Final Project Report Kiran

V .J .T.
I, MATUNGA INPLANT TRAINING REPORT
INTRODUCTION TO THE ORGANISATION
Godrej & Boyce Mfg. Co. Page 1

V .J .T. I, MATUNGA INPLANT TRAINING REPORT
INTRODUCTION TO ORGANIZATION
HISTORY
The Company celebrated its centenary in 1997. In 1897 a young man named
Ardeshir Godrej gave up law and turned to lock making. Ardeshir went on to make
safes and security equipment of the highest order and then stunned the world by
creating toilet soap from vegetable oil. His brother Pirojsha Godrej carried
Ardeshir's dream forward, leading Godrej towards becoming a vibrant multi-product
enterprise. Pirojsha laid the foundation for the sprawling industrial garden township
now called Pirojshanagar in the suburbs of Mumbai. GODREJ touches the lives of
millions of Indians every day. To them, it is a symbol of enduring ideals in a
changing world.
Godrej is today one of the largest engineering and consumer products

company in the country having varied interests from engineering to personal care
products with a total sales turnover of about US $ 1 Billion. It also one of the most
respected corporate houses known for our philanthropy and initiation of labour reforms
besides being recognized for our values of fair, transparent and ethical dealings.

The company has come a long way since 1897 & is celebrated its cenetary
year. While the company is successful in India, earning more than 200 million in foreign
exchange. It also has mfg. units in Indonesia, Malayasia & Singapore .As of today its
main works are located in Vikhroli. It has also shifted base to Pune, Mohali & Chennai.

COMPANY LAYOUT

INTRODUCTION
GODREJ Company was established in the year 1897 by Sheth Ardeshir
Burjorji Godrej. The purpose of its inception was to provide service to security when the
founder painted by the ample resources draining out of the country, felt the need of the
nations self dependent. The very first product of their colossal national establishment
was lock. These were developed to perfection by initially experimenting & gradually
devising improvement on imported ones.
YESTERDAY….
The Godrej Story began in 1897 when Ardeshir Burjorji Godrej, a lawyer
stepped into the Manufacturing industry by producing high quality surgical instruments.
These were so good that a reputed pharmacist wanted to sell them under a foreign brand
name. Ardeshir Godrej rejected the offer and decided to manufacture the best locks in
the world. And so it was. The locks were followed by safes & both product, by virtue
other superior quality were held in highest esteem by all.
If Ardeshir was the artist who began the painting, then it was his younger
brother, Pirojsha Godrej who enlarged the canvas to a stunning & rewarding proportion.
He possessed the rare foresight to buy land at Vikhroli, which today houses the diverse
Godrej Enterprises & is anonymously named Pirojshanager in memory of the man who
made it an Eden of productivity.
TODAY….
The company has come a long way since 1897 & celebrated its centenary
year in 1997. As for today, main works of the company is located at Vikhroli, Mumbai,
along the eastern express highway. This complex in Pirojshanagar, today houses the
different manufacturing units. The Company is one of the largest privately-held
diversified industrial corporations in India. The combined Sales (including Excise Duty)
of the Company, its subsidiaries and affiliates, during the Fiscal Year ended March 31,
2004, amounted to about Rs. 45,000 million (US$ 980 million).

TOMORROW….
While the company has been greeted with great success in India, the
products of the company together annually earn more than 200 million rupees in foreign
-exchange. The company also has mfg. units in Indonesia, Singapore & Malaysia. Its
major trust now is in the white goods sector. In order to cater to the increasing demand,
land has been acquired in northern India as well. The future lies in tomorrow in every
new assignment, in the smile of satisfied client. The GODREJ logo, which is devised
from PIROJSHA GODREJ'S signature, is nothing but Godrej's promise of superior
quality & unmatched service, & assurance signed in steel.

COMPANY PROFILE
A) GODREJ & BOYCE MFG. CO. LTD: -

It is a truly a multi-faceted company is made up of the following divisions.
OFFICE EQUIPMENT (O.E.) DIVISION:

Office Equipment division manufactures security equipment, industrial
storage system, office storage equipment, disking system & open plan office system and
scaling system. The steel processing plant also included in this division & it supplies
blanks in roll form.
LOCK DIVISION:
This division at plant no. 18 manufactures a wide variety of locks from
right latch to ‘Navtals’.
MATERIAL HANDLING EQUIPMENT DIVISION:

Which is housed in plant no.16 manufactures forklifts with lifting
capacities up to 40 MT in electric powered versions.
TYPEWRITER DIVISION:
Comprises of plant no.6, manufactures 'typewriters, with a host of unique
feature, which have established it as the reliable & the largest selling typewriter in India.
It has now begun making presentation Equipment (Overhead projectors, LCD projectors
etc.)

MACHINE TOOL DIVISION:

This division manufactures a wide range of sheet metal processing &
plastic processing machines. All these machines are available in a wide range of
capabilities to suit individual needs. This division is housed in plant-9 & plant 19 that
also undertakes the design & building of special purpose machines.
PRECISION EQUIPMENT DIVISION:

Located in plant 15 designs & fabricates a range of' custom made
sophisticated equipment for the chemicals, petrochemicals & fertilizers industries as for
aerospace & nuclear application Comprises of plant 7 uses state of the art sophisticated
machinery to produce press tools, die casting dies, plastic moulds, etc. it also designs &
manufacture press for high speed lamination presses, progressive dies, etc. formerly, it
supplied tooling only to the plants within the company. However, now it provides world
class tooling services to outsiders as well as the export market.
OFFICE AUTOMATION DIVISION:

The manufactures & markets electronic & computer related product like
electronic typewriters, printers, computers, CAD / CAM related software are located in
plant no 19.
B) GODREJ APPLIANCE LIMITED:

Which is housed in plant no 2, 3 & 5, is a company & manufactures
Refrigerators Of late it has begun marketing washing machines as well & will be
producing a wide range of white goods.

C) GODREJ & KIS LTD:

Western region & export office, (plant no13) is a new venture in the field
of the manufacturing of photographic & related equipment.
D) GODREJ PACIFIC TECHNOLOGIES LTD:

This company deals in trading of software & peripherals.
E) GODREJ HI CARE LTD:

A new company is India's largest home insecticide company &
world’s largest manufacture of mastic repellent mats.
F) GODREJ SOAPS PRIVATE LIMITED:
It manufactures a wide variety of toiletries like soaps, shampoos, shaving

creams etc., and is a market leader in this field.
G) GEOMETRIC SOFTWARE SERVICE LTD:
It is collaboration with an Australian firm and deals in software Services.
H) GODREJ TELECOM LIMITED:

It manufactures and markets designer telephone instruments.Godrej has
implemented Baan ERP (enterprise resource planning) package in all its plants. The
Godrej name wields powerful influence even in today's rapidly transforming social and
economic environment. As it strides ahead confidently, discovering diverse new roles for
itself, it gives direction to others.
It is the bridge between the future and a hundred years of history. It is a
living code of ethics for Indian industry as it races ahead.

THE GODREJ HISTORY IN BRIEF
• 1897: Seth Ardeshir Burjorji Godrej at the age of 29 switched from law to locks
making & founded the company at Lalbaug. Expansion & his younger brother
Seth Pirojsha Burjorji Godrej activated diversification.
• 1902: Safe /security equipment manufacturing started.
• 1918: Soaps was incorporated.
• 1923: Office systems storwel cupboards, tiling cabinets manufacturing started.
• 1936: Seth Ardeshir expired at the age of 68.
• 1942: Mechanical presses & press brakes manufacturing started.
• 1948: Vikhroli land acquired
• 1951: Cupboard & office Systems manufacturing shifted to Vikhroli.
• 1955: Manual typewriter manufacturing started.
• 1958: Refrigerator manufacturing started.
• 1961: Forklift truck manufacturing started.
• 1962: Service Division started.
• 1965: Steel foundry started.
• 1972: Seth Pirojsha expired at the age of 90.
• 1976: Process Equipment division started.
• 1982: Security Equipment division shifted to Vikhroli in plant-17.
• 1985: Electronic typewriter manufacturing started.
• 1990: Seth Navroji Godrej expired at the age 73.
• 2000: Seth S.P. Godrej expired at the age of 88.
• 2003: Godrej kept its first step in aerospace industry. Seth Jamshed N. Godrej
received the PADMABHUSHAN award.

