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ACKNOWLEDGEMENT

I enjoyed my training period in the JYOTI LIMITED at vadodara in the year of 2010.

I am extremely grateful to Mr. B.B. Suthar for give me a chance to learn about JYOTI COMPANY and

also for his support and guidance throughout the training period. I would also like to extend my gratitude

to all who devoted a lot their valuable time and shown keep interest in guiding us in their respective

department.

I found the knowledge imparted by them to be extremely helpful and of almost importance. It gave us

better understanding of practical application of the theoretical knowledge gained by us in the educational

institutions which may go a long way in the furthering our careers.

PREFACE

It is true that technical studies can not be perfect without practical training and perfections are basic

necessity of a student. In practical training a person deals with many technical problems, and hebecomes accustomed to the industrial atmosphere. Another aim in the plant training is to learn industrial

management and discipline.

The report consists of various unit operations as well as unit process involved in the various plants of the

JYOTI LTD. It also includes the systematic presentation of the vocational training.

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The Vision :

Jyoti Ltd. shall be a leading engineering company with Global Perspective offering superior quality

products and services for Water and Power sectors through reliable, economical and innovative turnkey

solutions in water management, power generation, and transmission and distribution areas.

The Mission :

Jyoti Ltd. will endeavor to achieve this Vision by continually upgrading its core competence through a

judicious mix of indigenous research & development, technology-imports, human resource development,

promoting team spirit and entrepreneurship among its employees in order to achieve total customer

satisfaction and add economic value to all stakeholders of the Company.

Awards received in recognition of significant

contributions

Making effective use of information technology with the help of state of the art hardware and software

tools, it has undertaken design product and analysis using advanced 3d modeling Pro/Engineering

software tools.

In addition to the national awards for important substitution from the govt. of India, Jyoti has received

awards for its pioneering efforts in developing technology for renowned national level organization like

FICCI, CII, ASSOCHAM, IRDA and international organizations like international association for small

hydro power and parametric technology corporation (PTC), USA.

Fulfillment of social responsibilities:

Jyoti made a modest beginning, as an engineering department of Alembic Chemical Works Ltd.

Vadodara, under the leadership of (late) Rajmitra Bhailalbhai Amin. In 1943, the engineering

department blossomed into an independent Private Ltd. Company, starting with the manufacture of

Hydraulic Pumps.

Shri. Bhailalbhai Amin's vision of Jyoti was further shaped and moulded by his son (late) Shri. Nanubhai

Amin whose conviction, perseverance and the unique ability to apply acquired knowledge guided Jyoti

to the success path. Under his focused leadership, Jyoti grew into a multi-product, technologically

advanced organization, powering the country's growth and shouldering social responsibilities for more

than fifty years and continues to do so even now under the leadership of Shri. Rahulbhai Amin, s/o

(late) Shri. Nanubhai Amin.

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y National awards from government of India:

Outstanding employer of orthopedically handicapped: 1971 & 1979.

Outstanding employer of the blind: 1975.

y National awards from Government of Gujarat:

Award for providing employment to considerable number of disabled persons - 1985, 1989, 1992

y From Federation of Indian chambers of commerce & Industry (FICCI):

In recognition Corporate Initiative in the field of training and placement of disabled persons - 1985

In recognition Corporate Initiative in the field of Rural Development - 1986

y From National centre for promotion of employment for disabled people (NCPEDP)

Hellen Keller award for promoting employment opportunities for persons with disabilities - 2000

y National Awards from Government of India for the development of:

Arno convertor for Indian railways (single phase to three phase conversion-1973)

33KV epoxy resin Insulator Bushing type current transformer - 1974

33KV, 750MVA, 12502amp, minimum oil outdoor circuit breaker - 1978

12|7.2KV, 40|44 KA, 1250 |2000 Amp. Minimum Oil Outdoor Circuit Breaker - 1984

y ASSOCHAM Award

ASSOCHAM Award for important substitution through indigenous & development from associated

chambers of commerce and industry of India, New Delhi-1977.

y

Development of Technology

FICCI Award in recognition of 'Corporate Initiative' in the field of 'Research in Science

& Technology' by Federation of Indian Chambers of Commerce & Industry (FICCI). -1985.

