Department of Mechanical &

Automobile Engineering

Final Report
INDUSTRIAL TRAINING
Godrej & Boyce Mfg. Pvt Ltd , Mohali, Punjab

Under the guidance Submitted by-

of –
Sagar Verma
Mr. Anoop Jaswal,
1867203
Assistant manager, 3MTMD
Compressor M/C Shop Dept.

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 CONTENT

 Declaration
 Acknowledgement
 Introduction of the Organization
 Products
 Particulars of the Mohali Plant
 Introduction about Plant and Allotted
Department
 Project No. 1
 Project No. 2
 Reference

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 DECLARATION

I hereby declare that the project entitled “Track Down and Reduce
Grinding Defects on Valve Plates” in an authentic record of my own
work carried out at Godrej & Boyce Mfg. Pvt Ltd, Mohali, Punjab as
a requirement of 30 days project in an Industry/Research Laboratory,
under the guidance of Mr. Anoop Jaswal during April 2019 to May
2019.

Sagar Verma
1867203
Date : _____________

Certified that the above statement made by the student is correct to the
best of our knowledge and belief.

Mr. Rajnish

Sr. Manager

Compressor M/C Shop Dept.

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 ACKNOWLEDGEMENT

Education is restricted when we are told about how anything works instead of being involved
in that work. Studies in our colleges do give us information but where that information is
applied is not a part of curriculum. Thus, being the reason that they emphasize and promote
trainings in between the duration of respective courses. The need of industrial exposure can be
seen as an importance in this. In an industry, the student gets to learn how to use his knowledge
to get an output accordingly with the need of a mechanical industry.

I am extremely grateful to Mr. Anoop Jaswal Assitant , Machine Shop Department), Godrej
And Boyce Mfg. Co. Ltd., Mohali for providing this opportunity to carry out project work in
the company.

I would also like to thank, Mr. Punit and Mr. for providing me infrastructural facilities to
work with, without which this would not have been possible.

I would like to express my deepest sense of gratitude to all members of Compressor as well
as Refrigerator Plant for their generous guidance, help and useful suggestions as a project
guide, and showing faith in my work. Also I put my special regards to the management, workers
and co-trainees who have always been so supporting and ready to help.

Thankfully

Sagar Verma

1867203, MTech Machine Design,

Christ University Faculty of Engineering, Bangalore.

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 Introduction of the organization

About Godrej
The Godrej Group is an Indian conglomerate headquartered in Mumbai, Maharashtra, India,
managed and largely owned by the Godrej family. Established in 1897, the Godrej group has
grown in India from the days of the charkha to nights at the call centers. Our founder, Ardeshir
Godrej, lawyer-turned-locksmith, was a persistent inventor and a strong visionary who could
see the spark in the future. His inventions, manufactured by his brother Pirojsha Godrej, were
the foundation of today’s Godrej Empire. One of India’s most trusted brand, Godrej enjoys the
patronage and trust of around 500 million Indians every single day. Our customers mean the
world to us. We are happy only when we see a delighted customer smile.

With 7 major companies with interests in real estate, FMCG, industrial engineering, appliances,
furniture, security and agri care – to name a few – our turnover crosses 3.3 billion dollars*.
You think of Godrej as such an integral part of India – like the bhangara or the kurta – that you
may be surprised to know that 26% of our business is done overseas. Our presence in more
than 60 countries ensures that our customers are at home with Godrej no matter where they go.
With brands you can believe in, service excellence you can count on and the promise of brighter
living for every customer, Godrej knows what makes India tick today.

Today, we are at a point in Godrej’s history when our amazing past is meeting up with its
spectacular future head on. Godrej is learning and relishing being young again.

A. PRODUCTS

1. Godrej Appliances Division manufactures and markets, today; a range of refrigerators from
100 liters to jumbo sized 400 liters. The largest selling is the 170 liters size. The 100 liters baby
addresses the need of a small family or a second refrigerator for a growing family. It also
addresses the needs of the Institutional and Hotel industry segment. The 300 liters size is the
most suitable for the typical large Indian family.