LIST OF ALL PLANTS WITH THEIR ACTIVITIES:
PLANT NO. ACTIVITY
01 ELECTRICAL & ELECTRONICS SERVICES
04 OFFICE FURNITURE (O.E. DIVISION).
07 TOOL ROOM, AEROSPACE
08 TOOL ROOM. & NUCLEAR DIVISON
09 MACHINE TOOL DIVISION, AEROSPACE
11 CORPORATE SERVICES.
13 STORWEL BUSINESS SOLUTION. (O.E. DIVISION).
14 SEATING SYSTEMS PLANT (O.E. DIVISION).
15 PRECISION EQUIPMENT DIVISION (P.E.D).
16 FORKLIFT MANUFACTURING (M.H.E)
17 SECURITY EQUIPMENT (O.E. DIVISION).
18 A LOCK MANUFACTURING (LOCK DIVISION).
19 MACHINE TOOL DIVISION, P.E.D.

INTRODUCTION TO THE PLANT
ELECTRICAL & ELECTRONICS SERVICES

(PLANT NO: 1)

1.2. INTRODUCTION TO THE PLANT
The name of the plant itself suggests its function. The plant is divided in seven
main sections,
1. ENCON Services
2. CAMS (Conserve Air)
3. DG/AC Section
4. TELECOMMUNICATION
5. ECD
6. PDS
7. ETSP
INTRODUCTION TO DEPARTMENT (DG/AC SECTION): -
 The DG/AC section looks after the central AC, window AC & refrigeration related
problems throughout the company.
 It also controls the supply of compressed air which is a major medium of input
required for production in a production-oriented company like Godrej.
 The DG section also supplies the west side of Godrej (pl-7, 4, 1, 12, 19) with
electricity on Saturday when there is no power supply from the TATA.
Power supply: -
The major job during the weekdays is of maintenance. The section carries
out regular scheduled maintenance for the AC plants, preventive maintenance for the
screw air compressors and the diesel generators. On the whole the DG/AC section plays
an important role in the better functioning of the company.

LAYOUT OF DGAC

ASSIGNMENT NO. 01
STUDY OF DIESEL GENERATOR

2.1 INTRODUCTION OF ENGINE
Description of Engine
The Daihatsu DS-28 Type Diesel Engine takes pride in excellent

performance and enduring characteristics as special emphasis has been placed in its
simple and sturdy construction, easy operation compact size, light weight and high
output.
Many of this type engines have been supplied to the world market as
marine propulsion engines, auxiliary engine and stationary engines. The engine make is
of Daihatsu Diesel Mfg Company Ltd Osaka, Japan.
Notation of types:
Example 6 DS (M) – 28 (L) (F)
6 : Number of cylinder.
DS : Medium speed, Vertical in line high supercharged.
(M) : Marine propulsion engine.
28 : Cylinder Bore (cm).
(L) : Modified for reverse rotation.
(F) : Modified for power takeoff from front end.

\
2.2 SPECIFICATION OF ENGINE
Model Unit 6DS – 28

Number of Cylinder 6
Cyli. Bore * Stroke MM 280 * 340
Engine Speed r.p.m. 750
Maxi. Continuous Rating PS 1800
Break Mean Effect. Press. Kg/cm2 17.19 – 17.20
Pmax Kg/ cm 2 115
Net Weight Kg 16,000
Height MM 2,705
Width MM 1,690
Length MM 3,785
Piston Overhauling Height MM 2,290
VALVE TIMING
Intake Valve Open Before T.D.C 700
Close After B.D.C 350
Clearance (Cold State) 0.52 mm
Exhaust Valve Open Before B.D.C. 500
Close After T.D.C. 600
Clearance (Cold State) 0.52 mm
Starting Rotary Valve Open O0
Close 1250
Fuel Pump Before T.D.C. 27 0

Injection Pressure 270 kg / cm 2
Lubricating oil pressure 3 kg / cm 2
Piston cooling oil pressure 2.5 kg /cm 2
C.W Temp. Engine outlet 70 0
Firing order 1–2–4–6–5–3

AUXILIARY EQUIPMENT
ITEMS TYPE REMARK
Turbocharger Exhaust Gas Turbocharger
Inter cooler Fin Tube Type
Governor Hydraulic Governor RHD 6
Fuel oil injection Pump Bosch Type
C. W. pump Separation type
L.O Pump Gear Type
F.O. Feed Pump Gear Type
Rocker Arm Lub. Pump Trochoid type
Nozzle Cooling oil pump Gear Type
L.O. Cooler Multi tubular Type
F.W.Cooler Multi tubular Type
F.O.Filter (Diesel side) Notch – wire type 200 mesh
L.O. Filter (full flow) Gauze- wire type 100 mesh
L.O.Filter (Bearing) Notch- wire type 200 mesh
Rocker Arm Lubri. Filter Laminate type 200 mesh
Nozzle cooling oil filter Laminate type 200 mesh special
Rocker Arm Lub. Oil tank Capacity 17 L
Leaked oil tank Capacity 10 L
Turbocharger Lub. Oil Capacity 1.5 L
Governor Lub. Oil Capacity 1.3 L

ALTERNATOR SPECIFICATION
PHASE 3PH 02 OUTPUT 1100KW
VOLTS 6600V 04 HERTZ 50Hz

EXCITATION ARMAYURE
120 V 06 1Y
VOLTAGE CONNECTION
ARM. INS. TOTAL
F 08 6600KG
CLASS WEIGHT
POLES 8 10 AMPERE 1203
FIELD AMPS 170 12 AMB. TEMP. 48

FIELD INS.
F 14 RPM 750
CLASS
2.3 DESCRIPTION OF ENGINE
The engine having following main part:

 Sole plate and frame
Sole plate is made up of cast iron. The sole plate and frame are firmly
jointed to each other by means of stud bolt .a water jacket is formed in between the
upper part of the frame. The crankcase is provided in between the lower part of the
frame. The crankcase has large window to inspect the main bearing shell, connecting
rod and other main part. The engine frame has safety valve and also mist gas outlet

hole. The crankshaft is located in the center of the frame. The sole plate is of dry
sump type, which does not store oil.
 Crankshaft
The crankshaft is made of high grade forged steel one piece type .for wear
prevention the bearing part is treated by high frequency hardening
 Main bearing shell

The main bearing shell is made up of aluminum alloy bearing lined, split
in two type mild steel. It is completed thin shell type. But be sure to replace the upper
and lower bearing shell at times as a pair.
The bearing shell in between the last cylinder and the timing gear function
also as receiver for the thrust bearing. The thrust bearing is inserted in between the
side of the main bearing housing and the crankshaft.
 Piston, Piston pin and Piston ring

The piston is built up type. Consisting of crown made up of forged steel
and a piston body is made up of cast iron. Piston cooling is performed in the cocktail
shaker type cooling oil chamber. There are three piston rings at the crown; one oil
ring at each upper and lower part of the body and a piston pin is inserted at its center.
The piston pin is made up of carburizing hardening chrome molybdenum steel. At
both end of piston pin the piston pin cap of aluminum are inserted. These caps not
only serve as the stopper for pin but also prevent lubrication oil from coming up
through the gap between the piston pin and the piston pin boss. Only the top piston
ring is chromium plated so as to minimize the wearing of the cylinder liner and ring
itself.
 Connecting rod and Crank pin bearing shell

The connecting rod is made of forged steel. It has a piston pin bush at it
small end and a crank pin bearing shell at its big end. It cross-section is I shaped.

The big end is split aslant into two with serrated surface and is fixed firmly by mean
of two crank pin bolts. The piston pin bush is mad up of forged cylindrical steel
babitted with lead bronze. The crank pin bearing shell is of aluminum alloy bearing
lined completed thin shell type.
 Cylinder liner
The cylinder liner is made up of high grade cast iron and is precisely hone
finished. It is so called wet liner forming a water jacket between the liner and the
engine frame .at the lower part, O-ring is inserted in its periphery so that no water
may leak into the crankcase.
 Cylinder head
Cylinder head is made up of high grade cast iron it has at it center the fuel
nozzle around which two pieces of intake and exhaust valve rocker arm, rocker arm
shaft holder starting valve cylinder safety valve and indicator valve are provided
 Intake and Exhaust valve

Both intake and exhaust valve are of mushroom type of heat resisting steel
and are provided with valve rotator .the intake valve seat is of special cast iron, the
exhaust valve seat is sheltie fuse plated. The valve spring is of double coil type. A
split in two-type cotter is inserted into the spring retainer to retain the spring and also
the valve.
 Cylinder safety valve and Indicator valve

When the combustion pressure inside the cylinder goes above the
specified limit the cylinder safety valve opens automatically to blow gas. The
indicated valve is constructed as one block with the safety valve.
 Camshaft and Cam

The camshaft is made up of carbon steel. It is driven at ½ rotation of that

of crankshaft. The camshaft bearing shell is white metal lined completed thin shell
type. The intake and exhaust cam are all of chrome molybdenum steel and
carburizing – hardened where they are come in contact with the roller. The fuel cam
is so constructed that as to revolve around the camshaft so that the slight adjustment
for fuel injection timing can be achieved.
 Fuel Injection Pump

