V .J .T.

I, MATUNGA INPLANT TRAINING REPORT

AN
INPLANT TRAINING REPORT
ON
DESIGN OF PULLER FOR ENGINE VALVE SEAT AND GUIDE.

AT
GODREJ & BOYCE MFG. CO. LTD.
VIKHROLI, MUMBAI- 400079

BY
PACHPANDE KIRAN ANIL
B. Tech. (PRODUCTION)
ROLL NO. – D-050724

GUIDE
MR. D. V. SHIRBHATE

DEPARTMENT OF PRODUCTION ENGINEERING

VEERMATA JIJABAI TECHNOLOGICAL INSTITUTE
MATUNGA (EAST),
MUMBAI-400019,
2008 - 2009.

Godrej & Boyce Mfg. Co.

 V .J .T. I, MATUNGA INPLANT TRAINING REPORT

VEERMATA JIJABAI TECHNOLOGICAL INSTITUTE

MATUNGA (EAST), MUMBAI 400019.

PRODUCTION ENGINEERING DEPARTMENT

CERTIFICATE
This is to certify that Mr. PACHPANDE KIRAN ANIL
(B. Tech. PRODUCTION) Roll NO. D-050724 has satisfactorily
completed, as a partial fulfillment of the requirements for the sandwich
inplant training as a part of course under University of Mumbai, under our
supervision and guidance during the period from 19th JUNE 2008 to 18th
DECENBER 2008 in the company GODREJ & BOYCE MFG. CO. LTD. at
VIKHROLI, MUMBAI.

Mr. D. V. SHIRBHATE Dr. D. N. RAUT

Guide H.O.D.
Production Engg. Dept.

Mr. C.T. Havewala

Senior Manager (DG / AC Section)
Godrej & Boyce Mfg. Co. Ltd.
Electronic & Electrical Services
Plant: - 35.

Godrej & Boyce Mfg. Co.

 V .J .T. I, MATUNGA INPLANT TRAINING REPORT

VEERMATA JIJABAI TECHNOLOGICAL INSTITUTE

MATUNGA (EAST), MUMBAI 400019.

NO OBJECTION CERTIFICATE

This is certify that we have no objection towards the content of the

project report completed by Mr. PACHPANDE KIRAN ANIL during his
tenure as an inplant trainee in the Electronic & Electrical Services (DG / AC
Section) Plant –35 at Godrej & Boyce Mfg. Co. Ltd., Vikhroli, Mumbai -
400079.
He has been allowed to include documents, sketches, and
photographs prepared by his pertaining his report during his training, for
which, we have no objection. We also have the no objection to the usage of
the content of the project report for the academic purpose.

Mr. C.T. HAVEWALA

(Sr. Manager DG / AC Section)

Godrej & Boyce Mfg. Co.

 V .J .T. I, MATUNGA INPLANT TRAINING REPORT

VEERMATA JIJABAI TECHNOLOGICAL INSTITUTE

MATUNGA (EAST), MUMBAI 400019.

CERTIFICATE

The project report, “Design of Puller for

Engine Valve Seat and Guide”, submitted by Shri Kiran
A. Pachpande, along with the other team members, is found
to be satisfactory and is approved for the Degree of B.
Tech. (Production Engineering) of The University of
Mumbai.

(Mr. Deepak Shirbhate)

Guide Examiner

Godrej & Boyce Mfg. Co.

 V .J .T. I, MATUNGA INPLANT TRAINING REPORT

VEERMATA JIJABAI TECHNOLOGICAL INSTITUTE

MATUNGA (EAST). MUMBAI 400 019.

Statement

I wish to state that the work embodied in this Project titled

“Design of Puller for Engine Valve Seat and Guide” forms my own
contribution to the work carried out under the guidance of Mr. DEEPAK
SHIRBHATE at the Veermata Jijabai Technological Institute.

This work has not been submitted for any other Degree or
Diploma of any University / Institute. Wherever reference has been made for
previous work of other, it has been clearly indicated.

Date: - Signature: -

Godrej & Boyce Mfg. Co.