2. Each of the major sizes of the refrigerators is made in different models, primarily created
to address the requirements of different segments of customers with differing balance among
taste, usage and cost considerations. Cold Gold and Ultra are designed with the taste of the up-
market customers, whereas the Classic packs the best value for money for a customer with
focus on economy with efficiency and no frills. All the models and sizes are made in a range
of colors that reflect the choice of the different segment of customers.

3. Keeping in tune with the changing technology and the distinct needs of the upwardly mobile
urban market, GODREJ APPLIANCES DIVISION has launched four models of Frost - Free
(165, 240, 260 and 400) refrigerators using indirect cooling technology. These models also are

5
in tune with the latest styling and taste of softer looks and pastel colors, in harmony with the
trend's worldwide.

4. The range, colors and the models are never static and it is always the tradition of GODREJ
APPLIANCES DIVISION to constantly upgrade the existing products, its range and bring to
the market the latest to satisfy the ever changing expectations of customers. The latest model
GODREJ APPLIANCES DIVISION introduced is the Jerry model.

5. GODREJ APPLIANCES DIVISION also offers a range of washers from semi-automatic

twin tub (5 kg & 3 kg) type to fully automatic or Fuzzy logic and Pulsate type single tub models.
As with refrigerators, the washers are also made available in different colors to suit the taste of
the customers. Washers are manufactured at Wing Works.

6. GODREJ APPLIANCES DIVISION have introduced a range of AC’s (manufactured and

sourced) from 0.75 TR to 1.5 TR window AC's and 1.5 TR splits. The AC's are made available
with trendy looks (grills) to enhance the interiors and in different colors.

B. DESIGN AND DEVELOPMENT

1. GODREJ APPLIANCES DIVISION understands that the quality is built into the product
rather than just inspected at the end of the production. Towards this end, GODREJ
APPLIANCES DIVISION has a well-qualified and experienced team of design engineers who
convert the expectations of the customers into a concrete product. Their knowledge is
constantly upgraded through training and exposure as well as access of technology from
collaborators. The documented system for design development supports their knowledge,
experience and creativity.

2. GODREJ APPLIANCES DIVISION also out sources product designs, designing activities
or aesthetics and styling concepts from experts in India or abroad. Although the specific
designing activity may be done by such experts, the larger intent of the design and development
requirements are supplemented / complemented by design verifications, design validations,
design reviews and design changes through the in-house Design, Quality, PMQ and NBD
teams. Such external experts / sources are approved by Design in consultation with the
management with executive responsibility.

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C. QUALITY

1. Throughout the design, manufacturing and testing of the appliances total attention is paid to
the quality aspects of the product. Besides the incoming inspection co-ordinate by the
Purchased Material Quality Cell (PMQ) and the in process monitoring by line function of
manufacturing, the system has built in audits of the product and the processes at different stages
by Quality Eng. Dept. to assure quality and provide fast feedback.

2. The End-of-Line Audit (EOLA) offers feedback on continues basis to the manufacturing as
regards the quality of the finished products. The Customer Acceptance Test and Customer
Usage Test Laboratory give confidence that the products meet functional and reliability
requirements. The Life Testing Laboratory for compressor and other appliances / components
provides data and facts about the reliability under adverse operating conditions.

3. The facilities are ably supported by a number of laboratories to analyze the material and
other inputs. These consist of the Plastic Lab, the Oil and Fresno Lab, Powder Coating Lab,
Metrology Lab, Metallurgy Lab, the Calibration Lab and Shipping test Lab.

4. The data from the laboratories, tests and the audit feedback is constantly analyzed and
corrective and preventive actions are taken to improve the performance of refrigerators in the
field and processes that build them in house.

5. The documented system in this Apex Quality Manual spells out, in the following chapters,
in elaborate details, the procedures, processes and the system in place to support the quality
aspects.

D. MARKETING AND DISTRIBUTION

1. GODREJ APPLIANCES DIVISION understands that availability and access to the

consumers is critical for their satisfaction in this business. 19 branches in five regions with the

7
dealership network of app. 1200 direct dealers and over 3000 retailers support the marketing,
selling and distribution across the whole country. The logistics department ensures the physical
distribution to feed branches, and they in turn feed the dealer network.