The Bosch type fuel pump is used. The rotation of the plunger having a
slanting cut adjusts the fuel oil quantity. Each cylinder has a pump installed on the
fuel oil pump mount, which is set in the fuel tappet hole on the frame like the intake
and exhaust tappet. The fuel pump is so set as to adjust the fuel tappet push rod shim
so that when the tappet roller is on the base circle of the fuel cam. The graduation on
the oval shaped window on the pump to indicate the base circle may accord with the
graduation on the plunger guide.
On the oval shaped window of the fuel injection pump there is the
graduation to indicate starting of injection beside the graduation to indicate the base
circle. When the plunger lifts to this graduation it mean that the fuel cam come to
position to begin fuel injection and fuel injection pump start from this graduation to
inject fuel accordance with the characteristic of cam profile.
 Nozzle And Nozzle Holder

The fuel oil forced out of the fuel pump goes through the F. O. injection
pipe, notch filter of the nozzle holder, passes the passage inside the nozzle holder and
finally will reach the nozzle equipped at the top. When oil pressure increases it will
over come the adjusting spring force of the nozzle holder to push up the needle valve
and thus fuel oil will be injected into the combustion chamber in a finely atomized
state, through the nozzle. As soon as the plunger reed of the fuel pump comes in
contact with the escape port the oil pressure inside the F.O. injection pipe and nozzle

will suddenly drop and the needle valve will be automatically closed by mean of the
spring force
 Governor
The Hydraulic governor (Diesel KIKI’s model RHD- 6) is used.
 Fuel oil control Mechanism

With the stop lever the engine can be stopped during running irrespective
of governor operation and revolution control can also be achieved for some extent.
When the stop lever is set at’ stop ‘ position the stop lever provided at the end of stop
lever shaft pushes down the control rod lever thereby makes the common rod totally
inactive and at the same time set the rack of the fuel injection pump at ‘NON FUEL
INJECTION’ position.
When it is set at “RUN” position, the stop lever will detach the control
rod lever and make it free. Thus the fuel rack follows the governor movement. Beside
“RUN” and “STOP” position, “START” position is also prepared for the stop lever.
When the engine is to be started the stop lever is to set always at this position. Pay
attention to this matter well especially for generator engine in which if it started with
the stop lever set at RUN position the engine revolution may rise up to the rated
revolution in instant to cause the trouble at the break in operation. When the engine is
started move the stop lever gradually to RUN position giving enough heed to the
revolution.
 Starting Devices: -
Starting Valve:
By using pneumatic pilot valve compressed air is made to operate the air
piston thereby moving the starting valve.
Starting Rotary Valve:

The starting rotary valve is driver by Oldham’s coupling through the

camshaft. With the starting valve opened and closed compressed air which entered
the rotary valve will be passed on to the starting air valve of each cylinder which is
now in expansion stroke, at the instant the hole of rotary valve driven by the camshaft
overlap the fixed hole of the rotary valve seat leading to the starting air valve of each
cylinder, depending on a present crank angle.
Starting Air Valve:

The starting air valve is an automatic valve installed on the cylinder head.
Usually it is closed by spring force. When the pressure air passing through the
starting rotary valve actuates it, it is forced to open and let the compressed air go into
the cylinder. The starting air valve of this engine is of pilot type in which the air
conducted from rotary valve actuates the valve to let the air from the starting air valve
in to the cylinder.
 Fuel Oil Service Device
Fuel Oil Feed Pump:

The fuel oil feed pump is of gear type, and is driven by a gear located at
the front end of the camshaft. On the suction and delivery side of the fuel pump there
are steel ball check valve, which will open by the difference in gravity, if priming the
engine with fuel oil is performed with the valve being kept open. Thus filling engine
with oil can be performed without running the fuel oil feed pump. This check valve is
kept closed automatically during operation by the delivery pressure.
Fuel Oil Filter:

The fuel oil filter is of 200 mesh notch wire, blow off operation by the
operator can use both side, or either side or select blow off operation by the handle
operation by resorting to the changeover switch. However the one side use should be
limited only for overhaul cleaning time.

Fuel Oil Pressure Relief Valve:

The fuel oil pressure relief valve is installed at the end of the fuel oil main
pipe and function to control the oil pressure inside the main pipe. Since the delivery
pressure of the fuel feed pump acts against the spring force of the fuel oil pressure
relief valve, the pressure inside the fuel oil main pipe is maintained always at higher a
degree than of the outside pressure by the degree of spring force.
 Lubricating Devices : -
Lubricating Pump:
The internal gear type lubricating oil pump is installed on the front part of
the engine. It is equipped with a safety valve to protect it from excessive pressure.
Lubricating Oil Cooler:

The lubricating oil cooler is of multiple tube type in which the lubricating
oil runs over the peripheries of the tubes while the cooling water runs inside the tube.
The lubricating oil travels a zigzag course between the baffle plates and will be
cooled off.
Lubricating Oil Pressure Relief Valve:

The pressure in the each branch oil going to the bearing system, piston-
cooling system is adjusted at each required pressure by the relief valve. Lubricating
oil led out from the lubricating oil cooler enters the relief valve and flows into the
bearing cooling system first. When the oil pressure reaches about 2 kg/cm 2, it begins
to flow to the piston cooling system. The oil pressure at the bearing cooling system
and piston system can be adjusted by the oil pressure adjusting screw. The viscosity
of lubricating oil changes considerable as temperature changes. Therefore the

pressure relief valves also play the role of safety valve at the time when the viscosity
is higher so that the oil temperature is lower.
Lubricating oil filter:

The lubricating oil filter provided in between the lubricating oil pump and
the lubricating oil cooler. Through this filter all oil passes.
 Turbocharger
The turbocharger is of the exhaust gas turbine type. Cooling of the
turbocharger is performed by a branch water between the water inlet main pipe of the
engine jacket and the water outlet main pipe.
 Intercooler
The intercooler is of fin type and is installed opposite to the turbocharger.
The outer surface of the air-cooling pipes is provided with a quantity of fins, and the
cooling water flows inside the pipe.
 Gauges
The following vibration proof gauges are provided on the board of the
engine:
• Tachometer: Mechanical Type, driven by flexible type
• Lubricating oil pressure gauges (bearing)
• Lubricating oil pressure gauges (piston)
• Cooling water pressure gauges (jacket)
• Cooling water pressure gauges (cooler)

• Cooling water pressure gauges (valve seat)

• Intake air pressure gauges
• Rocker arm L.O. pressure gauges
• Exhaust Thermometer
• Lubricating oil cooler inlet and outlet
• Cooling Water Thermometer: Each Cylinder outlet, inlet main pipe, valve cooling
water main outlet pipe.
 Piping System
Starting Air Line:

Starting of the engine is made by the compressed air. With the valve of the
air receiver opened and the starting control valve button being pushed down,
compressed air flows out from the air receiver to the starting valve, the starting rotary
valve, and to the starting air valve in the order named, and then compressed air will
be distributed to each cylinder in the functioning process in the firing order.
Fuel Oil Line:

Fuel oil is forced to circulate in the engine in the following order
Fuel oil tank – Fuel oil feed pump – Fuel oil filter – Fuel oil main pipe – Fuel oil
injection pump – Fuel oil injection pipe – Nozzle and than it will inter into the
cylinder according to the firing order.
By means of the pressure relief valve provided at the end of the fuel oil
main pipe the excess oil will be returned to the fuel oil tank.

Lubricating oil lines:

After circulating the lubricating oil in the following will drop in the sole
plate. Oil sump tank – L.O. Pump – L.O. Cooler – L.O. Pressure relief valve after
above order it will go to the following branches A. Bearing lubricating oil main pipe,
main metal, crank pin metal, camshaft metal, Tappet surrounding, Governor
surrounding, Idle gear bush, timing gear, piston cooling lubricating oil main pipe,
telescopic pipe, piston, piston pin bush.
Rocker Arm Lubricating Oil Line:

Oil in the rocker arm supply line goes in the following order.
Rocker arm lubricating oil tank:

Trochoid pump – oil filter – supply oil main pipe – rocker arm shaft bush
– rocker arm end – push rod seat returning main pipe – rocker arm L.O. tank.
Cooling Water Line:

The standard cooling water line is divided in to two part , the jacket line
and cooler line.
Jacket water line goes in the following order: Fresh water cooler – cooling
water pump – cooling water inlet main pipe – cylinder jacket – cylinder head –
turbocharger – turbocharger cooling water outlet cock – cooling water outlet main
pipe
Cooling water in the cooler line circulates in the following order: The
lubricating oil cooler – inter cooler and fresh water cooler and is discharged.
Exhaust Valve Seat Cooling Water Line:

A branch cooling water line is prepared for cooling the exhaust valve seat.
For this purpose fresh water should always used. It goes in the following order:
Exhaust valve seat cooling water inlet main pipe – Exhaust valve cage – Exhaust
valve seat cooling water outlet main pipe – fresh water cooler.

