UNIVERSITY OF MORATUWA

Faculty of Engineering

Non-GPA Module 3992: Industrial Training

TRAINING REPORT

Dynamic Technologies (Pvt) Ltd

From 20/10/2014 to 10/04/2015

Srikandaraj.S
110554K

Department of Mechanical Engineering

PREFACE
This report on Industrial Training covers all aspect of Mechanical Engineering Principal
covered at the company during the 25 weeks of training started at 20th October 2014 and ended
on 10th April 2015.The report includes manufacturing of Pneumatic conveying equipments
and its processes involved during working conditions. Details on practices involved in using
Design software is also described in the context along with the manufacturing processes. The
report also describes the Activities and documentations that were carried out during the ISO
documentation process and management activity.

ACKNOWLEDGEMENT

The success of this training would not have been possible without the ceaseless cooperation of some valuable people, whose guidance and encouragement let me to reach my
final goal.
My ever gratitude goes to Mr. Asoka Dharmawardana, CEO of Dynamic Technologies
Pvt Ltd for giving us the training opportunity at the company.
I would also like to thank to our Engineer in charge Mr. Prasad Weerasinghe and Hirosh
Wickramasinghe for their friendly support and guidance that helped me to complete this
training successfully.
I would like to convey my heartfelt gratitude to the staff of Dynamic Technologies Pvt
Ltd for spending their valuable time to provide precious information to complete the training.
Also special thanks go to Industrial Training Division of University of Moratuwa, and staff
members of NAITA.
Finally my gratitude goes to my team members, parents and my dear colleagues for the
encouragement and the massive support given in the successful completion of this Training.

ii

Contents
CHAPTER 1 ........................................................................................................................................... 1
1.1 Introduction to the Training Establishment .................................................................................. 1
1.2 SWOT Analysis ............................................................................................................................ 2
1.2.1 Strength of the company ....................................................................................................... 2
1.2.2 Weaknesses ........................................................................................................................... 3
1.2.3 Opportunities ......................................................................................................................... 4
1.2.4 Threats ................................................................................................................................... 4
1.3 Production and Improvements ...................................................................................................... 5
CHAPTER 2 ........................................................................................................................................... 6
2.1 Screw Conveyor Design ............................................................................................................... 6
2.2 Training on Pneumatic Conveying Process .................................................................................. 8
2.3 Silo Vent Filters Production ....................................................................................................... 10
2.4 Scissor Lift Design ..................................................................................................................... 12
2.5 Rotary Feeder design .................................................................................................................. 14
2.6

Solid works Sheet Metal Training and Production ............................................................... 15

2.7 ISO 18001 & ISO 9001 Audit Reporting Training..................................................................... 16

2.8 Blower Design ............................................................................................................................ 17
2.9 Tank Truck Parts, Pump and Compressor Manufacturing ......................................................... 19
2.10 Hydraulic Punch Design Research ........................................................................................... 20
2.11 Flipper Arm Design .................................................................................................................. 22
CHAPTER 3 ......................................................................................................................................... 23
3.1 Conclusion .................................................................................................................................. 23
ANNEXES .............................................................................................................................................. v
Annex - A ........................................................................................................................................... v
Annex - B .......................................................................................................................................... ix
Annex - C ........................................................................................................................................ xiii
Annex - D ........................................................................................................................................ xvi
Annex - E ........................................................................................................................................ xxii

iii

List of Figures
Figure 1-Screw Conveyor Assembly ......................................................................................... 6
Figure 2-Screw Conveyors ........................................................................................................ 7
Figure 3-Screw Trough .............................................................................................................. 7
Figure 4-Silo Vent Filter .......................................................................................................... 10
Figure 5-Pleated Filter Elements ............................................................................................. 10
Figure 6-Square Silo Vent Filter .............................................................................................. 11
Figure 7-Simulation of Silo Vent............................................................................................. 11
Figure 8-Scissor lift Assembly................................................................................................. 12
Figure 9-Rotary Feeder Assembly ........................................................................................... 14
Figure 10-Rotary Feeder Impeller ........................................................................................... 14
Figure 11-Y joint Reducer ....................................................................................................... 15
Figure 12-Y Joint Reducer ....................................................................................................... 15
Figure 13-Blower Design Software ......................................................................................... 17
Figure 14-Master Copy Design ................................................................................................ 18
Figure 15-Impeller Design ....................................................................................................... 18
Figure 16-RTL-80 Compressor................................................................................................ 19
Figure 17-Foot Valve ............................................................................................................... 19
Figure 18-Discharge Valve ...................................................................................................... 19
Figure 19-Hydraulic Punch ...................................................................................................... 20
Figure 20-Stress Analysis of Hydraulic Punch ........................................................................ 20
Figure 21-Displacement Analysis ............................................................................................ 21
Figure 22- Second Alternative Design's Stress Analysis ......................................................... 21
Figure 23-Flipper Arm ............................................................................................................. 22
Figure 24-Flipper Arm Top Body ............................................................................................ 22
Figure 25- Foot Valve ............................................................................................................... vi
Figure 26-Discharge Valve ....................................................................................................... ix
Figure 27-Vent ....................................................................................................................... xiii
Figure 28-Female and Male Coupling .................................................................................... xvi
Figure 29-Female Coupling .................................................................................................... xvi
Figure 30-PTO Pump .............................................................................................................xxii

iv

List of Tables
Table 1-Scissor lift bill of material .......................................................................................... 13
Table 2-Part list Foot Valve ....................................................................................................... v
Table 3- Part list Discharger ..................................................................................................... ix
Table 4- Part list Vent ............................................................................................................. xiv
Table 5- Part list Female Coupling ........................................................................................xvii