 V .J .T. I, MATUNGA INPLANT TRAINING REPORT

ACKNOLEDGEMENT

The six months training that I had in Godrej and Boyce Mfg. Co. Ltd.
was a unique experience. The written words have an unfortunate tendency to
degenerate genuine gratitude into stilted formality. However this is the only way
one can express ones feelings permanently.
I am extremely thankful to Training and Employment management of
Godrej & Boyce Mfg. Co. Ltd. and Mr. S. M. Bhide (Training Officer) for giving
me this golden opportunity to undergo in-plant training in this reputed and
esteemed organization.
I hereby take the opportunity to record my sincere thanks and heartiest
gratitude to Mr. C. T. Havewala (Sr. Manager-DGAC Section) for their useful
guidance and whose encouragement and guidance inspired me to carry out this
training and project at every stage.
I am also thankful to Mr. S. N. Shanbag, Mr. Shoeb Siddiqui, Mr. T.
K. Phalke, Mr. G.I. Panchal, Mr. Javeed Sheikh, Mr. Prashant Babar, Mr.
Vijay Gulvadi, and Mr. Viraj Desai for their assistance and guidance throughout
the project. Also I cannot forget the help & co-operation of the department
workers who too were very informative.
I would like to convey my special thanks to MR. D. V. SHIRBHATE. For
helping and guiding me in order to complete this report successfully.
Last but not the least, I want to express my sincere thanks and gratitude
to all those persons who directly or indirectly helped me in bringing my projects to
a fruitful end which I am sure will help me in industrial and personal life in future.

Mr. PACHPANDE KIRAN ANIL

Godrej & Boyce Mfg. Co.

 V .J .T. I, MATUNGA INPLANT TRAINING REPORT

INDEX

SR. CONTENTS PAGE

NO. NO.

01. INTRODUCTION 1
1.1 Introduction to the Organization 2
1.2 Introduction to E&E Services 12

02. ASSIGNMENT NO – 01 13
STUDY OF DIESEL GENERATOR
14
2.1 Introduction of Engine
17
2.2 Specification of Engine
Description of Engine 20
2.3
Maintenance of Main Parts 31
2.4

03. ASSIGNMENT NO – 02
STUDY OF CENTRAL AIR CONDITIONING 45
SYSTEM
3.1 Introduction to Air Conditioning 46
3.2 Related Terms 51
3.3 Working Cycle 52
3.4 Air Conditioning System 52
3.4.1 Room Air Conditionner 53
3.4.2 Package Air Conditionner 54
3.4.3 Central Air Conditionner 54
• DX System 55
• Chilled Waters System 55
• DX System & Chilled Waters System—A 56
Comparaison
3.5 Building Management System(BMS) 59
3.6 Air Conditioning Equipments 61
3.7 Air Distribution System 66

Godrej & Boyce Mfg. Co.

 V .J .T. I, MATUNGA INPLANT TRAINING REPORT

SR. CONTENTS PAGE

NO. NO.

04. ASSIGNMENT NO. – 03

DESIGN AND FABRICATION OF PULLER FOR 68

VALVE SEAT.

05. ASSIGNMENT NO. – 04

DESIGN AND FABRICATION OF PULLER AND 86

PUSHER FOR VALVE GUIDE.

06. RESULT AND DISCUSSIONS 108

07. CONCLUSION & FUTURE SCOPE 110

08. BIBLIOGRAPHY. 111

Godrej & Boyce Mfg. Co.

 V .J .T. I, MATUNGA INPLANT TRAINING REPORT

LIST OF FIGURES

SR.NO. FIGURE PAGE NO.

1. Piston Removal Tool 32

2. Piston and Connecting Rod Disassembly 32

3. Removal of Connecting Rod Cap 33

4. Piston Inserter 34

5. Piston Disassembly 35

6. Extraction of Cylinder Liner 37

7. Application of Deflection Gauge 38

8. Chilled Water Central AC System 56

9. Thermostatic Expansion Valve 64

Godrej & Boyce Mfg. Co.