2. The branch and dealer network are also the channels of information to get the feedback on
the consumer satisfaction, emerging expectation and the competitive offerings so that the
product range and the introduction of varieties of models and colors are in tune with the
changing market trends.

E. SERVICE SUPPORT

1. Product in the field, in the hands of the consumers, needs the support of education and
training at the time of installation for deriving maximum benefits during use. It is equally
essential for the consumers to understand the care and caution to minimize the inadvertent
misuse that may lead to product malfunction and possible injury to the users.

2. And should the need arise, the service back up is geared to diagnose and rectify the product
problems during and even after the warranty period, either at the user's premises or if required,
at the workshop with minimum disturbance to the customers. The service organization is
adequately equipped to provide spare parts for the current and prior models in the use in the
field through dealers and the branch network. The service set up also provides the training and
education support to the dealer network so that they in turn can extend the same level of service
to their customers.

3. GODREJ APPLIANCES DIVISION believes that the field personnel are the important
source of information and hence seek their feedback on the product performance on a regular
basis, which forms the trigger for continuing improvements of the products and the processes.

F. PURCHASING

GODREJ APPLIANCES DIVISION understands that to be able to satisfy the ultimate

consumers, it needs quality inputs from the vendors. Vendors are the partners in this process
and therefore, GODREJ APPLIANCES DIVISION puts considerable emphasis on their

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development through clear communication, education and early involvement in product
development stages, rather than just the monitoring and control through feedback from
incoming inspection.

G. PEOPLE

People provide the inner strength to GODREJ APPLIANCES DIVISION. The organization
takes pride in the fact that it has some of the best people in place to achieve the objectives of
Technology leadership, quality and market presence. It has in place, a process of recruitment
and training to groom the best talent. The welfare of the people is paramount for GODREJ
APPLIANCES DIVISION, accordingly the company has invested substantially in the housing,
medical and education support for the employees and their families.

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10
 PRODUCTS

Appliances
Offerings in the refrigerator, washing machine, air conditioner and microwave oven ranges.

FMCG
Cinthol, Good Knight mosquito repellent, Hair Color and Hair Dye.

Batteries
Godrej and GP Batteries offer a range of zinc chloride, alkaline & rechargeable batteries and
a range of chargers.

Construction

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Variety of construction services like real estate development, ready mix concrete, horticulture
and enviro-tech.

Locks

Locking solutions for different security needs to ensure optimum safety.

Electricals and Electronics

Industrial automation, power distribution, compressed air solutions & green business
commissioning.

Precision Systems
Machining & fabrication, heat & surface treatment, assembly, testing & supply of complex.

Security Solutions

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Safes, lockers, banking automation products, electronic security systems, premises security &
hi-tech doors.

Chemicals
Oleo chemicals and surfactants.

Furniture
Furniture for home, office, educational institutions, establishments, labs, hospitals, shipyard.

Storage Solutions
Warehousing solutions, automation and consulting.

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 PARTICULARS OF THE MOHALI PLANT

GODREJ APPLIANCES HAS THREE PLANTS IN MOHALI

1. REFRIGERATOR PLANT

2. WASHING MACHINE PLANT

3. COMPRESSOR PLANT

PLOT SIZE : 75 ACRES

CAPABILITY : 5 LACS

PRODUCTIVITY : REFRIGERATORS

INVESTMENT : Rs 120 CRORES

INAUGRATED BY : S. HARCHARAN SINGH BRAR

INAUGRATION ON : 28TH FEBRUARY, 1996.

14
 INTRODUCTION ABOUT PLANT AND ALLOTED
DEPARTMENT

COMPRESSOR PLANT

A refrigerant compressor is a machine used to compress the vaporized refrigerant from the
evaporator and to raise its pressure so that the corresponding saturation temperature is higher
than that of cooling medium. It also continually circulates the refrigerant through the
refrigerating system. Since the compressor of refrigerant requires some work to be done on it,
therefore, a compressor must be driven by some prime mover.
Since the compressor virtually takes the heat at low temperature from the
evaporator and pump it at high temperature to the condenser, therefore, it often referred as Heat
Pump.