CHAPTER 1
1.1 Introduction to the Training Establishment
Dynamic Technologies (Pvt) Ltd was established in 1993 by a sole proper tier named Asoka
Dharmawardena. The headquarters of the company is situated at New airport road Ratmalana
and the second workshop is situated at gall road Ratmalana and the bouser and bulk carrier
manufacturing plant is situated at Pallekala Kandy.
The company specializes in manufacturing the following
* Trailers
* Road Tankers and tanker equipment
* Cement Bulk Carriers
* Truck Bodies
* Bulk Material Handling Equipment
* Silos, Bins, Hoppers, Screw Conveyors
* Pneumatic Conveying Equipment
* Machinery Fabrication
The main clients of the company are mostly cement producing companies such as Holcim and
Lafarge. The company also produces oil bousers for Ceylon Petroleum Corporation and private
petroleum companies. The company also producers pumps which are used in oil bousers (PTO
pumps) and compressors which are used in cement bulk carriers for pneumatic conveying
purposes.
The company manufactures and owns several cement bulk carriers which are used to transport
cement powders. The company also specializes in manufacturing screw conveyors, sliding
gates and various dust collecting system and air-condition ducts. The company also
manufactures customized machinery equipments according to the clients specifications.
As another new initiative the company has started manufacturing blower units with the help of
an Indian Consulting Company. The in house gantry cranes were also designed and
manufactured by the company itself and as another initiative the company also seeks to
manufacture gantry cranes for external clients.
The training for the undergraduate was conducted in the headquarters work shop where the
training schedule includes the aspects of manufacturing and machine design and as the
company has received the ISO 18001 and ISO 9001 a special training was given ISO
documentation and layout preparation of the workshops.

1.2 SWOT Analysis

1.2.1 Strength of the company
The company has specialized in making cement plant machineries, bulk carriers, oil bouser,
bouser valves and pumps. The workers are highly trained in the manufacturing process of the
above mentioned products. The company possesses highly trained engineers in producing
pneumatic conveying equipments.
Since the company is well established in the manufacturing and designing sector it has a wellestablished supply chain. Apart from steel material which obtained from well-established
importers such as A.C.Paul, other equipments such as gear motors are directly imported
through a subsidiary company named Magnum Technologies hence delay time in receiving
material reduced.
The machinery available in the workshops are very well sufficient for the production of the
company and investments are frequently made for new machinery for example a 10 ton gantry
crane is being made in the Ratmalana II workshop for heavy lifting. In both the workshops
situated in Ratmalana separate machining facilities are available for machining purposes.
Machines available at the workshops are

Lathe Machine with various bed sizes

Bending and flanging machines

Automatic profile cutters

Milling machines

Vertical and horizontal boring machines

Steel plate rolling machine

H iron rolling machine

Shearing machine

Drilling machines

All the above machines are serviced properly and all the workers trained properly to use it
safely and efficiently. The company manages work by also hiring external contractors for
working in sites for the installation of manufactured equipments. Another important
fabrication aspect is welding in which the company has well trained and welders who
specialized in Arc, Tig and Mig Welding.

1.2.2 Weaknesses
One of the biggest inefficiency of the company is material wastage since no technique was
used to cut off steel plate is used properly. Most of the time the company orders are prioritized
as urgent and hence if material delay is encountered from a frequent supplier a more expensive
material is bought from a different supplier and hence higher cost is encountered.
Another inefficiency is the rise of labour cost due to lack of planning of the project. The
company does not use any project management softwares to have parallel ongoing project and
has to pull labour from one project to successfully finish another project. The idle time of
workers are also relatively high due to lack of planning and hence huge amount of overtime
has to be done to complete projects in time. The labour force is motivated to over time to
complete project hence the company is very lenient in its overtime policy for employees.
Quality control is another problem hence no records of control is properly maintained for future
references so that any problem regarding the manufactured projects could be easily rectified.
For example if a screw conveyor is made the dimensions of the plates must be checked with
the relevant drawings and deviations must be recorded and corrected. This practice would
highly reduce the mistakes that could occur in future projects.
Store keeping is one of the big issues in the workshop. Tools are not distributed to workers
based on projects and hence the tools get misplaced very often. The store keeping is not done
properly and no proper records are maintained on who is using the tool.
Even though products are designed using Solid Works, Auto CAD and Inventor no proper
simulations were done on the projects to look upon on structural strength and its feasibility and
hence most of the products are over designed. Over designing products has incurred huge cost
on usage of material.

1.2.3 Opportunities
Huge opportunities exist on the sector of machinery manufacturing for the company and bulk
carrier and bouser manufacturing. The has huge expertise manufacturing screw conveyors and
belt conveyors and these conveyors not only applicable for cement manufacturing and could
be used food processing machines, for example recently the company received orders to make
stainless steel shredder and hoppers from PRIMA and there many companies such as PRIMA
in need of efficient production technology.
Recently the company has sent its engineers to India to be trained in blower manufacturing
technology. These blowers are to be made using the Keith Blackman Blower technology. The
blowers will be mainly aiming dilute phase pneumatic conveying technology and HVAC
engineering. The demand for blowers have increased as new cement plants are being opened
in Srilanka.

1.2.4 Threats
Manufacturing industry is a highly competitive industry where new technologies in order
improve cost cutting and quality and also to improve the efficiency of production. But this
company does not have R & D facilities to create new products and machines and to do cost
cutting research. This one of the main threats as other companies such Load Star has a
modernized R & D facility.

1.3 Production and Improvements

New investments has be bought into the company to increase efficiency and cut costs for
example screw flights are manufactured manually in this company but it could improve its
efficiency by investing screw flight making machine which reduce the cost of making the screw
and the labour intensity of the production. It will also improve the quality of the products it
makes which increase the value of its brand name.
Another important factor is that the company invest more on safety and to develop the
workplace environment to easy place to work so that human resource would be retained for a
very long period of time.

CHAPTER 2
2.1 Screw Conveyor Design
Screw conveyors are manufactured in the company for cement manufacturing clients and food
manufacturing clients. The material used for manufacturing the screw conveyors are Mild Steel
plate and stainless steel plates. The most important aspect of the screw conveyor is the pitch of
each flights and the trough size.