Nozzle Cooling Line:

If the heavy oil (B) be used the nozzle will be cooed. For cooling nozzle
the heavy oil A is to be used. As a standard the nozzle cooling line is independent and
closed one. The order is: Separate cooling oil tank – Nozzle cooling pump – oil filter
– oil cooler – cooling oil inlet main pipe – nozzle- cooling oil outlet main pipe –
nozzle cooling pump.
FUEL OIL
The fuel oil used is having following characteristics
Heavy oil A Heavy oil B

Specific Gravity 15/4 C 0.85-0.90 0.92 under
Viscosity RW #50 C 35 ~ 50 120 under
Reaction Neutral Neutral
Flash Point C 60 ~ 90 60 ~ 100
Pour point C -5 under 5 under
Carbon Residue ( % ) 0.5 under 5 under
Water content 0.1 under 0.5 under
Ash (%) 0.01 under 0.02 under
Sulphur (%) 1 under 2.0 under
Lower Calorific Value 10,000 more 9,800 ~ 10,200
Kcal / kg
If the temperature of fuel oil at engine inlet is excessively low (below 10)
or excessively high (above 50) viscosity adjustment is required.
COOLING WATER

It is desirable to keep cooling water in the following condition -
General condition Clean & Clear

P.H. 6 ~ 8.5
Total Hardness (CaCO 3 ppm) 100 ppm & under
Chrorine Ion Density 100 ppm & under
Total Salt 250 ppm & under
2.4 MAINTENANCE OF PARTS
Overhaul, Inspection and Cleaning of Cylinder Head

Carbon accumulation inside of the cylinder head may result in bad combustion,
distortion or crack of the cylinder head due to high temperature. Therefore periodical
overhaul and cleaning are inevitable.
Overhauling Process
1. Remove the cover of the cylinder head cover.
2. Remove the fuel oil high pressure pipe.
3. Remove the valve rocker arm shaft holder.

4. remove the cylinder head cover

5. Remove the push rod.
6. Remove the push rod protective tube.
7. Remove the cooling water outlet cock.
8. Remove the nozzle holder.
9. Remove the exhaust manifold fitting bolt.
10. Remove the intake manifold.
Extraction, Inspection and Measurement of Piston: -

The extraction interval for piston is basically 4000~7000 HR but it is advisable to
judge the timing for extraction by the lubricating oil consumption. When the lubricating
oil consumption ratio increases to double the usual ratio, it is time for extraction and
inspection of the piston.
Process for disassembling: -

1. Remove the set bolt for the connecting rod bolt rock-washer and take out the
rock-washer.
2. Set the crank pin at 20 ~ 30 off the top dead center in the regular rotation
direction of the crank, and pull out the connection rod bolt.
3. Take off the connection rod cap by the tool holding the larger end of the
connection rod.
4. Attach the piston extracting tool on the top of the piston and lift it up.
5. When the piston pin is extracted out of the cylinder liner, attached the piston
pin holder tool.
6. Place the piston at predetermined place and pull out piston pin cap. Pull out
the piston pin while supporting the connection rod.


Process for assembling: -

1. Assemble the piston pin and connection rod.
2. Insert the piston inserting frame into the liner top part.
3. Attach the piston extraction tool at the upper part and extract it.
4. Place the crank pin at the same position before disassembling, and insert the
crank pin gradually into the liner using the piston inserting frame as a guide.
5. Insert a connecting cap from the bottom, and tighten the connecting bar rod
with a specified torque to prevent slippage.
• Remove connecting rod cap
• Attach piston pin holder.
• Attach piston insertion frame.

Overhaul and inspection of Piston: -

When the piston is extracted, check whether sludge is seen on the inner surface of
the piston cap. If the disassembling is quite necessary perform in the following order.
Process for disassembling
Extract the piston rings and oil rings upwards one by one.
1. Remove piston crown bolt, check pin, washer and U-nut. and then, remove
washer to take out bolt and distance pieces.
2. Remove piston crown bolt.
3. Remove crown.
4. Remove O-ring.

Crank Pin Bearing Shell : -

1. When detaching the crank pin bearing shell from a connecting rod, lightly tap the
notch side of the bearing shell with a piece of wood to have a gap between the shell and
the bearing housing.
2. In order to ensure that the crank pin bearing shell maintains close contact with the
surface of the housing, the crank pin bearing shell has proper crush and tension. Refrain
from employing files or scrapers at any time.
3. On assembling the crank pin bearing shell into the connecting rod, wipe out dust
or foreign matter thoroughly. Tap the center part of the bearing shell by hand few times
to have it fit with the housing.

Inspection and Measurement of Cylinder Liner: -

1. The average lifetime of the cylinder liner is 6-8 years in the engine with fresh
water cooling system. Although the extent of its wear per 1000 hours is
3/1000mm~5/100mm, since this varies largely by the kind of fuel oil in use and
supervisory condition of the lubricating oil, every care should be taken as
regards the supervision and control of these oils.
2. Remove the carbon stuck to the cylinder liner when overhauling and inspect and
measure each part with care
Process for measurement: -

Set the liner abrasion measuring place gauge at the crankshaft direction and at the
rotation direction. Measure the abrasion extent by means of a cylinder bore gauge.
Process for extraction and attachment: -

1. Extraction and attachment of cylinder liner are to be performed by using the
cylinder liner extraction tool in the following way.
2. Be sure to have the telescopic tube retainer removed.
3. At the time of extraction, be sure to give tally incisions on the engine frame and
liner to ensure correct tallying at the time of reassembling.
4. When assembling meet mark line(cylinder centre, crankshaft direction) on the

top side of frame to the mark line on the side of liner.
5. When reassembling, replace the upper packing and O rings every time.

Measurement of Crankshaft Deflection: -

Excessively large deflection of crankshaft may sometimes cause breakage of the

crankshaft. Therefore measurement of crankshaft deflection should be done at the time of
installation of the engine and every six months after it is put into operation. Measurement
should be done when the crankshaft is in the cold state.
Process for measurement: -
1. Set the crankshaft at 30 deg. to the bottom dead center and apply the deflection
gauge.
2. The position for application of the deflection gauge should be the dot where the
extension line of the journal external circumference crosses the centerline of the
crank web.
3. Set the graduation to ‘0’. Turn the crankshaft in the reverse direction this time.
Read the graduations at each angle of the shaft-A,B,C,D,E.

STARTING OF ENGINE
When the engine does not start:

When the engine does not start the operator should examine the major check
point given below. The engine is at easiest position for starting when the flywheel passé s
its TDC by approximately 20 degrees.
When the engine does not revolve:

Pressure of the air receiver may be low.
Piston may at top dead center.
Air leakage at the starting rotary valve or defection of the valve itself.
Sticky or leaky valve.
When the engine may revolve but no combustion takes place:

Insufficient desecration in the fuel oil line.
Not enough fuel in the rack to ensure starting (fuel level must be 13 th mark on the rack at
the time of starting)
The engine may not be free of load.
When the cylinder safety valve blows:

Due to the defective fuel oil nozzle.
Opening pressure of the safety valve may be low.
Dust accumulated on the safety valve seat.
Fuel oil cam is not well fit or the tally marks of the timing gear are not well matched.
Over-cooled engine.
Fuel rack not fully arranged.
WHEN THE HUNTING EXISTS?

When the deviation of the tachometer after the starting stays large:
Defective tachometer is of flexible wire.
Uneven combustion due to insufficient warming up.
Fuel injection pump rack and common rod may be too tight.
There is F.O. cut cylinder or fuel rack not fully arranged
Governor out of order.
Insufficient air- bleeding of F.O. lines.
Abnormal Sound Immediately After Starting:

Uneven combustion due to insufficient warming.
Fuel injection pump or nozzle out of order.
Intake or exhaust clearance out of order.
Sticky exhaust or intake valve.
Broken exhaust or intake valve spring.
When the exhaust gas shows abnormal color?

The resistance in the turbine outlet exhaust manifold may be excessive.
Due to an extended period of idle operation, oil deposits may be accumulated in the
exhaust manifold.
Inferior fuel oil.
Fuel oil nozzle.
Combustion pressure.
Excessive circulation of lubricating oil.
Wearing of piston ring or oil ring interference of sludge.