Confederation of India Industry (CII, Formally known as AIEI) award in recognition ofoutstanding Performance in Technology and Innovation 1985.

Award for outstanding contribution as equipment manufacturer for the development of Small

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DEPARTMENTS

Pattern Shop

Hydraulic Machine Shop

Tool Room and Tool Design Dept.

HREM Assembly

Turbine Assembly

Stamping Unit

Standard Pump Production Department

Tool Store

REM Testing

Hydro Power (SHP) in India, constituted by the International Association for Small HydroPower - 1997.

Award for commendable and outstanding contribution to Renewable Energy Sector from IndiRenewable Energy Development Agency (IREDA).

Award for development of computer aided design for 6 MW Generator and 1400mm diameter

Francis Turbine using the most advanced Pro/ENGINEER Software from ParametricTechnology Corporation (PTC) USA.,at first National Pro/USER Conference.

The Assembly ofHorizontal Pelton Turbine - One of the top five entries in Industrial EquipmCategory at Pro/USER conference USA for the PTC Award 2000 Competition.

Clients That Included

Reliance Industries Steel Authority of India Ltd.

Essar Indian Petrochemical Corp Ltd.

Tata Electricals and Co. Tata chemicals and Fertilzers LtdIndian Power Corp. Grasim Industries

Indian Oil Corp. Larsen and Turbo Ltd

Gas Authority Of India Ltd. National Thermal Power Corp.

Oil and Natural Gas Corp.

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Corporate Quality Dept.

Repair & Maintenance Dept.

REM and Pump Marketing Dept.

R&D Dept.

P.E.C.

Switchgear Plant

E.C.S. division

Details of some important departments are given below,

PATTERN SHOP

WHAT THEY DO

In pattern shop,we see the pump and their parts.Like,Impeller,Bowl,Suction Bell,HS Casing,Coupling

pump hail,Bearing House. Actually there is a wooden pattern of parts. It is made of nos. of woods of

pieces and then it is assembled with the help of steel wire and adhesives. For making of pattern first the

blade angles are found by mathematically by pressure distribution theory. Usually sag, teak wood, Sal,

etc are used as a wooden material.

WORKING OF PATTERN SHOP

y Get the drawing of the part of to be cast from the R & D department.

y

Drawing has the following details.They are cross check by pattern shop.y If ok then taken into plan.

Special instruction for the actual angular alignment of the diff. Parts like ribs of the both matching

male and female parts.During assembly of the pattern the following special features are taken into

account,

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y allowances (Machine,Shrinkage,Draft)

y as per sketch turning and jointing is done over the job.

y After that they are do the finishing and painting of the job.

y Inspection is taken on that finished job.If found not ok then it again send to R & D department.

y

And if ok then send it to in foundary shop.y Casting is come from the fuondary shop in pattern shop.

Turbine Assembly

Aturbineis a rotaryenginethat extractsenergyfrom afluidflow and converts it into useful work.

The simplest turbines have one moving part, a rotor assembly, which is a shaft or drum with bladesattached. Moving fluid acts on the blades, or the blades react to the flow, so that they move and impart

rotational energy to the rotor. Early turbine examples arewindmillsandwater wheels.

Several physical principles are employed by turbines to collect this energy:

Impulseturbines

These turbines change the direction of flow of a high velocity fluid or gas jet. The resulting impulse

spins the turbine and leaves the fluid flow with diminished kinetic energy. There is no pressure

change of the fluid or gas in the turbine rotor blades (the moving blades), as in the case of a steam or gas

turbine, all the pressure drop takes place in the stationary blades (the nozzles).

Before reaching the turbine, the fluid'spressure headis changed tovelocity headby accelerating

the fluid with anozzle. Pelton wheelsand de Laval turbinesuse this process exclusively. Impulse turbines

do not require a pressure casement around the rotor since the fluid jet is created by the nozzle prior to

reaching the blading on the rotor.Newton's second lawdescribes the transfer of energy for impulse

turbines.