Figure 1-Screw Conveyor Assembly

The manufacturing process of the screw conveyor is quite complex. The pitch and the height
of the flight are determined by the flow rate required by the client through the conveyor. The
main components of a screw conveyor are,

Screw flight

Screw trough

Flight carrying pipe

The end shafts

Inlet and outlet

Hanging bearing

Pillow blocks

Inspection door
6

Mostly the screw conveyors manufactured in the

company uses Mild steel plate to produce screw
flights for normal usage but if the usage involves
heavy corrosive environment the a special hardox
plate is used and if the conveying involves food
processing stainless steel is used as the material.
When stainless steel is used as material to produce
the screw conveyor special care has to be taken
when welding the material. Stainless steel welding
rods are used and at the end a special acid is used
Figure 2-Screw Conveyors

to wipe away the burned marks off the material.

Each of the screw flights are cut separately using the plasma arc profile cuter as circular shape
and then each flights are pulled using workshop made manual puller to the required pitch and
then each of the flights are welded together and a spiral of flights are formed. Then the screw
pipe is set on a stand and the spiral of the flights are inserted onto the pipe.
Then one end of the spiral shape is welded to one end of the pipe and the other end is puled
using a chain and a lever block until the correct pitch is accurately obtained. Welding tacks are
put in important places of the flights to maintain pitch until complete welding is done.
The end shaft that is used to end of the pipe to couple the screw with the motor is machined at
the machine shop. The end shaft machined with a taper at the inserting side of the shaft so that
the pipe could be inserted easily inside the pipe. The shaft inserted tight fit into the pipes and
then welded together. A hydraulic jack is used to insert the
shaft inside the pipe.
The screw trough is the outer body of the screw and it is
formed in circular shape or half circular shape depending on
the clients request. If a circular trough is required a pipe is
used to form the trough if a half circular trough is required
Mild steel plates are rolled to obtain the required shape and
flanges are welded to each end of the screw trough. A cover
has to be made to cover the top of the half circular trough
and mostly circular trough screw conveyors are used in
inclined position conveying.

Figure 3-Screw Trough

2.2 Training on Pneumatic Conveying Process

A special training was given on Pneumatic conveying systems where air is used to convey
particles from one place to another. This process is mostly used in cement production where
most of the raw materials are in powder form. The ideal candidate for pneumatic are free
flowing non-abrasive and non-fiber material.
There are four distinct zone in a pneumatic conveying system.
1. The prime mover
2. Feeding, mixing and acceleration zone
3. The conveying zone
4. Gas-solids separation zone
The prime mover consists of blowers, fans and compressors which provides the necessary
energy to the conveying gas to carry to solid particles. A wide range of pressure is used to for
the transportation of solids and additional functions such as drying cooling and filtering could
be implemented in the in prime mover component.
Feeding is done through various mean depending on the density of the conveying material, the
feeding could be done through blow tanks for dense phase systems and rotary feeders are used
in dilute phase pneumatic conveying systems. In this particular zone solid are introduced into
the flowing gas and large change of momentum occurs. Acceleration of the particles are also
done using in between air flows inside in the pipes.
Once the solids have passed the feeding and the acceleration zone they enter into the conveying
zone. The conveying mainly consist of piping and consideration has to be given to reduce ware
and frictional losses and maintain the required pressure requirement. The conveying zone
consists of the following areas,
1. No of bends
2. Diverter valves
3. Dampers
4. Air slides
5. Small acceleration zones
Small acceleration zones are present after every bends to compensate losses at the bend.
Diverter valves are used to change direction in conveying process. Air slides is another
important aspect.

In normal condition the a 45 degree angle inclination is required for the gravitational fall of
particles but when particle are levitated using air the flowing inclination could be reduced to 4
degree of angle. This reduction has reduced the cost of building the pneumatic convey system
and has improved the efficiency.
The gas solid separation consists of silo vent filters and conical filters. This stage consists of
several stages of separation zone depending on particle sizes that are being filtered. Conical
filters are used to separate heavy particle and used at the beginning of the zone and silo vent
filters used on top of silos and are used to separate very fine particles.
There two different modes of pneumatic conveying they are
1. Dilute phase systems
2. Dense phase systems
In Sri lanka most of the systems involves dilute phase pneumatic conveying systems. In this
system blowers are used as prime movers and the particles inserted in to the moving air by
means of rotary feeders. The rotary feeders air lock feeders where the particle is fed into the
system using air lock mechanism.
In the dense phase system particles are conveyed using air compressors and a special blow tank
is used pressurize the particles. The particles conveyed in pockets through the pipe and this is
achieved by means of air knife. In the blow tank the particle are in a fluidized stage by means
of flowing air.
Dese phase systems are used in high pressure low flow rate application. In these system wear
and frictional losses are less as the system is a slow system and much cost effective. High
pressure multi impeller blowers could also be used to power the particles.
Dilute phase systems are used in high velocity low pressure application and special feeding
systems are implemented to feed the particles inside the moving air. In this system wear and
frictional very due heavy impact of particles with the wall of the system.

2.3 Silo Vent Filters Production

Figure 5-Pleated Filter Elements

Figure 4-Silo Vent Filter

Silo vent filters are used on top of the cement silos to filter fine cement dust particles at the exit
of the pneumatic conveying system. Pleated filter elements are used to at this silo vent filers
manufactured in the company.
These filter elements are air tightly fitted to tube sheet using pieces of c-channels and the
sometimes venturi element is fixed with the tube sheet to fix the pleated elements. The filter
elements are cleaned using reverse jet air flow from compressor to blast of the dust particles
adhered to the filter elements. A solenoid valve is used to control the air flow time and circuit
is placed in an enclosure box.
Circular cylinder is obtained by rolling a steel of 4mm thickness and welded at the end and the
small cylinder to for compressed gas to exist is obtained by using a pipe. Another special design
is the inspection door where it is designed to sealed even when the door not tight locked by
butterfly nuts. The operator need to pull the door forward before you could open it wide. This
door ensures that the filter element does not get wet by any means of water get inside the filters.
The top lid of the silo vent filter is manufactured using sheet metal spinning and a rolled circular
sheet is welded to the end of the spinned lid. The manufacturing of the circular type silo vent
filters are complicated and its very time consuming to weld the holders of the air cylinder and
the inspection door and hence a new design has is been done and the shape was of silo vent
filter is made in rectangular shape so that the parts that has to be welded to filter could be easily
placed at the exact position.