Turbocharger may be soiled considerably.
Overload
Intermixture of air or moisture into fuel oil, filter clogged.
Timing of the operation of intake and exhaust valves affected by clogging or gas leak.
When engine revolution hardly rises to the prescribed rate:

In this case, if the engine revolution is low compared with the temperature
of the exhaust gas:
a.) Propeller may be damaged.
b) Revolution may be low due to too dirty turbocharger
c) Intake manifold is clogged.
d) Combustion pressure is decreased.
e) Excessively worn injection pump plunger.
f) Piston liner is out of order.
g) Bearing friction plate of reduction gear and other sliding section are out of order.
When the fuel rack register is disorder.

When the fuel register a high consumption the exhaust temp. does not rise too much.
Insufficient desecration of fuel system intermixture of moisture.

Fuel oil filter or pipe clogged.
Leakage from delivery valve packing of the injection pump.
Injection pump plunger is worn out or delivery valve is out of order.
Joint of the F.O. injection pipe may not be working satisfactory or the pump may be
cracked.
CLEANING OF TURBOCHARGER
The dirty blower might result in the bad efficiency of the turbocharger, the
lower pressure of the intake air and in the higher temperature of the exhaust gas. Clean it
in accordance with the method mentioned below. So if the intake air pressure is found
difficult to be returned to the normal value even after the cleaning is done duly, it is
necessary to overhaul the turbocharger and clean it thoroughly.
a) Inject the cleaning liquid into the blower syringe (Quantity of the cleaning liquid 500
cc, injection time 20 – 60 sec)
b) Set the Cyringe in accordance with the drawing.
c) Open the drain cock provided under the intake manifold during the cleaning.

d) After injection of cleaning liquid inject the fresh water of the same quantity by the
same method and close the drain cock of the intake manifold.
NOTES
• Keep the engine load more than 75 % and after cleaning operate the engine with
load at least 1 hour.
• Clean the blower at least every 200 – 300 hour running.
• Use the cleaning liquid recommended by the company.
STOPPPAGE OF ENGINE
A) STOPPAGE
a) If the engine is operated with heavy oil B be sure to operate it with heavy oil A before
stoppage.
b) Inspect the every section of the engine at the time of stoppage to ensure that no trouble
will occur at the time of starting.
c) Stop the engine in unloads stage.
In an engine with turbocharger ascertain that the turbocharger is stopped

smoothly although the time required from the stoppage of the engine to that of the
turbocharger generally 2 – 4 minutes.
After the engine has been stopped open the indicator valve and the engine
turn the several times so that the combustion gas will discharge.
Leave the cooling water undrained until the engine is completely cooled.
It is important to drain the cooling water from the engine and turbocharger when the
stopping time is accepted to be prolonged. Since the water pressure is higher than the oil
pressure at the stopping time, water may leak to the lubricating oil tank. Special care

should be taken in wintertime, since the cooling water is liable to freeze and cause and
accident.
B) CESSATION
When the cessation is accepted to be prolonged to a considerable extent,

take rust preventive measures on the engine. Apply grease to the exposed machine-
finished portions cover the cylinder head.
Operate the engine more than once a week for 10 minute so that
lubricating oil film may not be cut. When operation is unable make turning for several
time to change the contact position of piston bearing shell, cam etc.
Apply proper cover to the exhaust silencer, cleaner of turbocharger and
mist gas vent to water from making its way to them.
Apply cover over the electric equipment as a whole so that the insulation resistance may
not be impaired.
WHEN THE ENGINE MUST BE STOPPED IMMEDIATELY?

• When an abnormal sound is heard at working parts.
• When smoke is observed at bearing and other working part.
• When the lubricating oil pressure drops suddenly.
• When the lubricating oil pressure has risen suddenly.
• When the engine revolution has increased rapidly due to failure of governor or
fuel injection pump.
• When the supply of cooling water has stopped an immediate supply cannot be
provided.
• When the temperature of the cooling water raised to high and any adjustment
therefore is ineffective in lowering it.

• When any damage or looseness of the stop screw or bolt of the working part is
detected.
• When the piping for fuel oil, lubricating oil or bolt of the working part is detected.
• When the water leakage in the lubricating oil is detected.
• When the revolution of the turbocharger is decreased or the exhaust gas
temperature has rise to an abnormal extent.
• When the propeller or its shaft is out of order.

ASSIGNMENT NO: 02
STUDY OF CENTRAL AIR CONDITIONING

SYSTEM

3.1 INTRODUCTION TO AIR CONDITIONING
The application for industrial purpose has opened a new area in the air-
conditioning industry. The air-conditioning is commonly used now a day for the
preservation of food in automobiles and railway, jute and cloth industries and many
others. Its varied application has opened a new field for the air-conditioning engineers to
solve the problems with full success. Air-conditioning is commonly used to ease mans
environmental problems on earth and in a space.
The refrigeration and air-conditioning industry in India got the impetus to

progress with the dawn of independence in India. This industry has achieved phenomenal
growth in less than three decade in our country. The annual output has increased from
800 tons to the 80000 ton in 1970. This industry is now produces a wide range of light
and heavy equipment which has reduced the import from 50 to 5 percent Air-
conditioning industry in India now produces packed air-conditioner, water chilling unit
upto 200 tons capacity, hermetic compressor air handling unit cooling coil and variety of
other equipment apart from well known items like room air-conditioner, refrigerator deep
freezer food display unit and water cooler. This forms a solid base to satisfy practically
all need of refrigeration and air-conditioning equipment in the country.
An engineer can confidently tackle any problem in the design of

refrigeration and air-conditioning equipment used for different purpose They have proved
their competence by successfully designing complicated job like cooling system for
concrete dams defense installation dairy milk chilling unit railway air-conditioning quick
freezing plant for fish and deep freezers for storage of fish, air-conditioning and
refrigeration system for ship and many other. The nation is proud for increase in export
from Rs. 4 lakhs in 1955 to Rs. 60 lakhs in 1970. Presently, this industry has been rightly

placed on a priority list by the Government of India and national panel has been formed
to plan it development.
Indian atmospheric conditions are varied in different part of country.

Particularly the summer conditions in India are quite uncomfortable in most part of the
country. And winter conditions are uncomfortable in few part of country. No, doubt air-
conditioning will become a necessity for Indian in coming few decade with rapid
industrial development and with the economic growth of the country.
Air-conditioning is the application of refrigeration; with the working

substance is moist air. Air-conditioning means the conditioning of air or the combined
effect of specific condition of temperature, humidity, velocity and purity of air means
dust level inside the enclosed space.
Air-conditioning plays a key role in the progress of 20 th century. It is a

field of work, which never stagnates. Air-conditioning is commonly used for the human
comfort so that human being work harder and more efficiently, play longer and enjoy
leisure .Air –conditioning also proves its importance in development of industrial and
space progress.
It is widely used in military center to operate track & intercept hostile

missiles around the clock, Atomic submarines modern medicines exploration of space
and different types of industries .Air conditioning is the necessity for human life progress
and not a luxury.

3.2 PSYCHROMETRIC PROPERTIES OF AIR
 Relative Humidity:
It is ratio of actual amount of moisture present in one unit volume of dry
air at certain temperature to amount of moisture needed to saturate it at that temperature
is called as relative humidity.
 Absolute Humidity:
It is mass of water vapour present unit volume of dry air. It is expressed in
kg/ m3 of dry air.
 Specific Humidity:
It is the mass of water vapour present in 1kg of dry air. It is expressed as
kg/kg of dry air.
Dry Bulb Temperature (DBT):
The temperature of air as measured by an ordinary thermometer is the dry

bulb temperature of the air.
Wet Bulb Temperature (WBT):
It is temperature of the air measured by a thermometer when its bulb is

covered with the wet- cloth and exposed to atmosphere.
Dew Point Temperature:

It is define as temperature at which the moisture present in the air begins to

condense when air is further cooled.
Saturation Temperature:
The temperature at which the refrigerant of given pressure condenses or

vaporizes.
Enthalpy:
Enthalpy is the heat content of a refrigerant measured from the base

saturation temperature of 40°
Latent Heat:
Latent heat is the heat added or removed from a substance, which causes
change of state but without change in temperature.
Sensible Heat:
Sensible heat is the heat added or removed from a substance, which results
in change of temperature.
Super Heat:
Any addition or removal of heat to a liquid refrigerant and its vapour in

equilibrium in a closed container will only cause the liquid refrigerant to vapourize or the
vapour to condense. However if the vapourized refrigerant is separated from the portion
and the heat is added it will raise the temperature above the saturation temperature
corresponding to the pressure and the rise in temperature is the Super heat and the vapour
is called as Superheated.