Reactionturbines

These turbines developtorqueby reacting to the gas or fluid's pressure or mass. The pressure of

the gas or fluid changes as it passes through the turbine rotor blades. A pressure casement is needed tocontain the working fluid as it acts on the turbine stage(s) or the turbine must be fully immersed in the

fluid flow (such as with wind turbines). The casing contains and directs the working fluid and, for water

turbines, maintains the suction imparted by the draft tube.Francis turbinesand moststeam turbinesuse

this concept. For compressible working fluids, multiple turbine stages are usually used to harness the

expanding gas efficiently.Newton's third law describes the transfer of energy for reaction turbines

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PeltonTurbine FrancisTurbine

Turgo Impulse Turbine Horizontal Tubular Turbine

Horizontal kaplan

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Micro Turbine Generator Vertical Semi Kaplan

R & D Activities

'JYOTI' Pumps are produced with continuous indigenous R & D efforts. With experience of more than

50 years they have a tradition of reliability and high performance. Jyoti undertakes concept to

commissioning of Large Circulating Water Pumping Systems i.e. sump model testing, design and

manufacturing of pumps, motors valves, erection and commissioning with undisputed responsibility.

Jyoti's Research and Development Center, where pump designs are optimized on basis of efficient

feedback from field and laboratory experiments, undertakes research in the areas like :

Hydraulics

y Development of high efficiency models

Type Head M Output KW) Application

Pelton(Impulse) 100-700 100-10000 High Head

Turgo(Impulse) 40-200 30-5000 Medium Head

Francis(Reaction) 30-160 50-10000 Medium and Low head

Conventional(Reaction) 15-50 500-10000

Kaplan or Propeller 3-40 250-10000

Tabular Turbine 2-25 5-8000 Low Head

Turbines

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y Development of models having better performance with low NPSH requirements

y Studies of noise level in pumps

y Development of high head models.

y CFD analysis of large pumps.

PUMP & REM MARKETING

REM marketing department is related to marketing of the rotating electrical machines. In this

department decisions are taken about how to deal with customers. Some information about various

contract and terms of payments are as follows,

TYPES OF CONTRACTS

1. Supply contract

2. Contracts for supply and a separate contract for supervisory erectioning of the supplied goods.

3. Separate supply contract and a separate erectioning and commissioning contract on a lumpsom

basis.

4. A total works contract.

TERMS OF PAYMENTS

1. Tax deduction at source (TDS)

2. Bank guarantee

3. Guarantee

4. Deemed export

STAMPING UNIT

WHAT IS STAMPING

Stampings are the limitations used for making the rotor and stator of motor, generator,

transformer.Rotor and stator are laminated and not make as a single solid piece to reduce eddy current

loss and hysteresis loss due to heating.The losses are reduce the efficiency of the machine.so,we are

using laminations.

CIRCULAR CUTTING SHEAR MACHINE

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This machine is used to cut the square or rectangular plate in a circle like shapes.

NOTCHING PRESS

Notching presses are used for the economic manufacture of rotor and stator. Laminations for

electric motors in small and medium sized batches. The laminations are taken in out by hand. The rotor

and stator notches are stamped cut individually on the notching press.

P.E.C.

Utility demands that terminal voltage of generator is maintained constant under all operating conditions of

load , ambient temperature variations etc over a long period of time.

The AVR achieves this by feeding a required current to the exiter field of the generator through a thyristor

rectifier deriving its control from a feedback system.

The electronic circuit sets up a stable reference for the terminal voltage,compares feedback signal from

terminal voltage with this reference and utilizes amplified error signal to adjust the firing angle of the

controlled rectifier and thus maintains the generator terminal voltage constant.

The exitation power to the AVR is derived from the same generator terminal.

PRINCIPLE OF OPERATION

The AVR senses the generator terminal voltage , compares a rectified and filtered voltage with a stable

reference voltage and supplies the field current required to maintain the generator terminal voltage

constant within its regulation limit.