10

Figure 6-Square Silo Vent Filter

Figure 7-Simulation of Silo Vent

The new design was tested using the Solid works simulation by applying load 500N to the
casing to observe any failure structure and was optimized to bear the load of the air cylinder
which is attached to the silo vent filter.
A problem was encountered after the design at bottom flange of the filter. Usually silo tops are
in conical shape and in the original circular shaped silo vent filter fixing it to the top of the silo
vent filter will not be an issue as it is circular shaped but in the square shaped silo vent filter a
transition of rectangular to circular has to be made in order fix the new silo vent filter.

11

2.4 Scissor Lift Design

Figure 8-Scissor lift Assembly

A scissor lift was being asked to be designed by the trainees and as a team the above scissor
lift was designed. The lift is capable of lifting 5 ton of weight. The calculation was done based
on virtual work theory experiment which is annexed in this report.
Safety was the main aspect when designing this scissor lift and hence two hydraulic jacks were
placed in two different optimum weight handling places. From designing this scissor lift more
knowledge was gained on using standard components such as I beams and box bars. ISO
standard structural elements are used here.
More knowledge was also obtained in using and handling Solid works when modelling this
software and using standard element from Solid works tool box. The calculation as mention
above was taken from journal paper and the research emphasizes on the optimum placement of
the hydraulic cylinders for optimum weight handling.

12

Total material cost was 434000/- LKR and a bill of material was also prepared using the
current market price of structural elements.
Table 1-Scissor lift bill of material

From this designing assignment a better knowledge was obtained on the aspects of
fabrication and costing when commencing new projects.

13

2.5 Rotary Feeder design

3 Rotary feeders were overhauled for repairing

purposes. Rotary feeders were an important
aspect in pneumatic conveying systems. In the
dilute phase pneumatic conveying system
particles are fed through rotary feeders. It also
functions as an air locking mechanism where
backward air flow in to the hopper is blocked
and particles carried in feeder pockets and fed
Figure 9-Rotary Feeder Assembly

into the flowing air of the pneumatic conveying.

The obtained rotary feeders showed heavy ware on the edges of the rotating impeller inside
feeder casing. The project involved in filling the edges using welding and machined in the
lathe.
The shaft, coupling to the motor also has to be machined as it showed heavy ware due to
unsymmetrical loading and a new bearings also was installed. From this project knowledge
was obtained on overhauling heavy equipment and
filling of worn components. A separate solid works
drawing was asked to drawn for future references.
This figure shows filling of the worn edges and
machining. A special rubber material is also fixed to
the edges of the impeller of the rotary feeder.

Figure 10-Rotary Feeder Impeller

14

2.6 Solid works Sheet Metal Training and Production

Various shapes of reducers were asked to be drawn, by

the engineer to provide drawings for production. Solid
works sheet metal was used to draw and obtain flat
pattern drawings for the purpose of manufacturing.
One of the challenging task to draw was the Y joint
reducer where it was challenging to draw combining
both the shape of Y joint and the reducing aspect.
Figure 11-Y joint Reducer

Another important factor is that various commands

such as Edge flange, Flat pattern, and Loft pattern to sheet metal conversion were learned in
this training.
Opportunity was also given to participate in the manufacturing process of the sheet metal
reducers with the help of workers.

Figure 12-Y Joint Reducer

Through the production training various skills were obtained such as using the sheet metal
bending machine and rolling machine to form the required profile.
Another problem occurred during the production of the Y Joint reducer because of its complex
profile. While bending the edges of the side curve the correct profile could not be obtained and
hence the side bend was adjusted by using the hammer after welding it to the main structure.
The training obtained from this exposure provided us with knowledge on sheet metal
fabrication and its importance.

15

2.7 ISO 18001 & ISO 9001 Audit Reporting Training

The company taken the ISO certification a year back and training opportunities were given by
an Indian consultant and were taught on producing various documentation for ISO audit
purposes. The documents that were prepared for the Rathmalana branch were,

Hot work Permit

Height work permit

Job safety analysis form

Fire Training guide

Quality Control Reports

Tool Box Meeting

Apart from only doing documentation we were asked to draw a new layout of the workshops
Rathmalana 1 and Rathmalana 2. The layout has to be drawn in a manner so that movement
inside the work safe and easy.
ISO 18001 is all about Occupational health safety standards and we were asked to prepare a
list of safety issues related to current work shop condition in order to rectify it and improve the
safety condition.
ISO 9001 is all about quality control on production and a Microsoft Access based quality
control creating system was developed in order to make documentation easy for the engineer
or supervisor.
We also prepared a list of machines available in both the work shop and created safety report
on all machines and conducted an awareness program for the workers with the help of the
safety officer.
Vital amount of knowledge on ISO 18001 and 9001 was provided to us with management
advices was provided to us by the Indian consultant.

16

2.8 Blower Design

The company has initiated new plans to start manufacturing blowers for the industry. An Indian
company was consulted for the new plan and has obtained rights to manufacture blowers based
on Keith Blackman series blower specification. Training opportunity was given to design
blowers using solid works based on Keith Blackman specification. A software was given by
the Indian company which shown below

Figure 13-Blower Design Software

From the above software a blade no could be obtained based on the impeller diameter and using
the diameter and using Keith Blackman hand book the correct profile of the housing and the
impeller could be selected. A master copy of the profile of the housing was also given by the
Indian company so that the relevant scaling factor could be used to construct the housing.
The master copy was cross checked by actually drawing fan under the specification provided
by the software provide and there were no noticeable difference between the scaled drawing
and the real drawing created using Auto CAD.