15
The various components of reciprocating compressor:-

1. Shell
2. Cover
3. Body
4. Stator
5. Rotor
6. Cylinder Head
7. Piston
8. Shaft/Crank
9. Connecting Rod
10.Gudgeon Pin
11.Lock Pin
12.Spring
13.Oil Tube
14.Muffler
15.Valve plate
16.Reed
17.Retainer
18.Suction Gasket
19.Suction Reed
20.Discharge Gasket
21.MS Plug
22.Oil Cup
23.Relay Guard
24.Glass Seal Terminal
25.Discharge Tube
26.Suction Tube
27.Charging Tube

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28.Coil/Port Cover
29.Piston Washer
30.Bolts
31.Shaft Washer
32.Copper bolt Washer
33.Holding Rubber
34.Stopper
35.Stopper Plate
36.Port Cover Washer
37.Pedestal
38.Muffler Rubber
39.Rubber GST
40.Rubber of
1. Suction
2. Discharge
3. Charging tube
41.Pedestal rubber

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The compressor plant is divided into various departments

 Machine Shop
 Metrology Department

 Assembly Department

 Unit Department
 Maintenance Department
 Tool Room
 Store

 Quality Department (PMQ)

Layout of compressor plant

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Compressor models manufactured are:
1. GV17T2-TR600a

2. GV16T2-LTR600a

3. GVI7E1T2-LR00a

4. G18E1T12R600a

5. G19BT1T2R600a

6. G16F1T2R600a

7. G17F1T2R600a

8. G18C1T2R600a

9. G19CT2R600a

10. G16H1T2R600a

11. GA1-R134a

12. GB1-R134a

13. GC1-R134a

14. GV19T2LR600a

COMPRESSOR MACHINE SHOP

Compressor machine shop manufactures following parts

• CRANK CASE BODY

• SHAFT

• VALVE PLATE

• CONNECTING ROD

• PISTON

• G PIN

1. CRANK CASE BODY:- it is made of cast iron material, come from vendor BRICKS
& MUNJAL.
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 Machines in CMS shop:-

Machine 1-EMT 682

Machine 2-EMT 683

Machine 3-EMT 684

Machine 4-EMT 685

Machine 5-EMT 686

Machine 6-EMT 687

Machine 1-EMT 682:- It is a SPM(special purpose machine) doing variety of different

operations on same work piece. This machine performs 12 operations. The description of
machine tool and its operation is as follows:

s.no Station Tool description operation

no.
1 2H Holder and Cutter (Indexable Inserts) Horizontal facing and outer Dia.
chamfer
2 2V Holder and Cutter (Indexable Inserts) Block face milling (rough)

3 4H Drill( 17.5*18*143mm) and Cutter Shaft bore drilling

(dia=80mm)
4 4V Drill( 17.5*18*143mm) and Cutter Block face semi finished milling
(dia=80mm)
5 5V U-Drill( dia 20*24mm) Index Inserts Piston bore drilling

6 6H Center Drill (10*4mm) Leg hole centering

7 7H Indexable Inserts Leg and shaft bore fine facing

8 8H HSS DRILL DIA 4.5*126 MM Shaft bore inner dia chamfer and leg
hole drilling
9 9H HOLE MILL (5.05*130 mm) Shaft bore milling and leg hole milling
Ream dia (18 mm)

Machine 2-EMT 683:-It is a second machine of body line. It performs 9 operations on the
body. It is also a SPM. The description of machine tool and its operation is as follows:

s.no Station Tool description operation

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 1 2H Center drill (3.15*8 mm) Gas hole centering
2 2V Holder ( Indexable Inserts) Shaft bore Seat milling and
Outer Dia chamfering.
3 3V Drill (5.1*86 mm) and Holder Port hole drilling and
Indexable Inserts. counter boring
4 4H HSS Drill (4.5*126mm) Gas hole drilling

5 6V CARBIDE BRAZED TP cutter U slot milling

6 7V HSS DRILL DIA (5.1*86)MM and Leg relief hole drilling and
Forming Tool Model Marking.
8 8H HSS HOLE MILL REAMER Gas hole reaming
Machine 3-EMT 684:-It is a third machine in body line. It performs 2 operations on the
body. It is also a SPM The description of machine tool and its operation is as follows:

s.no Station Tool description operation

HSS DRILL DIA 4.5*126MM PISTON BORE
1 1H LONG SERIES. CHAMFERING AND RELIEF
HSS COUNTER SINK TOOL HOLE DRILLING.
DIA 33MM.