AUXILIARY RELAYS

In the Relay, movements of the armature because of coil attracting the armature.Armature having amoving contact.Whenever coil is energized the moving armature is attracted towards the fixedcontact.so the NO will become NC and NC become NO.The contacts of pure silver & fitted in such a

way that it gives reliable and low resistance contact.The moving contact reeds are made of speciallytreated materialto preserve initial elasticity under the fast switching conditions.

Jyoti Plug-in type RE-300 & RE-400 Auxiliary Relays are widely used for interlocking functions inThermal Power Stations, Petrochemical Complexes and Cement Plants. They are also used formultiplication of contacts, voltage selection, anti pumping in circuit breakers and as output element inPLC Systems. To protect Distribution Network, Electric Work Motors and Alternators, Jyoti hasdeveloped a wide range of Protective and Auxiliary Relays. These Relays, with solid-state technologyare designed to provide primary protection to rotating electrical machinery and 11 KV-33 KV distributionfeeders. They also provide back-up protection to HV transmission lines. These relays are approved by

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serveral consultants and are used by various electric utilities.

Voltage operated Auxiliary relay

FunctionRelayType

Technical Particulars : Applications :

Voltage operatedAuxiliary operations

RE-300 With 4 C/O contactsWith plug-in-base suitable for front and rearconnection.

With Electromechanical Flag

Coil Voltage DC : -12,24,30,48,50,75,110,127,220,240 & 250 V

Coil burden 4 wattsPick-up 80%(max)Coil voltage 24, 30, 36, 110, 115, 127, 150,220, 230, 240 &415 VAC, 50Hz.

Coil burden 6 VA (3W)Pick up 80% (max)

Non-standard voltage coils within the range of6 V to 250VDC or upto 415 VAC 50Hz can be suppliedagainstspecific requirements.

Auxillary relay panelsMultiplication ofcontacts

Voltage selectionAnti-pumping As an output relay inPLC systemsFuse failure indicationin control circuits

Mini Auxiliary Relay

FunctionRelayType

Technical Particulars : Applications :

Mini Auxiliaryrelay

RE-400 With 4 C/O contactsWith plug-in-base suitable for front connection

Coil voltage DC : -12,18,24,30,48,50,75,110,115,220VCoil burden 2.3 watts *Pick up 80% (max)

Coil voltage AC, 50 Hz. -12,18,24,30,48,50,63.5,110,115,127,150,220,230,240 V

Auxiliary relay panelsMultiplication of contacts

Voltage selectionAnti-pumpingAs an output relay in PLCsystemsFuse failure indication incontrol circuits

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1. Triple pole Solid State non-directional IDMTL Over current& Earth Fault Relay in Draw-out-case(3 O/C OR 2 O/C + 1 E/F)

JTRSA - O/C : 50 to 200% OF 5A / 1A- E/F : 10 to 40% OF 5A / 1A 20 to80% OF 5A / 1A- Instantaneous Unit : 400% to2000%- Characteristics : 3Sec / 1.3 Sec

- Aux Supply : 24/30/50/110/220VDC- LED Flag Indicators

Used for protection ofmotors, generators,transformers,distribution lines andas back-up relay onEHV transmission

lines.

2. Single Pole Solid State non-directional IDMTL in Draw-outcase

JSRSA As per Sr. No.1 As per Sr. No. 1

3. Single Pole Solid State non-directional IDMTL Over currentor Earth Fault Relay in Draw-out-case

JSRSA - With Very Inverse Characteristics- Rest as per Sr. No. 1

As per Sr. No. 1

Relays Sr. No. 1 to 3 are also available without instantaneous unit.

4. Instantaneous Under / Overvoltage relay in Draw-out-case

PV - Voltage Setting Range :- Under Voltage : 40 to 80% or 30 to90%- Over Voltage : 110VAC, 50 Hz- Nominal Voltage : 110 VAC, 50 Hz- Aux Supply : 24/30/48/110/220VDC- LED Flag Indicators- Relay with any fix voltage settingalso available

- Over voltageprotection ofgenerators, powercapacitors, etc.- Under voltageprotection of ACmotors.- Automatic voltagechange overschemes.