17

A Solid works drawing of the impeller was also obtained to

observe the reliability of the obtained data from the software as
well as the handbook.
The Engineer in charge Mr.Hirosh Wickramasinghe shared his
knowledge on manufacturing blowers as he was trained by the
Indian consulting company. We were taught on different sub parts
that accompany the blower unit which increases its efficiency.
Figure 14-Master Copy Design

The training also provided guidance in the selection of material and structural design to cope
with the vibration produced by the fan and also to produce fans with less noise.

Figure 15-Impeller Design

18

2.9 Tank Truck Parts, Pump and Compressor Manufacturing

The company producers the following which are regularly manufactured in the company for
assembling purposes for the bousers and bulk carriers which they make in the Pallekala
workshop.

Foot Valve

Discharge Valve

Tank Vents

Female and Male coupling

PTO Pumps

RTL -80 Compressor

Figure 16-RTL-80 Compressor

Training opportunities were in the production of each

products mentioned above. The production and features detail
of these products annexed in this report separately as a
production report.
These products were made based worker experience and no
documentation existed in the company for any references and
we were asked by the engineers to create a production report

Figure 17-Foot Valve

on the above mentioned products.

Measurements were taken from the samples and complete
drawings were created for these components and a report was
written mentioning the manufacturing techniques and features
of the products designed.
Information on testing of these parts are also mentioned in the

Figure 18-Discharge Valve

report. Knowledge on production of these parts obtained by getting involved in the production
and testing of these part with responsible workers. The workers eagerly assigned us tasks to
experience the methodology of the manufacturing practice of these products.

19

2.10 Hydraulic Punch Design Research

A 40 Ton hydraulic Punch was asked to be designed
using the off cut pieces of steel plates and steel blocks.
The

engineer

in

charge

was

Mr.

Prasad

Wickramasinghe.
Two alternatives were proposed one is to use 25mm
plates to create the outer structure or to a solid steel
block to create the structure.
According the proposed design the hydraulic cylinder
will have a diameter 110mm and will joined to the
structure using thread connection for high stability
Figure 19-Hydraulic Punch

Figure 20-Stress Analysis of Hydraulic Punch

A 50 ton weight was applied to the structure when the simulation is done using solid works
simulation the mesh setting given was very fine to obtain accurate results but the time
consumed for processing was very high. The stress plot above shows a shear strength failure at
the inside edge of the structure.
Optimization was carried out to reduce impact due to stress on that area but with addition of
material cost and weight increased. Weight of the total assembly according to Solid works was
100kg which could still be lifted using a fork lift and could be made portable.

20

Another problem involved with the

structural strength is that the plates are
going to be welded to each other. The
connection type resembled in the solid
works simulation is rigid connection
which

100%

connection

and

match
hence

the

welding

in

practical

situation the load which the structure

withstand is much less than the expected
40 ton weight.
Figure 21-Displacement Analysis

This figure shows the simulation done for a solid steel

block and it shows a more positive results but still
using plates is cheaper to make than using a solid steel
block. If a more strong material than Mild Steel is
used one could expect a much positive result.
From this research thorough knowledge of using solid
works simulation and motion study was obtained.
Figure 22- Second Alternative Design's Stress
Analysis

21

2.11 Flipper Arm Design

Flipper arms are manufactured in the company for
Srilankan Ports Authority. Flipper arms are merely guiding
arms used in cranes lifting container boxes. One of the
important aspects that needs to be taken care of when
manufacturing the product is that inside edge of the flipper
should be exactly 90 degrees otherwise the container box
will not properly align with the crane hooks.
Knowledge on making jigs were obtained from the project
where 90 degree jig has to be made by using a sample
flipper arm sent by the client
Figure 23-Flipper Arm

The required amount material was calculated and amount

of steel plates needed for project was submitted. Training

was obtained on using the profile cutter using Auto cad drawings.
One of the biggest problems that has happened on one of the previous manufacturing process
was that the when welding has been done to the bush due to heat a small deflection has taken
place and hence the inside edge was not aligning properly with the container box.
In the current project the trainees were an opportunity to supervise and make a quality control
report to the engineer. Each dimensions of the drawing were cross checked with original sample
and reported. The project also provided great amount training in fabrication of steel plates for
example arc welding, plasma arc cutting and grinding.
Full guidance of the workers given in the fabrication
process of the flipper arm. The bush that connects the
shaft is machined properly so that no misalignments and
this in order to prevent the previous error the bush will
not be welded at the work shop but will be welded on
site while assembling it to the crane.
Another important thing considered is that in order to
have proper alignment the steel plates were tacked
together prior drilling holes for bolts.

Figure 24-Flipper Arm Top Body

22

CHAPTER 3
3.1 Conclusion
A vast amount of knowledge on mechanical engineering principal and practices was obtained
from the Industrial Training at Dynamic Technologies Pvt Ltd. A thorough understanding
pneumatic conveying and its principals were obtained from this training session. The company
staff were eagerly sharing the knowledge which they accumulated along all these years with
us.
A thorough knowledge on manipulation soft wares such as Solid Works and Auto Cad was
obtained during the training process and were taught on the industrial application of the theses
software. More emphasis were given structural simulation studies using Solid works
Simulation 2014.
The workers eager to share their knowledge on manufacturing activities there were keen to
make us get involved in manufacturing procedure of the products.
A thorough knowledge on ISO 18001 and 9001 certification was provided to us from the Indian
consultant and we were able to contribute the company our share of work on ISO
documentation requirements and workshop layout arrangements.
There were other activities which were also done during the training period, they are

Motor winding introduction

Gantry crane manufacturing for the workshop

Interpenetration curve drawing using Solid works

Basic training on Aluminum sheet rolling machine

Flow simulation basics

Introduction to Ansys work Bench

Supervision and Managing work forces

The above mentioned were only basic introduction and observation activities and hence not
include in the context of training experiences.
The engineers in charge

Mr. Prasad Weerasinghe

Mr.Hirosh Wickramasinghe

Provided us with all the help in achieving the required goals throughout the training session.