Sub Cooling:
If the liquid portion is separated from the vapour portion and is cooled, then
any removal of heat will lower its temperature than the saturation temperature
corresponding to the pressure. The temperature drop is sub-cooling and the liquid is
called sub-cooled liquid.
Ton of Refrigerant:
One ton of refrigerant is equal to the amount of heat removed from one ton
of water at 0°c to ice at 0°c within a period of 24 hrs.
1TR = 3.54 kW = 210 KJ/SEC
Energy Efficiency Ratio:
Efficiency of the refrigerant can be measured in terms of following ratios.
Coefficient of performance (COP):
It is defined as the ratio of refrigerant effects and amount of energy spent,

where refrigerating effect is amount of heat removed / absorbed from the substance to be
cooled.
COP = Useful Refrigerating Effect
Net energy is supply from the external sources.
Specific Power Consumption:
It is the ratio of power consumption in (KW) and refrigerating effect in

TR.

Specific power consumption = Power Consumption (KW)

Refrigerating effect in (TR)
3.3 VAPOUR COMPRESSION AIR CONDITIONING CYCLE
A typical air conditioning system can
be described as follow.
When compressor is operating, it takes refrigerant gas at a relatively low

pressure and compresses it to a much higher pressure. In doing so, the gas temperature
rises because its heat energy has been concentrated in to much smaller volume. This state
is called as superheated, because the gas is at a higher temperature than the boiling
temperature for the exiting pressure.
The superheated gas is then passed through an assembly of tubing or coils,

called as a condenser, which has a relatively large surface area exposed to the cooler
ambient atmosphere. When the gas passes through the air-cooled condenser it gives up
the heat that it had accumulated during compression and condenses into a liquid.
The liquid refrigerant is then passed through a metering device, which

restricts the flow of refrigerant. A simple but effective metering device found in many air
conditioning systems is a length of smaller diameter called capillary tubing.
Since the high pressure liquid refrigerant encounters a restriction when passing
through the metering device, the pressure on the exit side of the device is relatively low,
and the liquid boils at a temperature indicated in the pressure / temperature chart.
In order for the liquid to change state, it must absorb heat from its heat from its
surroundings. The liquid refrigerant, passing through a series of coils called as
evaporator, causes the temperature of coils to decreases. The airflow through the
evaporator provides the heat necessary to vaporize the refrigerant. When the refrigerant,

now in gaseous state, leaves the evaporator, it returns to the suction of the compressor
where the cycle repeats.
3.4 AIR CONDITIONING SYSTEM
3.4.1. ROOM AIR CONDITIONERS
This is the simplest form of air conditioning system inside a casing suitable
for installation on windows or wall opening. The assembly incorporates a refrigeration
unit and a double shaft fan motor with fans mounted on either side of motor, one on the
evaporator side and other on the condenser side respectively. The room (or cooling) side
and the outdoor (or heat rejection) side of the unit are separated by an insulated partition
within the casing. The front panel with supply – and return –air grills and a door/opening
to get access to the control/operating panel on the unit face, is attached to the unit front at
the room side. The other components on the room (or indoor) side of the unit are, the
cooling coil with air filters mounted on it, the centrifugal evaporator blower, the
operating panel consist of selector switches, thermostat, knobs for fresh air and the
condensate drip and drain tray bellow the cooling coil. The outdoor side of the unit has a
compressor, condenser coil, fan motor and propeller for the air-cooled condenser. The
supply air grill on the front has adjustable horizontal louvers for adjusting the direction of
air up and down or horizontally. Vertical adjustable louvers are also provided in many
models to adjust sideways flow of air. The distribution of the cool and dehumidified
supply air to the room thus can be finely adjusted. Motorized (vertical deflectors are also
fitted in some of the air flow continuously to provide uniform distribution. The system
the consist of: the refrigerant system, the control system (thermostat and selector switch),
electrical protection system (motor overload switch and winding protection thermostat on
the compressor motor), Air circulation system (fan motor, centrifugal evaporator blower
and propeller fan for air- cooled condenser) and ventilation (fresh air damper) and
exhaust system. The refrigerant used is R12 or R22.

The evaporator fan sucks the air from the room to be conditioned through
the air filter and the cooling coil of refrigerant unit and delivers the cool and
dehumidified air back to the room. This air mixes with the room air and brings down the
temperature and humidity levels in the room to maintain the comfortable condition. Fresh
air is admitted through a damper and is mixed with the return air before passing it over
the air filter and the cooling coil. The filter mounted in front of the cooling coil, in
addition to the filtering the room air- fresh air mixture also helps to keep the cooling coil
fins and the tube surfaces clean to obtain optimum heat transfer capacity from the coil.
By incorporating a reversing valve, the unit can be used for heating the room during the
winter.
3.4.2. PACKAGE AIR CONDITIONER
This can be considered as bigger version of the room air conditioners and
are used for air conditioning loads beyond the capacity range of the room air
conditioners. They are available in the nominal capacities of 3, 5, 7, 10, and 15 tonne.
Like the room air conditioner, the package unit also houses the air filtering, cooling-
dehumidifying and air handling components and is factory assembled. Components for
heating and humidifying can also be included within the unit. The condenser can be of
water cooled type or the air-cooled type. The water-cooled type can be completely
factory assembled, charged (with refrigerant) and tested. Thus the laying of the
refrigerant piping, pressure/leak testing, evacuation, charging, etc. need not have to be
carried out in the field. This not only reduces the field labour, but also ensures the cleaner
system, being assembled in factory with the strict quality procedures.
The air-cooled type obviously cannot be factory assembled and charged.

Laying of refrigerant piping between the indoor and the outdoor unit, pressure testing,
evacuation, charging, etc. have to be carried somewhere in the field. Because of the
scarcity of the water, air cooled unit are favoured, though their capacity will be less than
that of water- cooled condenser using the same compressor. For the evaporator side,
centrifugal fans are provided which can develop higher static pressure. So air distribution
ducts and grill can be connected to the unit. Resin bonded fiberglass mats are firm set to

the inside surfaces of all the panels of the units for insulation. These mats also act as a
acoustic treatment to reduce noise level from the unit. A thermostat with its sensing bulb
is provided to cycle the compressor as per the setting desired. High/ low-pressure switch,
overload relays for all the motor, water flow and air flow switches are provided in the
units.
3.4.3. CENTRAL AIR CONDITIONER
The various component of air conditioning plant, namely the compressor

with its drive motor, condenser, Air Handling Unit (AHU) with its cooling coil, throttling
devices and interconnecting refrigerant piping are carefully selected and field installed.
The performance characteristic of each equipment should match with that of the whole
system capacity required ton handle the load.
The condensing unit (compressor with its drive motor and condenser) is
located in the plant room separated from air-conditioned space and air handling unit. The
air handling unit room is as far as possible, may contiguous with air-conditioned area. In
case Air Handling Unit has to be located away from the air-conditioned space, a duct will
have to be provided to carry the return air through the air-conditioned area to the Air
Handling Unit. Both the supply and return air duct has to be insulated, as they will have
to pass through non-conditioned areas. Hence the Air Handling Unit should be in
contiguous with the conditioned room.
The central air-condensing unit can be either of the direct or indirect

type. In the direct system, the air from the space to be conditioned is circulated over the
cooling coil in which the low-pressure liquid is boiling. The latent heat from the air is
being circulated over the coil. So this is known as Direct-Expansion (DX) system. In
Indirect Expansion system, chilled water or brine from the refrigeration plant is circulated
over the cooling coil located in the AHU to cool and dehumidify the room air. Such
system is also known as the Central Chilled Water (or brine) system.