5. Definite Time Lag Under / OverVoltage relay in Draw-out-case

SPVK - Time range : 0.05 Sec to 120Secs.- Rest as per Sr. No. 5

As above

6. Power Unit JDL-110

JDK-110

- With trip circuit healthy and DChealthy indicators (For captivetripping of circuit breakers)- With 20 watt-sec output energy- Input Voltage 110/240 VAC, 50 Hz.- Output Voltage 110 VDC- Without plug-in-base (Case ref.EGE-301)- With 20 watt-sec output energyand built in RE-300 relay

Where provision ofstation batteries is noteconomical, powerunit is used forenergizing trip coil ofthe circuit breaker.

7. Voltage operated AuxiliaryRelay

RE-300

- With 4 C/O contacts- With plug-in-base suitable for frontand rear connections- With Electromechanical Flag- Coil voltage DC : -12,24,30,48,50,75,110,127,220,240& 250 V- Coil burden 4 watts- Pick-up 80%(max)

- Auxiliary relaypanels- Multiplication ofcontacts- Voltage selection- Anti-pumping- As an output relay inPLC systems- Fuse failure

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RE-302

- Coil voltage AC, 50 Hz. 24, 30, 36,110,115,127,150,220,230,240 415V- Coil burden 6 VA (3W)- Pick up 80% (max)- Non-standard voltage coils within

the range of 6V to 250V or up to 415VAC, 50 Hz. can be suppliedagainst specific requirements(anyone)+/- 10%, 50Hz +/- 3%,Single Phase.Coil burden 2.1 wattsCoil voltage:24 , 48 V DC

indication in controlcircuits

USED as inter-PosingRelay.

USED as inter-Posing Relay.

8. Mini Auxiliary relay RE-400

- With 4 C/O contacts- With plug-in base suitable for frontconnection- Coil voltage DC:12,18,24,30,48,50,75,110,115,220V- Coil burden 2.3 watts* Pick up 80% (max)- Coil voltage AC, 50 Hz.- 12, 18, 24, 30, 48, 50, 63 5, 110,15, 127, 220, 230, 240 V

- Coil voltage AC, 50 Hz.- 12, 18, 24, 30, 48, 50, 63 5, 110,15, 127, 220, 230, 240 V- Non-standard voltage coils withinthe range of 6V to 250V or up to 415VAC, 50 Hz. can be suppliedagainst specific requirementsanyone)+/- 10%, 50Hz +/- 3%,Single Phase.

- Auxiliary relaypanels- Multiplication ofcontacts- Voltage selection- Anti-pumping- As an output relay inPLC systems- Fuse failureindication in controlcircuits

CUSTOMERS

Areva Honeywell Automation

Asia Brown Boveri HPCL

Bharat Heavy Electricals Ltd.,Bengalore IFFCO, Panipath

Bharat Heavy Electricals Ltd.,Bhopal IFFCO, Phulpur

Bharat Heavy Electricals Ltd.,Haridwar Indian Oil Corporation Ltd.

Bharat Petroleum Co. Ltd. Jindal Power

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Bihar Alloy Steel Larsen & Toubro Limited

Calcutta Metro Mihir Cement

Control & Schematic National Aluminium Co. Ltd.

Crompton Greaves Limited National Fertilizers Ltd.

Delhi Metro National Thermal Power Corporation

Department of Atomic Energy Popular Switchgear

DVC Reliance Industries Jamnagar.

Electronics Corporation (I) Limited Reliance Industries Patalganga.

FCI Talchar Siemens Limited.

Gas Authority of India Ltd. Steel Authority of India Limited

GE Alstom State Electricity Boards.

GE Fenuc Ultra Tech

Gujarat Narmada Valley Fertilizers Co. Yokogawa India Limited

DIFFERENCE BETWEEN RE-300 & RE-400 RELAY

APPLICATIONS OF RELAYS :

Auxiliary relay penals Multiplication of contacts Voltage selection Anti- Pumping As an output relay in PLC systems Fuse failure indication in control circuits

These relays are used at Thermal power stations , process plants & refineries.