23

Training was also given to us the following contexts as well

Managerial

Costing

Human Resource Management

Ware house management and Stock control

These were related to the ISO documentation practice.

The training obtained from the company is a valuable asset for Mechanical Engineering
Students who have and will undergo training at this place.

24

ANNEXES
Annex-A
Valve production
Foot Valve
Private valves are type of foot valve which are used in oil tanks in order to prime the pump and
to maintain continuous flow. The valves are based on the Emco tank truck valve configuration.

Features
o
o
o
o
o
o
o

High quality die cast body and component materials to international standards for
durability and performance
Lightweight aluminum construction for increased payloads
Self-centering plunger and durable compression spring
Removable bonnet assembly enables easy seal change
Parts common to other valves in our range to minimize spares inventory
Hydrodynamic body design minimizes pressure drop to give high flow rate
Viton seals are standard for compatibility with high-octane fuels and additives
Table 2-Part list Foot Valve

NO

Part Name

Material

Form of Material

Piston Rod

Aluminum

Casting

Spring Plunger

Aluminum

Casting

Spring

Piston(Rubber holder)

Aluminum/Steel

Casting

Foot Valve Rubber

Rubber

Piston nut

Aluminum

Casting

Filter Mesh

Aluminum

Mesh

Valve Housing

Aluminum

Aluminum

Figure 25- Foot Valve

vi

Valve housing
Initially the castings are obtained from the supplier .Then each end of the valve is
machined to obtain the required thickness of the flange. The outlet and the inlet
openings were also machine to obtain the required thickness. The valve seat is
machined to reduce its surface roughness so that the rubber washer is properly seated
and prevent leakages.
Then four slots are cut in equal circular displacement around the inlet edge to fix the
spring holder through it and fix it with a twist. The filtering holes are then filed to obtain
the smooth edges. Since the housing is made of Aluminum the slots are cut using the
hack saw.
Using the tap drill 4 holes are drilled so that the plunger could be firmly fixed to the
valve body using an M6X1mm nut.

Spring Plunger
This part is also obtained as Aluminum casting and then the in groove of this plunger
is machined properly so that the spring could be placed inside with perfect fit. Outside
four slots are drilled and filed on the four protruding segments. These are made for
fixing the plunger with a valve housing and with the spring inside.
The plunger is fixed inside by using the twist and fix mechanism with valve housing.

Piston nut
The seat bottom nut casting was obtained and the bottom part is machined to obtain a
concave surface so that the rubber washer is fixed and aligned properly and the nut is
tapped to obtain a M18 nut thread with a pitch of 2.5mm.

Valve Seat Piston

The valve seat piston is also obtained as a casting and a circular groove was cut into the
piston so that the rubber washer could be placed in that groove tightly. The grooves are
fine finished properly so that the rubber washer could be placed tightly.

Piston Rod
The rod which is obtained as an Aluminum casting is also machined to obtain the
required diameter. The outer thread is also of the same type of pitch which is 2.5mm.
vii

The other parts such as

1. Spring.
2. Valve Rubber.
3. Filter Mesh.
Were supplied by external suppliers.

viii

Annex - B
Discharge valve
Discharge valve is a valve for controlling the rate of flow from the pipe or tank. This valve is
used in the oil, fuel and milk bowsers to discharge the inlet of the bowser. The idea behind the
discharge valve is that it provides the ability to adjust that flow in order to respond to situations
that require a change in the volume or speed of the flow.
Discharge valve mainly consists of nine parts.

Figure 26-Discharge Valve

Table 3- Part list Discharger

PART NO

DESCRIPTION

QTY

PART - 01

Valve Body

PART - 02

Barrel Nipple

PART - 03

Outer Cap

PART - 04

Key

PART - 05

Gland Cover

PART - 06

Tongue

PART - 07

Valve

PART - 08

Hexagonal Cap

PART - 09

Spring

ix

Part 1 Valve Body

Valve Body acts as a housing for this valve. 1st the valve body was machined to get the desired
thread sizes. Then the Rough edges were removed by filing & smoothened the surface using
sand papers.
Material Aluminum
Manufacturing method Metal casting
Thread gauge 18 (inch) for Barrel Nipple & Hexagonal Cap
Thread gauge 18 (inch) for Gland Cover

Part 2 Barrel Nipple

This part is used to connect the pipe inlet with the valve body. This is a metal casted item. 1st
the Barrel Nipple was machined to get the desired thread size. Then the Rough edges were
removed by filing.
Material Brass
Thread gauge 18 (inch)

Part 3 Outer Cap

This part is used as a lid for this valve. 1st the Outer Cap was machined to get the desired thread
sizes. Then the Rough edges were removed by filing & smoothened the surface using sand
papers.
Material Aluminum
Manufacturing method Metal casting
Thread gauge 18 (inch)

Part 4 Key
This part acts as a connector between tongue & the opener. The desired shape was taken by
filing.
Material Brass
Manufacturing Method Metal casting

Part 5 Gland Cover

This part is used to tighten the gland. This is made from a hexagonal brass shaft by machining.
Material Brass
Thread gauge 18 (inch)

Part 6 Tongue
This part is used to open the Valve by pressing. This is a metal casted item. Desired dimensions
were taken & the rough edges were removed by filing.
Material Brass
Manufacturing Method Metal casting