Machine 4-EMT 685:- it is a third machine in body line. It do 5 operations on the body. It is
also a SPM It is also a SPM The description of machine tool and its operation is as follows:

S.no Station Tool description Operation

1 2H FACE MILL DIA 80MM Block face milling
2 3V Boring Bar ( Dia- 18.5 mm) Shaft rough boring
3 4H Boring Bar (Dia 21.9 and Piston fine boring and
25.975 mm) chamfering.
4 4V Boring Bar ( Dia 19.043mm) Shaft finish boring

Machine 5-EMT 686:- it is a third machine in body line.it do 6 operations on the body. It is
also a SPM

s.no Station Tool description operation

1 2H CENTER DRILL (3.15*8*48 mm) Gas hole centering
2 3H CENTER DRILL (5.5*10*168 mm) Block Face centering
3 4H DRILL ( 4.5*126mm) Gas Hole Drilling
4 7H HSS DRILL (4.2*120mm) Block Face Drilling
5 5V HSS TAP (M5*0.8*58mm) Block Face Tapping
6 8H HSS Hole(5*95mm) Gas Hole Reaming

Machine 6-EMT 687:- It is a third machine in body line.it do 1 operation on the body. It is
also a SPM.

s. no Station no. Tool description Operation

1 1H HSSE Tap (M6*1*56MM) Legs Hole Tapping

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Grinding section

MACHINE-1 WMW:- It is a centre less cylindrical grinding machine with PLC panel
installed with it. There are basically two grinding wheels which are to grind the large end of
the shaft in microns. The different units installed are lubrication unit, hydraulic unit, electrical
panel unit. The main grinding wheel rotate in clockwise direction while shaft large end rotate
in anti clockwise direction and counter wheel rotate in clockwise direction. For safety of
workers the safety gaurds are installed at the front of the machine. For checking the grinding
cut in microns. There is bakers gauge installed for checking the finishing of shaft large end
after grinding. 6 jet of air are located inside the through which the finishing of shaft is checked.

MACHINE-2 CNC MACROMATIC GRINDING MACHINE:-It is a CNC grinding

machine with PLC panel installed with it. The different units installed are lubrication unit,
hydraulic unit, electrical panel unit. There is only one grinding wheel for grind the small end
of the shaft. The shaft is inserted into the jaws of adjustable chuck (adjusted according to the
different models of compressor).The main grinding wheel and shaft rotate in different direction
to each other.

MACHINE-3 PISTON GRINDING:-The piston is the main part of the compressor. There
is different piston for different compressor according to the size and capacity of compressor.

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MACHINE RANKING IN COMPRESSOR PLANT

Most critical
S CLASS equipment
28 points

CRITICAL
A RANK 21-28 POINTS
EQUIPMENT

LESS CRITICAL
B RANK 14-20 POINTS
EQUIPMENT

NON- LESS THAN 14

C RANK CRITICAL POINTS
EQUIPMENT

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Other Components Of Comperessor

1. Oiltube :- This is a metallic tube which is used to lubricate the shaft and other
components like conn rod, piston, Gudgeon pin Etc. As the rotor rotates the
centrifigual force will be produced as oil tube is fitted in bottom end of shaft
and it sucks oil to lubricate.

2. Muffler cap:-Muffler cap is used for directioning the gas into the compressor
after the whole cycle completion. There is small restriction on one side of this
cap so that even a single particle of dust containing moisture will be eliminated.
The one end is attached to the cylinder head and a rubber cap is fitted at one
lower end of muffler.

3. Piston :-The piston is the main part of the compressor. There is different piston
for different compressor according to the size and capacity of compressor.

4. stator and rotor :- The stator is rotatory windning of aluminium wiring. The
rotor is fitted in stator with the help of hydraulic press in assembly shop. As the
voltage of 170 watts is given to the comperessor the rotor rotates in stator and
rotate other assembly with itself.

