Final Project Report Kiran

V .J .T. I, MATUNGA

INPLANT TRAINING REPORT

INTRODUCTION TO THE ORGANISATION

Godrej & Boyce Mfg. Co.

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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.

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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.

Godrej & Boyce Mfg. Co.

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COMPANY LAYOUT

Godrej & Boyce Mfg. Co.

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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).

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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.

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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.)

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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.

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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.

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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

•

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.

Vikhroli.

• 2003: Godrej kept its first step in aerospace industry. Seth Jamshed N. Godrej received the PADMABHUSHAN award.

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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 19

Godrej & Boyce Mfg. Co.

LOCK MANUFACTURING (LOCK DIVISION). MACHINE TOOL DIVISION, P.E.D.

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INTRODUCTION TO THE PLANT

ELECTRICAL & ELECTRONICS SERVICES (PLANT NO: 1)

Godrej & Boyce Mfg. Co.

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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.

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LAYOUT OF DGAC

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ASSIGNMENT NO. 01

STUDY OF DIESEL GENERATOR

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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.

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\ 2.2 SPECIFICATION OF ENGINE Model Number of Cylinder Cyli. Bore * Stroke Engine Speed Maxi. Continuous Rating Break Mean Effect. Press. Pmax Net Weight Height Width Length Piston Overhauling Height

Unit MM r.p.m. PS Kg/cm2 Kg/ cm 2 Kg MM MM MM MM

6DS – 28 6 280 * 340 750 1800 17.19 – 17.20 115 16,000 2,705 1,690 3,785 2,290

VALVE TIMING Intake Valve Clearance (Cold State) Exhaust Valve Clearance (Cold State) Starting Rotary Valve

Open

Before T.D.C 700

Close

After B.D.C 350

Open

0.52 mm Before B.D.C. 500

Close

After T.D.C. 600

Open

0.52 mm O0

Close

1250

Fuel Pump

Before T.D.C. 27 0

Injection Pressure Lubricating oil pressure Piston cooling oil pressure C.W Temp. Engine outlet Firing order

270 kg / cm 2 3 kg / cm 2 2.5 kg /cm 2 70 0 1–2–4–6–5–3

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AUXILIARY EQUIPMENT

ITEMS

TYPE

Turbocharger

Exhaust Gas Turbocharger

Inter cooler

Fin Tube Type

Governor

Hydraulic Governor

Fuel oil injection Pump

Bosch Type

C. W. pump

REMARK

RHD 6

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

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ALTERNATOR SPECIFICATION

PHASE

3PH

02

OUTPUT

1100KW

VOLTS

6600V

04

HERTZ

50Hz

120 V

06

F

08

POLES

8

10

AMPERE

1203

FIELD AMPS

170

12

AMB. TEMP.

48

F

14

RPM

750

EXCITATION VOLTAGE ARM. INS. CLASS

FIELD INS. CLASS

ARMAYURE CONNECTION TOTAL WEIGHT

1Y 6600KG

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 Godrej & Boyce Mfg. Co.

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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.

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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

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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 Godrej & Boyce Mfg. Co.

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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: Godrej & Boyce Mfg. Co.

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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.

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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, pistoncooling 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 Godrej & Boyce Mfg. Co.

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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) Godrej & Boyce Mfg. Co.

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•

Cooling water pressure gauges (valve seat)

•

Intake air pressure gauges

•

Rocker arm L.O. pressure gauges

•

Exhaust Thermometer

•

Lubricating oil cooler inlet and outlet •

INPLANT TRAINING REPORT

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.

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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.

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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

Specific Gravity 15/4 C Viscosity RW #50 C Reaction Flash Point C Pour point C Carbon Residue ( % ) Water content Ash (%) Sulphur (%)

Heavy oil A

Heavy oil B

0.85-0.90 35 ~ 50 Neutral 60 ~ 90 -5 under 0.5 under 0.1 under 0.01 under 1 under

0.92 under 120 under Neutral 60 ~ 100 5 under 5 under 0.5 under 0.02 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

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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. Godrej & Boyce Mfg. Co.

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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.

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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.

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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.

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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. Godrej & Boyce Mfg. Co.

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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.

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Measurement of Crankshaft Deflection: Godrej & Boyce Mfg. Co.

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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.

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STARTING OF ENGINE When the engine does not start:

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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?

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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:

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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.

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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

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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 machinefinished 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. Godrej & Boyce Mfg. Co.

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•

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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.

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ASSIGNMENT NO: 02

STUDY OF CENTRAL AIR CONDITIONING SYSTEM

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3.1 INTRODUCTION TO AIR CONDITIONING The application for industrial purpose has opened a new area in the airconditioning 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 Airconditioning 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

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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 airconditioning 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.

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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:

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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.

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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. Godrej & Boyce Mfg. Co.

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Specific power consumption =

INPLANT TRAINING REPORT

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,

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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. Godrej & Boyce Mfg. Co.

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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, coolingdehumidifying 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 Godrej & Boyce Mfg. Co.

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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.

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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 semihermetic 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 aircooled 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 Godrej & Boyce Mfg. Co.

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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 Godrej & Boyce Mfg. Co.

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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 airhandling 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 Godrej & Boyce Mfg. Co.

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in DX plants, the distance and height difference between the condensing unit and airhandling 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.

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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 Godrej & Boyce Mfg. Co.

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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.

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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

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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 Godrej & Boyce Mfg. Co.

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 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 Godrej & Boyce Mfg. Co.

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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 Godrej & Boyce Mfg. Co.

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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 AirConditioning 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

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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 Godrej & Boyce Mfg. Co.

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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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