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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,
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