SURFACE TREATMENT

After machining of the component, the components are sent for a surface treatment. Surface
treatment is done in order to prevent the component from the rust and coating of shaft. The
components are treated with various chemicals like Nutrapon, Rustoken 25. In a surface
treatment area, the small components like oil tube, spring etc are cleaned in a small component
cleaning machine.

In surface treatment, shafts is coming after all maching operation coating is

done in various steps.

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Wet tumbling

 This is a vibrator in which ceramic media is vibrating along with shafts . This is used
to remove the burr on shafts.

Dry tumbling

After dry tumbling , shafts is again vibrating with dry media for polishing and finishing the
shafts. Then shafts is degreasing in ultrasonic heater for removing some amount of dirt etc .

Mn. PHOSPHATING COATING SYSTEM OF SHAFTS

In the system , there are 12 no. of tanks . It provide coating on shafts . These Tanks are:

1. DEGREASING 1
2. DEGREASING 2
3. DEGREASING 3
4. WATER RINSE
5. ACTIVATION 1
6. ACTIVATION 2
7. PHOSPHATING1
8. PHOSPHATING 2
9. WATER RINSE 2
10. PASSIVATION
11. OVEN 1
12. OVEN 2

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 UNIT SHELL

The process flow diagram for a compressor in the compressor unit shell department is
shown below.

Layout chart compressor plant processes at various points on conveyor

Supply of Cleaning of shell Removal of

Cover
compressor shell and cover in moisture from
checking
and cover two chemical shell
and two water
tanks

Conveyor goes to
assembly where
all components Cover and Marking on
are loaded and shell loaded
the cover
various on conveyor
performance are
tested

Checking of
MAG WELDING weld by
Pressing of cover
passing
on shell (8 MACHINES) through water
(leakage test)

Passing Treatment
Drying
through in 4 tanks Rubber fixing
in oven
paint

Dehydration Pre dispatch FINALLY,

burner (2ovens inspection (PDI) PACKING
lower and upper)
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 Project 1
Track Down and Reduce Grinding Defects
on Valve Plates
As mentioned earlier, the Valve Plates are manufactured in various Machines
in Machine Shop Department, namely,

 Russian Grinder M/C

 Rough Lapping M/C
 Fine Lapping M/C
 Deburring M/C
 Seat Milling M/C

In these processes, a deep line scratch on the Valve Plate was observed which was a
havoc for the quality standard of the company as these valve plates are meant to
regulate the flow of Refrigerant in the Compressor. This manufacturing defect was
needed to be resolved so that the efficiency of product could be increased.

The production of Valve Plates was 4000-5000 per day, or 2000-3000 per shift, more or
less. The project was undertaken as stated below:

No. of Samples Taken: 100

 Russian Grinder:

o The casted Valve Plates arrived from the supplier are subjected to rough grinding
on this machine.
o In this process, the Valve Plates are made to be grinded at roughly 150 microns.

After Processing :
It was observed that there were some fine scratches on the Valve Plates but the Defects
which were needed to be studied were not due to this Machine as the cut is very high
and rough, and it being the first process.

 Rough Lapping:
o The grinding wheels used in this machine are finer than the Russian Grinder as it
makes a cut of approximately 130 microns.
o This machine is provided by best in the class lapping by LAPMASTER WOLTERS,
model DSG 720HP.

27
 After Processing :
Number of specimen with negligible lining : 96

Number of specimen with fine line scratches : 5

Number of specimen with deep line scratches : 0

Note : There were regions of incomplete grinding done on the Valve Plate.

 Fine Lapping:
o This machine fine cuts the Valve Plate process by 100 microns depth.
o It is also provided by LAPMASTER WOLTERS, model DSG 720 FINE.

After Processing :
Number of specimen with negligible lining : 39

Number of specimen with fine line scratches : 36

Number of specimen with deep line scratches : 35

 Deburring:
o In this machining process, Silicon Carbide brushes were used to deburr the surface
and the edges on a Valve Plate.
o There is no cut observed in this machine.