Part 7 Valve
This is a metal casted & machined equipment. A rubber sealer was attached to this for better
sealing purpose.
Rubber Seal Details O/D = 73 mm , I/D = 60.5 mm, h = 12 mm
Material Brass
Part 8 Hexagonal Cap
This part is used to guide the Valve seal & hold the Spring. 1st the Hexagonal Cap was
machined to get the desired thread size. Then the Rough edges were removed by filing &
smoothened the surface using sand papers.
Material Brass
Manufacturing method Metal casting
Part 9 Spring
This part is used to tension the Valve & its an imported item.
Material Spring steel
Number of Turns 10
Height 52 mm
Pitch 5.2 mm
I/D = 24 mm , O/D = 28 mm
Spring diameter - 2 mm
xi

Testing:
The important thing is to check the leakage in valve body. Therefore the main parts were
assembled to the valve body & pressurized it up to 1 bars of pressure. All the thread surfaces
must be sealed using Thread Seals before doing that. Then the valve surface was checked
deliberately. There can be some invisible holes in the valve body due to sand casting procedure.
We can see that the liquid is spreading through those holes because of the pressure. Those
spotted hole surfaces cleaned & added Metal filler. We can finally smooth the surface using a
sand paper after 24 hours.

Painting:

1st step is to apply primer coating for the Valve. Therefore the threads were fully covered by
using masking tape before this step.
Finally the Signal Red color was applied with a spray gun.

xii

Annex - C
Vent production
Vent is generally used to aerate and de-aerate tanks of the fuel bowsers .it maintains a constant
pressure inside the tank during the discharge process. This product is consisting with 7 sub
parts, 2 springs and a steel net. This vent is only installed for the fuel bowsers. The base of the
body is made by Casted aluminum; Machining and joining processes are used in the
manufacturing process.

Figure 27-Vent

xiii

MATERIAL PROPERTY
There are 7 main parts in the vent. The exploded view of the vent is given below.
Table 4- Part list Vent

Part No

Material

Form of Material

Part 1

Aluminium

Casting

Part 2

Aluminium

Aluminium bar

Part 3

Aluminium

Casting

Part 4

Aluminium

Casting

Part 5

Aluminium

Casting

Part 6

Aluminium

Casting

Part 7

Aluminium

Casting

Part 1
This part is obtained as Aluminum casting and facing and turning operations are done
to obtain the required dimensions.
Facing and Turning : Chuck rpm 270-470.

Part 2
Facing, turning and drilling : Chuck rpm 640-970.
This part is also obtained as aluminum casting and then the hole is drilled to the
required dimension shown in the drawing and facing and turning operations are done
to obtain the required diameter and the slots are cut into it.

Part 3
Facing, turning and tapering : Chuck rpm 270 4200
This part is also obtained as aluminum casting and facing, turning operations are done
in order to obtain the required diameter and threads were cut, one in the long hollow
section and the other on in the outer section of the part. Thread size is 3/8 of inch.

Part 4
Facing, turning and tapering : Chuck rpm 550 830
This obtained as a small aluminum castings and facing and turning operations are
done to obtain the required diameter and tapered four protruding edges.

xiv

Part 6
This part is also obtained as aluminum casting and facing and turning operations are
done in order to obtain the required diameters and inside thread is cut into one edge
and knurling was done in the other edge.
The thread size is 5/8 of an inch.
Facing, turning and knurling : Chuck rpm 220 300

Part 7
This part is obtained as aluminum casting and facing and turning operations are done
to obtain the required diameter at each end. Threads are machined at the each end of
the part.
Thread sizes are 3/8 of an inch for the shorter edge and 5/8 of an inch for the longer
edge. The inside slots are smoothed using a file.
Facing and Turning : Chuck rpm 320- 480

xv

Annex - D
Female and male couplings
In mechanical trades and manufacturing, each half
of a pair of mating connectors or fasteners is
conventionally assigned the designation male or
female. The "female" connector is generally a
receptacle that receives and holds the "male"
connector. The part bearing one or more
protrusions, or which fits inside the other, being
designated male in contrast to the part containing
the corresponding indentations, or fitting outside
the other, being designated female.
Features

Easy maintenance: Parts can be easily

Figure 28-Female and Male Coupling

replaced without getting much more time.

Easy to handle.

Having long lifetime.

Female Coupling

Female Coupling consists with three main parts. They are rolled section with five racks,
Adjustable handle with two clippers & bondable opening with seals.

Figure 29-Female Coupling

xvi

Table 5- Part list Female Coupling

PART NO

DESCRIPTION

QTY

PART - 01

Rolled Section

PART - 02

Inner Bracket

PART - 03

Outer Bracket

PART - 04

Adjusting Part

PART - 05

Rubber Seal

PART - 06

Clipper Mounting Bracket

PART - 07

Hexagonal Handle

PART - 08

Hexagonal Handle Mounting Bracket

PART - 09

Clippers

PART - 10

Rack

PART - 11

Pin - 1

PART - 12

Pin - 2

Part List
Part 1 Rolled Section
Rolled Section is used to connect Female Coupling with the pump outlet. 1st step is to cut
the required size of rectangular shape plate by using Shearing Machine. Then it will be
rolled until it gets the required size.

Plate thickness 3 mm

Welding rod E 6013

Part 2 Inner Bracket

This part is used to hold the outer bracket with the rolled section. The shape of this
bracket is formed by a die.

Plate thickness 3 mm

Welding rod E 6013

Dimensions before forming O/D = 210 mm , I/D = 105 mm

xvii

Part 3 Outer Bracket

This part is used to hold the rubber seal with the Inner Male Coupling. The shape of this
bracket is formed by a die.

Plate thickness 3 mm

Welding rod E 6013

Dimensions before forming O/D = 210 mm , I/D = 105 mm

Part 4 Adjusting Part

This part is used to mount the two handles & adjust the whole part with reference to the Male
Coupling. 1st step is to cut the required size of circular shape by using Gas Cutter. Then it was
machined to get the required size of teeth.

