversal protection
 Phase Unbalance protection
 Auto Start of Pump with ON delay (switch ON the pump after analysing the voltage
conditions)
DOL STARTER FASD STARTER
SMART STARTER

CONCLUSION
• While working on this project during one month, I have study complete detail of maintenance of
submersible motor and its part.
• This specification and learned by me from the employees of each division of engine and these method
production add a gem in my knowledge.
• The employees know their work very well and very helpful in guided us.
• I tried to learn to my best and make the most of it and I will carry this knowledge for my future
experience and studies.
.I tried to give my best effort on this project but it could be better if I would have theoretical knowledge
about workshops before taking this project. As this topic was new to me and due to time constraint I
was not able to through each and every Procedure.

Bibliography
1. http://idup.gov.in/
2. SlideShare.net
3. www.wikipedia.com

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