After Processing :
Number of specimen with negligible lining : 78

Number of specimen with fine line scratches : 17

Number of specimen with deep line scratches : 5

28
 Result:

 It was seen that this defect was caused due to Fine Lapping process, the reason being:
 Operational factors.
 Work Material Factors.
 Machine Tool factors.

 As a result, we can inspect and rectify the issue by following means:

o Inspection:
 Flatness : Recommendation by lapping machine manufacturer LAPMASTER
WOLTERS are Flatness Gage and Straight Gage to check the parallelism of
grinding wheel with respect to the Valve Plates.
 Curvature : To measure the curvature of the respected wheel using Brass Test
Plug, is also recommended.

o Remedies for this defect:

 For the operation is that the process should be done with preventive measures
to reduce the contamination of impure particles to reduce irregular scratches
on Valve Plates as these particles comes in between the tool and specimen.
 The grinding wheel in the fine lapping process should be inspected timely due
to the reason that there were similar scratch patterns observed due to the
rotation of the relative motion of the grinding wheel with the Valve Plates.
 Brass Test Plug be used on the rough lapping so as to check the curvature of
the grinding wheel for reducing regions of variable cut.

29
 Project 2
Modelling of Ramming Machine for
Biogas Plant

BIOGAS PLANT DESCRIPTION

 Biogas plant is run and maintained by maintenance department.

 Biogas plant is used to run two dehydration burners in compressor plant and three
burners in refrigerator plant and three burners in line 4.

 Wood is used as biomass to produce biogas.

 In compressor plant the dehydration burners are used to soak and dry the paint from
compressors as well as removal of internal moisture from the compressor.

 There are 2 dehydration burners (i.e. upper and bottom oven respectively).

30
Working:

The reactor is rolled from mild steel and has an inner lining of cold face and hot face
insulation and high alumina ceramic brick. The insulation helps in retaining the heat
within the system and reduces heat loss. The schematic of the reactor is shown in Fig.
1. There are air nozzles (provided around the combustion zone), which are kept open
during operation.

A water seal forms the top of the reactor with a removable cover. This cover is kept
open during the entire operation. There is an ash extraction system provided at the
bottom to hold the charge and also discharge ash periodically. The discharge end of
ash extraction system is dipped in a water seal, to prevent air entry. Further, the
char/ash is conveyed used an ash/char conveying system.

The hot dust laden gas exiting from the reactor is led through a cyclones and blower.
The gas then flows either to gas burner or to the flare.

31
Project Details:

• Observation was made on the process of ramming by operator for

automation.

• When operator presses the wood downwards the rod is pushed for 5 to 10
minutes continuously until wood bed is fully tight so that no air can entrap into
the fire section

• The cavity in which wood is fed into is of circular section, so worker hits the
wood at the corners only, so automatically wood at centre portion goes
downwards.

• And action of worker arm is high arm. He has to hit into cavity with some
strength, so it is tiring process along with high temperatures.

• The dimensions of wood insert area was done along with the displacement
and required ram for the correlative machine to be installed.

Automation Requirement:

 Safety of the worker.

 Increase in morale of the worker.
 Automation will reduce the man effort.
 Man deployment can be reduced.
 Opportunity to increase the biogas production.

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Modelling:

FRONT VIEW

ISOMETRIC VIEW

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SIDE VIEW

TOP VIEW

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 Mechanism:
 In this machine, the crank’s rotatory motion will enhance the linear motion of ram
which will uniformly push the wood into the reactor.
 The rotation and diameter of the disc in the machine is made so as to get the
required displacement of the ram at the other side.
 The arm is installed to connect the disc through connecting rod with the ram.
 This ramming will hit the incoming wood into the reactor entry.
 The machine is designed in such a way that the centre of mass is almost in the
middle of the base support so as to maintain stability of the machine under
ramming process.

Advantages:
 Simple mechanism.
 Comfortable processing.
 Will require less maintenance.
 Adequate force can be generated through this mechanism.

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 REFERENCES

 www.godrej.com
 www.wikipedia.com
 www.micromaticgrinding.com
 Help by mentors , workers
 www.mohalimanuals,com

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