• DX SYSTEM
The compressor and condenser (or condenser unit) of the refrigeration
plant are located in a plant room near the air-handling unit room. The cooling coil of the
refrigeration plant is fixed in the AHU. The suction and liquid lines connects the
condensing unit to the cooling coil. The compressor can be of the open or the semi-
hermetic type. In the case of the water-cooled system, the water-cooled condenser is
fitted to a structural steel framework on which the compressor and the motor are also
mounted, thus forming a compact condensing unit. In the air-cooled system, the air-
cooled condenser coil with its fan and fan motor can be located in the plant room if
sufficient area is available to allow for free flow of outside air for the air-cooled
condenser. It can also be fixed outside the plant room. The thermostatic expansion valve
is provided quite close to the cooling coil.
• CHILLED WATER SYSTEM

The compressor with its drive motor (or semi-hermetic compressor), the
water-cooled condenser and the chiller (evaporator) are all assembled in a structural steel
framework making a complete compact refrigeration plant, known as chiller package.
Since all the components of all the refrigeration system are assembled in one framework,
the refrigeration piping (discharge, liquid and suction lines) with the thermostatic
expansion valve, liquid line solenoid valve and line shut-off valve too becomes compact.
The chiller in the chiller package and the cooling coil/s in the air handling unit/s are
connected by chilled water pipes to a chilled water pump. This pump circulates the water
between the chiller and the cooling coil/s. To ensure that the compressor works only
when there is sufficient water flow rate through the chiller, a water flow switch is
provided in the chilled water line. The flow switch, which is connected in series with the
hold on coil of the compressor motor starter, makes contact only when sufficient water
flow-rate is established in the chilled water system. Flow switches are provided on the

water lines of the water–cooled condensers also as a safety control. Chillers can be of the
dry expansion (DX) or of the flooded types. Tank and coil arrangement connected to a
condensing unit is also used at times for producing chilled water. A typical layout of
central air conditioning plant with chiller system is shown in the fig.
• DX AND CHILLED WATER SYSTEMS - A COMPARISON

The DX system can be considered more efficient since the heat transfer is
directly between the air to be conditioned and the low pressure boiling refrigerant in the
cooling coil. In the chilled water system however, the heat -transfer is through the
secondary medium (chilled water) which in turn has to be cooled by the chiller. Further,
the chilled water gains some heat through heat transmission and due to frictional heat in

flowing through the chilled water lines and also by being worked upon ()pumped) by the
pump. Due of to this heat gain, there will be a slight rise in the temperature of the chilled
water during its flow from the chiller water outlet point to the inlet port of the cooling
coil and again from the outlet point of the cooling coil to the pump and then to the water
inlet port of the chiller. The temperature rise due to this heat gain will be extremely small
for example for a 80 ton chilled water system with about 100 to 150 meters of chilled
water lines insulated with 50 mm thick insulation material, the temperature rise due to
transmission and pump horsepower will be around 0.15º to 0.2ºC(0.25º to 0.35ºF). Also
the system consumes extra power for operating the chilled water pump, which is not the
case in DX plant. Further, the chiller package has to operate at a lower evaporating
temperature (i.e. lower suction pressures) than the DX system to maintain the required
chilled water temperature in the cooling coil, resulting in reduced plant capacity yet
consuming more energy to pump from the lower suction pressure to the same discharge
pressure thus the Bhp/TR goes up.
In the DX system however, the distance and height difference between the
condensing unit and cooling coil (i.e. air-handling unit) has to be kept to the minimum to
limit the adverse effect of pressure drop in the interconnecting refrigerant piping on the
capacity of the plant. If the condensing unit is at a lower level than that of the air-
handling unit, the effect of the height difference will be more pronounced in the liquid
line. The liquid pressure will have a pressure drop in lifting the mass of refrigerant liquid
against gravity, up the vertical height of the liquid line. The pressure drop will be 0.12
kg/cm2 per meter (0.5 psi/foot) of vertical lift of R-22 and 0.13 kg/cm2 per meter (0.55
psi/foot) of vertical lift in R-12 systems. With higher pressure drop in the liquid line,
flash gas is formed, which impedes the continuous flow of liquid in the line, thus
affecting the capacity of the plant.
If the condensing unit is at a much higher level that the air-handling unit, oil
movement up the suction line riser can become poor, resulting in oil return problems. To
overcome this, suction line of smaller diameter is used. However this in turn results in
higher pressure drop in suction line and consequent reduction in plant capacity. Therefore

in DX plants, the distance and height difference between the condensing unit and air-
handling unit will have to be kept small. In multi-storied or widely spread-out buildings,
due to structural limitations it necessitates laying of long lengths of refrigerant piping
with plenty of joints. Hence the pressure drop in the lines can increase. Moreover with
large number of joints, the possibility of refrigerant leakage is also increased. Hence a
DX system is not suited for such installations. For such cases central chilled water
systems offers the best selection.
Summarizing, DX systems are most suitable for installations where the

condensing unit and the evaporators/air handling units are not far apart. Plants with
multiple DX systems are commonly used to meet larger loads, so long as the condensing
units and their respective evaporators are in close proximity with condenser water system
common to all systems. In such multiple DX system plants, it is generally, preferred to
have a number of independent DX systems having a common condenser water system. If
a refrigerant leak occurs in a component of one system, the loss of refrigerant and system
capacity will be limited to that system only.
Though chilled water system requires more power per unit of refrigeration
(KW/ton), the system offers plenty of flexibility in selection, layout and operation. The
chiller packages can be located in a central plant room, away from the air-conditioned
space. The air-handling units too can be located at convenient locations at each zone/area
and interconnected to the chiller packages with chilled water lines. Multiple chiller
packages interconnected on the water sides (chilled water as well as well condenser water
systems) can be used for high loads. For loads exceeding 200 ton water chilling packages
with centrifugal compressors can be used, here again in multiples for handling higher
loads.

3.5 Building Automation System (BAS) Or Building Management

System (BMS)
The management of operation, monitoring, controlling and maintenance of all
these facilities and for economical and efficient operation (control of utilization of
energy) becomes quite complex. The Building Management System (BMS) is
management through centralized and computerized automation, monitoring and control
has made it easy and efficient.
Microprocessor based controls have helped improve the management and
control of all building services. The energy consumed by air conditioning and
refrigeration system constitutes a major portion (about 50%) of total energy consumed by
all the services in the building and so if their energy efficiency is maintained high, energy
utilization of building comes down. Integrating the chiller control panel with BAS has
vastly benefited the building services. The integrated BAS collects and analyses
operating data, helps in maintaining steady comfortable inside conditions ,saves energy
,controls inside energy, identifies trouble areas, sequences the operation of equipments,
prolongs their life, give the alarm when safety/security is threatened and accomplishes all
these with very much reduced manpower.
The chiller and the BMS manufactures work together for the development of
software to achieve proper integration between the control panel and BMS.
A simple example of the usage of the integrated BMS is the diagram of the
cooling system (denoting the components) is displayed on the computer screen and when
a pump is started and run; the respective symbol turns green to show that the equipment
is on, the data is constantly updated.
Some of the typical functions of the integrated BMS are detailed below:
Data Collection and Analysis: The BMS continuously gathers and displays operating
information from the complete building, required for the management of the building
such as temp, rh, equipments in operation, etc) and compares with the programmed
values and gives an alarm message when there is a deviation indicating a possible

malfunction / problem. The data collection starts only after the system stabilizes after the
start. Problems are identified and pointed out, while they are actually occurring and still
minor, thus enabling easy and early rectification. Monitors time of each equipment and
points out preventive maintenance schedule.
Sequencing operation of chiller package. Chiller package gives highest efficiency
while working on full load. So the optimal combination of chiller packages is selected to
meet the prevailing load. For instance, in a system of one 150TR chiller and two chillers
of 300TR each, the combination of each chillers are automatically selected and started
to meet the prevailing load, e.g. to meet a load of about 600TR, two of the 300TR chillers
are put on line or for a load of 450TR, one 300TR and 150TR chillers are started.
Management of Electrical Load: The equipments are put off when building is not
occupied-this is the simplest of energy management. An important function is ‘electrical
demand limiting’ by putting of selective non-essential equipments when the demand
target tends to get down. It provides historical data, which becomes quite valuable in
trouble shooting.
Security Alarm System: Displays the floor plan diagram-helps the security personal to
trace the movement of the intruder.
Man Power Saving: Eliminates the tedium of manually recording the operating data in
log sheets periodically.
Normally the operator has to move over to all the areas of the building to read and
record operating data (readings) manually, in the process mistake can creep in
reading/recording and further the time taken to cover the full building may be too long in
large buildings and so simultaneous reading of all data is not possible-that meant the true
picture of the operation does not get reflected when abnormal condition can be missed for
long period of time i.e. the rounds of the operator. With a BMS all these tedious,
inaccuracies, delays, loss of precious time, etc are completely eliminated and strength of
manpower too gets drastically reduced.

