useful for mechanical students.

1. 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)

2. 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

3. 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

4. 1) company profile
2) Services provided by opex
3) Technology learnt (engine)
4) Trouble locating chart
5) conclusion

5. 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

6. 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.

7. Hand tools
carpentry tools
Garage tools
Industrial tool
Measuring tools

8. pliers
pincers
spanners
wrenches

9. 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)

10.  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
ASSEMBLY
CYLINDER HEAD, INLET & EXHAUST VALVE
LAPPING IS DONE ON DRILL MACHINE, VALVE
SPRING SET, VALVE CUP SET, 5/16” BSF STUD,
7/16” BSF STD
3 ROCKER BOX
ASSEMBLY
ROCKER BOX, ROCKER SHAFT, ROCKER LINER
SET, DECOMPRESSURE SHAFT,
DECOMPRESSURE SHAFT SPRING, ROCKER
SCREW, GRUB SCREW
4 FUEL PUMP BRACKET
ASSEMBLY
FUEL PUMP BRACKET, FUEL PUMP LINER, FUEL
PUMP LINER SPINDLE, 5/16” BSF STUD
5 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 BALLS
6 MAIN BEARING
HOUSING ASSEMBLY
MAIN 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.

11. 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.

19. Images of Assembly of diesel engines

20. 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 TESTING
2. 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 ENGINES
2. PERFORMANCE TEST: - ONE ENGINE OUT OF 20 ENGINES
1. CHECK THE BHP MARKED ON ENGINE
2. CHECK THE LOAD, SFC CHART BEFORE TESTING THE ENGINE.
LOAD APPLIED ON ENGINE: - 2.5 Kg X BHP
SFC STANDARD: - 252 gm/kw/hr
3. 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

21. 2. 50 % 1500 15 MIN ENGINES AS PER
3. 100 % 1500 15 MIN IS : 11170 - 1985
4. 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 HRS
2. FUEL CONSUMPTION TEST 4 HRS
PERFORMANCE TEST :- AS PER IS : 10000 PART VIII
S.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 HRS
4. 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 RUN
1. 0 % 1500 30 MIN
2. 20% 1500 30 MIN
3. 40 % 1500 30 MIN
4. 60 % 1500 30 MIN
5. 80 % 1500 30 MIN
6. 100 % 1500 30 MIN
7. 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.

22. 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.

23. (DIESEL ENGINE TESTING PROCEDURE AND MAINTANING OF ENGINE
TESTING RECORD)
ENGINE TESTING PROCEDURE BEING DONE IN 3 PARTS:-
4. PREPARATION OF ENGINE FOR TESTING
5. 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 ENGINES
2. PERFORMANCE TEST: - ONE ENGINE OUT OF 20 ENGINES
5. CHECK THE BHP MARKED ON ENGINE
6. CHECK THE LOAD, SFC CHART BEFORE TESTING THE ENGINE.
LOAD APPLIED ON ENGINE: - 2.5 Kg X BHP
SFC STANDARD: - 252 gm/kw/hr
7. ROUTINE TESTING OF DIESEL ENGINE BEING DONE OF ALL ENGINES.
S.NO LOAD RPM RUNING TIME SFC

24. 1. 0 % 1500 15 MIN SFC CHECKED OF
ALL
2. 50 % 1500 15 MIN ENGINES AS PER
3. 100 % 1500 15 MIN IS : 11170 - 1985
4. 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 HRS
4. FUEL CONSUMPTION TEST 4 HRS
PERFORMANCE TEST :- AS PER IS : 10000 PART VIII
S.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 HRS
4. 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 RUN
1. 0 % 1500 30 MIN
2. 20% 1500 30 MIN
3. 40 % 1500 30 MIN
4. 60 % 1500 30 MIN
5. 80 % 1500 30 MIN
6. 100 % 1500 30 MIN
7. 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

25. 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.

26. Trouble locating chart

29. Export
Machine is ready for export

31. Packaging material for the engine

32. 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.