QUALITY CONTROL

RE-300 RE-400

Big in size Very compact in size

Pure siver is used at contacts Bimetal (copper silver ) is used

Cost price is more Cost price is less

Single polarity LED is used for indication Bipolar LED is used for indication

It is more durable It is less durable

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Quality controlis a process by which entities review the quality of all factors involved in production. This

approach places an emphasis on three aspects:

1. Elements such as controls, job management, defined and well managed processes, performance

and integrity criteria, and identification of records

2. Competence, such as knowledge, skills, experience, and qualifications

3. Soft elements, such as personnelintegrity,confidence,organizational culture,motivation,team

spirit, and quality relationships.

Total Quality Control is the most important inspection control of all in cases where, despite statistical

quality control techniques or quality improvements implemented, sales decrease.

IR Inspection Report and QAP Quality Assurance Plan

Example of quality control of Row Material ;

Components Raw Material

Characteristics Checked chemical composition , mechanical properties etc.

Classificaton minor or major

Type of check measurement , chemical analysis,hardness test etc.

Quantum of check random or 1 per lot or 2 per lot etc.

Reference documents drawings

Acceptance Norms -- IS: 2004 , IS::7283 etc.

Format of Record IR,STC,MTR etc.

Agency QC, SUPLR LAB

Remarks once in 4 months

HRM MACHINE SHOP & ASSEMBLY

The process is given that done in HEAVYROTATING MACHINE shop are given below,

y The stampings are combined by applying hydraulic pressure of the stator.

y Bundled of stampings are weld together without removing hydraulic pressure.

y Inner surface of the stator is smothinig and winding is done manually inside rotor.

y For Varnishing the stator part is put inside the varnishing chamber.

y Drying of that varnishing it is put inside the ovan.

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y Dried stator is welded into the casing.

y Rotor is fit into casing then assembly is done of all the other parts of motors.

STATOR OF MOTOR

There is a one CNC machine named VERTICAL TURNING LATHE.(Company name :YOU JI) which

costs 2.5 crore ruppees.It is use for automatic operation by programming.Its main functions are : turning ,

drilling, winding , healing ( in 2 dimensions)

There is another machine named Horzontal machining center (company name :JUARISTI) which costs

3.5 crore rupees.It is also for same purpose.Its main functions are : turning , drilling, winding , healing ( in

3 dimensions)

HM ASSEMBLY

PUMPS :

Lifting Your Dreams to Reality

From Pre-independence days, Jyoti pioneered the development of pumps to handle water for irrigation

and water supply schemes. To meet the growing requirements, Jyoti has continuously widened its rangeof medium and large pumps.

Today, they meet requirements of :

Condensate, Circulating and Cooling Water in Thermal Power Stations. More than 50% of ThermalPower Stations in India are equipped with 'Jyoti' Circulating Water Pumps.

Irrigation Projects and Water Supply Schemes.

Dewatering of laobocles and drainage of storm water.

Process and Engineering Industries.

There are also special purpose pumps such as Lubricating Oil Pumps for Steam Turbines and ModeratorPumps for handling heavy water in Nuclear Power Stations.

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Some of names of pumps of JYOTI are given below,

VM Vertical mix pump

HS Horizontal split casing pump

VT Vertical turbine pump

NC Non clock pump

VNC vertical non clock pump

FANC Fransis Auxiliary non clock pump

MOP Main oil pump

BOP Booster oil pump

HREM ASSEMBLY

Computer - aided design facilities, Pump model and sump model testing facilities, Non-DestructiveTesting (NDT) and Dynamic Balancing ensure superior hydraulic and mechanical performance of 'Jyoti'Pumps.

A large test-bed with 25,000 cubic m/hr. and power up to 1500 KW ensures the quality and performanceof 'Jyoti Pumps'.

Roating ElectronicsMachines

y Alternators/ Generators

y Medium/ High Voltage Motors

y Special Purpose Rotating Electrical Machines

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y Generator for Wind Turbine

y Largest Rating Vertical Motors for Lift-Irrigation schemes

Jyoti has pioneered the development of Rotating Electrical Machines for more than fifty years. Theyinclude,