3.6 AIR CONDITIONING EQUIPMENTS
The basic equipment uses in the air conditioning cycle are as follows:
 Compressor
 Condenser
 Throttling devices.
 Evaporator
3.6.1. COMPRESSORS
These are used to compress the vapour refrigerant from the evaporator
and to vary its pressure so that the corresponding saturation temperature is higher than
that of the cooling medium. They also do the function of circulating the refrigerant in the
entire system. The different types of compressors as follows:
1. Reciprocating Compressors:
 Sealed or Hermetic Compressor

 Semi sealed compressor
 Open Type Compressor
2. Rotary Compressor:
 Screw Type Compressor
 Vane Type Compressor
 Roller Type Compressor
3. Dynamic Compressor:
 Centrifugal Compressor
 Axial Compressor

STAGING IN THE COMPRESSOR
Single stage compressor can be either used for water-cooled or air cooled
applications. This is because of the compression ratio. Single stage compressor are
normally suitable for evaporative temperature of around 30°C with condensing
temperature of +40°C to +45°C in case of the halocarbons such as R-22; the compressor
used for air conditioning application can’t normally go below (-5°C) evaporating to 60°C.
These are one suitable for air-cooled applications.
When lower evaporating and higher condensing temperature are required,

single stage compressor can be used, as the compression ratio required are much higher
than the capability of the single stage machines. These types of compressors are used
with various method of interfolding.
3.6.2. CONDENSER
The condenser is the important device in the high pressure side of the
refrigeration system. The function of the condenser is to desuperheat the high-pressure
gas, condense it and also sub-cool the liquid. Heat from the hot refrigerant is rejected in
the condenser to the condensing medium, i.e. air or water. The hot vapour refrigerant
consists of the heat absorbed by the evaporator and the heat of compression added by the
mechanical energy of the compressor motor. The heat from the hot vapour refrigerant in
the condenser is removed first by transferring it to the walls of the condenser tubes and
then from the tubes to the condensing or cooling medium. The cooling medium can be air
or water or combination of the two. The different types of condensers are as below.
1. Air Cooled Condenser:

 Natural convection

 Forced-Air Type
2. Water Cooled Condenser:

 Tube in Tube Type.
 Shell & Shell Type
 Shell & Coil Type
3.6.3. THROTTLING DEVICES
The Throttling (expansion or Metering) device is an important device the

high-pressure side and low-pressure side of the refrigeration system. It is connected
between the receiver (containing liquid refrigerant at the high pressure) and the
evaporator (containing liquid refrigerant at high pressure). The expansion device
performs the following functions:
1. It reduces the high-pressure liquid refrigerant to low pressure liquid refrigerant before
being fed to the evaporator.
2. It maintains the desired pressure difference between the high and the low-pressure
sides of the system, so the liquid refrigerant vaporizes at the desired pressure in the
evaporator.
3. It controls the flow of the liquid refrigerant according to the load on the evaporator.
The different types of throttling devices used are:
A) Capillary Tube
B) Automatic Expansion Valve
Thermostatic Expansion Valve

Feller tube
Pb
PS PS
Diaphragm
To Evaporator
Valve Seat
Valve Needle
Spring
Fig. Thermostatic Expansion Valve
3.6.4. EVAPORATORS
The process of heat removal from the substance to be conditioned is

done in the evaporator. The liquid refrigerant is vaporized inside the evaporator (coil and
shell) in order to remove the heat from the fluid such as air, water or brine. The fluid to
be cooled can be made to pass over the evaporator surface inside which the refrigerant is

boiling: such a system is called the direct expansion system. In certain cases, such as in
big air conditioning systems or in industrial processing, water or brine is chilled in the
evaporator. The chilled fluid is circulated through copper or steel coils over which the air
or substance to be cooled is passed. Such a system is called the indirect system.
Evaporators are generally classified into two main categories as mentioned
bellow.
A) Dry Type Evaporator

B) Flooded Type Evaporator
3.6.5. MISCELLANEOUS EQUIPMENTS.
Following are the miscellaneous equipment used in the Central Air-

Conditioning System.
1. Water piping
2. Refrigerant piping
3. Return/supply Ducts
4. Water pumps
5. Oil separator
6. Insulation
7. Filters electrical equipments
8. Thermostat
9. Cooling Tower

3.7 AIR DISTRIBUTION SYSTEM
The main purpose of air distribution system is to supply the conditioned

air from the AHU to the room to be conditioned and to carry the warm air from the
conditioned space back to the AHU. The main objective of distribution system is to
maintain the right temperature and humidity in the occupied zone of conditioned area. All
this is done in such a manner that occupant do not find any draft.
The important to be taken care of in air distribution are:
1. The quantity of air to be distributed to the various room, wings, or building should be
in proportion to the load in the respective region.
2. It is advisable to have the temperature difference between the room air and supply air
to be around 8.5°c (15°f). If this difference is greater, it is likely to create an
uncomfortable cold draft wherever the supply air descends to the occupied level before it
has the chance to mix with the room air and rise in temperature.
3. The supply air emerging out of the outlet or grill should be directed such that it does
not create unpleasant draft at the occupant level, say below a 2m height
4. Air passing through the ducts and coming out of the ducts and coming out of an outlet
can produce objectionable noise, if the velocity is high. In offices residential building,
hotel, etc. where the nominal noise level will be otherwise low, the velocity of air in the
ducts and outlet has to be kept low.
5. The throw of the air should be well calculated. It depends on the velocity of air and
height of the supply outlet. It increases with the velocity and height of the supply outlet
from the floor level. The desirable throw is about three-forth of the distance from the

outlet to the opposite wall or to the center line of the hall where the supply ducts and the
outlets are provided on the either side of the hall.
CLASSIFICATION OF DUCTS
The ducts are classified as following:
1. According to the cross-section of the duct

a) Circular ducts
b) Rectangular ducts
c) Square ducts
2. According to the type of air it carries

a) Supply ducts
b) Return ducts
c) Fresh air ducts
3. According to the velocity of flow in duct

a) Low velocity ducts
b) High velocity ducts
c) Medium velocity ducts
4. According to pressure in the ducts
a) High pressure ducts

b) Low pressure ducts
Medium pressure ducts


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V .J .T.

I, MATUNGA INPLANT TRAINING REPORT

INTRODUCTION TO THE ORGANISATION

Godrej & Boyce Mfg. Co. Page 1

Godrej is today one of the largest engineering and consumer products

Godrej & Boyce Mfg. Co. Page 2

Godrej & Boyce Mfg. Co. Page 3

Godrej & Boyce Mfg. Co. Page 4

Godrej & Boyce Mfg. Co. Page 5

Godrej & Boyce Mfg. Co. Page 6

A) GODREJ & BOYCE MFG. CO. LTD: -

OFFICE EQUIPMENT (O.E.) DIVISION:

MATERIAL HANDLING EQUIPMENT DIVISION:

Godrej & Boyce Mfg. Co. Page 7

MACHINE TOOL DIVISION:

PRECISION EQUIPMENT DIVISION:

OFFICE AUTOMATION DIVISION:

B) GODREJ APPLIANCE LIMITED:

Godrej & Boyce Mfg. Co. Page 8

C) GODREJ & KIS LTD:

D) GODREJ PACIFIC TECHNOLOGIES LTD:

E) GODREJ HI CARE LTD:

F) GODREJ SOAPS PRIVATE LIMITED:

It manufactures a wide variety of toiletries like soaps, shampoos, shaving

G) GEOMETRIC SOFTWARE SERVICE LTD:

It is collaboration with an Australian firm and deals in software Services.

H) GODREJ TELECOM LIMITED:

Godrej & Boyce Mfg. Co. Page 9

THE GODREJ HISTORY IN BRIEF

Godrej & Boyce Mfg. Co. Page 10

LIST OF ALL PLANTS WITH THEIR ACTIVITIES:

PLANT NO. ACTIVITY

01 ELECTRICAL & ELECTRONICS SERVICES

04 OFFICE FURNITURE (O.E. DIVISION).

07 TOOL ROOM, AEROSPACE

08 TOOL ROOM. & NUCLEAR DIVISON

09 MACHINE TOOL DIVISION, AEROSPACE

13 STORWEL BUSINESS SOLUTION. (O.E. DIVISION).

14 SEATING SYSTEMS PLANT (O.E. DIVISION).

15 PRECISION EQUIPMENT DIVISION (P.E.D).

16 FORKLIFT MANUFACTURING (M.H.E)

17 SECURITY EQUIPMENT (O.E. DIVISION).

18 A LOCK MANUFACTURING (LOCK DIVISION).

19 MACHINE TOOL DIVISION, P.E.D.

Godrej & Boyce Mfg. Co. Page 11

INTRODUCTION TO THE PLANT

ELECTRICAL & ELECTRONICS SERVICES

Godrej & Boyce Mfg. Co. Page 12

1.2. INTRODUCTION TO THE PLANT

INTRODUCTION TO DEPARTMENT (DG/AC SECTION): -

Godrej & Boyce Mfg. Co. Page 13

Godrej & Boyce Mfg. Co. Page 14

STUDY OF DIESEL GENERATOR

Godrej & Boyce Mfg. Co. Page 15

2.1 INTRODUCTION OF ENGINE

The Daihatsu DS-28 Type Diesel Engine takes pride in excellent

Godrej & Boyce Mfg. Co. Page 16

Model Unit 6DS – 28

Fuel Pump Before T.D.C. 27 0

Godrej & Boyce Mfg. Co. Page 17

ITEMS TYPE REMARK

Turbocharger Exhaust Gas Turbocharger