Welding rod - E 6013

Thread pitch 5 mm

Thread depth 3 mm

Thread gauge 5.0 (mm)

Part 5 Rubber Seal

This part is used to seal the opening between Female & Male Couplings.

This is a purchase item from Lancor Rubber (Pvt) Ltd.

Part 6 Clipper Mounting Bracket

This part is used to mount the Clippers with the Hexagonal Handle Mounting. 1st step is to
cut the required size of plate by using Shearing Machine. Then it was bended according to the
drawing by using Bending Machine. Finally holes were drilled.

Plate thickness 3 mm

xviii

Part 7 Hexagonal Handle

This part is used to move the clippers up & down & also to rotate the Adjusting part. It is
made by using a hexagonal bar & the shape was taken by bending the bar using Hydraulic
Press & a die.

Part 8 Hexagonal Handle Mounting Bracket

This part is used to mount the Hexagonal Handle with the Adjusting Part. 1st step is to cut the
required size of plate by using Plasma Cutter. Then it was grinded until it gets smooth surface
finish & required shape. After that it was bended according to the drawing by using Bending
Machine. Finally holes were drilled.

Plate thickness 3 mm

Welding rod for Hexagonal Handle & this Mounting Bracket E 6013

Welding rod for stainless steel pins - E 308-16

Part 9 Clippers
This part is used to tight the Male & Female Couplings. 1st step is to cut the required size of
plate by using Plasma Cutter. Then it was grinded to get the required shape. Finally it was
welded to the Clipper Mounting Bracket.

Plate thickness 12 mm

Welding rod E 6013

Threaded Segments
This Threaded Segments are used to move the Adjusting Part up & down. There are 5
segments used in one component. 1st step is to cut the required size of plate by using Plasma
Cutter. Then it was welded to the Main Pipe & finally machined to get the required thread
size.

Thread pitch 5 mm

Thread depth 3 mm

Thread gauge 5.0 (mm)

xix

Pin 1
This pin is used to connect the Clipper Mounting Bracket & the Hexagonal Handle Mounting
Bracket. This is a machined part

Steel Rod diameter 12 mm

Material Stainless steel

Welding rod - E 308-16

Pin 2
This pin is used to connect the Adjusting Part & the Hexagonal Handle Mounting Bracket.
This is a machined part.

Steel Rod Diameter 12 mm

Material - Stainless steel

Welding rod - E 308-16

Male Coupling
Male Coupling is the fixed part & Female Coupling is the movable part. Male coupling
consists with three main parts. Each part is separately describe below.
Part 10 Rolled Section
Rolled Section is used to connect Male Coupling with the bowser inlet. 1st step is to cut the
required size of rectangular shape plate by using Shearing Machine.
Plate thickness 3 mm
Welding rod - E 6013
Part 11 Inner Bracket
This part is used to hold the outer bracket with the Rolled Section. It was manufactured by
using a 3mm thickness plate.

The shape of this bracket is taken by using a die.

E 6013 Welding rod is used for final welding.

Dimensions before forming O/D = 210 mm , I/D = 105 mm

xx

Part 12 Outer Bracket

This part is used to hold the rubber seal with the Inner Male Coupling. It was manufactured
by using a 3mm thickness plate

The shape of this bracket is taken by using a die.

E 6013 Welding rod is used for final welding.

Dimensions before forming O/D = 158 mm , I/D = 93 mm

xxi

Annex -E

PTO Pumps and RTL Compressors

Blackmer PTO Pumps for Tank Trucks
Sliding Vane Pumps
Blackmer PTO sliding vane pumps are excellent at pumping clean, low viscosity fluids
including non-lubricating fluids. Ideal uses include refined fuel trucks and oil delivery tankers.
Basically, any truck tank, specialty truck, or tanker that hauls fuel oil, diesel, kerosene,
gasoline, avgas, LP gas, jet fuel, or light lube oils can benefit from using a PTO sliding vane
pump from Blackmer.

Figure 30-PTO Pump

Features
Unique sliding-vane pump design self-adjusts for wear to maintain flow rates.
Excellent self-priming and dry run capabilities.
Dual ended shaft on 2, 2.5 and 3 inch models simplifies installation.
Blackmer mechanical seal and ball bearing construction provide maximum reliability.
Symmetrical bearing support assures even loading and wear for long life.
Adjustable relief valve protects pump against excessive pressures.
External ball bearings are isolated from pump age by mechanical seals to maximize bearing
life and minimize contamination risk.
Easy maintenance: vanes can be easily replaced without removing pump from truck.

xxii

Process Applications
Many of the chemicals used in industrial process applications are difficult to handle, often toxic
or corrosive in nature, difficult to seal, and expensive to purchase. These materials pose some
of the most demanding pump service of any industry. Blackmer sliding vane pumps are
available in compatible materials with shaft sealing options that make them the products of
choice for many chemical process applications.
The sliding vane operating principle imparts a very low rate of shear to the material being
handled and provides a smooth, almost pulsationless flow. Sliding vane pumps "self-adjust" to
compensate for "normal wear," providing like-new pump performance over the life of the
product. When repairs are required, maintenance is a simple, requiring few tools and minimal
training to ensure proper performance.

RTL-80 Compressor
RTL 80 compressor is a multi-cell compressor which works on the displacement principle.
They provide a constant low-pulsation supply. The machines are single-phase and have a
cylindrical bored housing. The vanes divide the crescent-shaped working chamber into cells of
different sizes. As the rotor turns, the cell volume on the intake side increases, and the resulting
under pressure draws air into the cell, which at this point is open to the intake suction nozzle.
As the rotor continues to turn, the cell is closed and the volume of the cell decreases.
RT- Rotor type compressor
L- Housing is cooled by air cooling
80- Size of compressor
Vacuum operation or Pressure Operation

xxiii