A Study on Manufacturing Process of Centrifugal Pumps at Milnars Pumps Ltd.

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A Study on Manufacturing Process of Centrifugal Pumps at Milnars Pumps Ltd.

Submitted By

Md. Mehedi Hasan

ID # 12207070

Department of Mechanical Engineering

IUBAT—International University of Business Agriculture & Technology

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In the name of Allah, The Most Beneficent, the Most Merciful

and the Most Gracious

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A Practicum Report Submitted to the Department of Mechanical Engineering at IUBAT – International University of Business Agriculture and Technology in Partial Fulfillment of the Requirements for the Degree of Bachelor of Science in Mechanical Engineering.

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Student’s Declaration

This to inform that the Practicum Report “A Study on Manufacturing Process & Quality Control of MILNARS PUMPS” has been prepared only for academic purpose. I also confirm that it has not been submitted elsewhere for any reward or presentation or any other purpose.

Md. Mehedi Hasan

ID # 12207070

Department of Mechanical Engineering

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Acknowledgement

In the process of preparation of my practicum report, I am very thankful to the Almighty who

made be able to complete my research and the practicum report.

In this connection I would further like to pay my gratitude and respect to certain personalities for

their help and enormous co-operation herein.

First of all I would like to pay my gratitude to our respected Prof Dr Engr A Z A Saifullah,

Professor & Chair, Department of Mechanical Engineering, IUBAT, who gave me the

opportunity to do the report on “A Study on Manufacturing Process of Centrifugal Pumps at

Milnars Pumps Ltd.”

Then I would like to pay my gratitude to Engr Md. Miraz Hossain, Additional General Manager of Milnars Pumps Ltd, for his kind leading. And also thank to A S M Sayeam, Faculty, Department of Mechanical Engineering IUBAT and my advisor, who helped me a lot to prepare this report successfully.

Finally, I would like to thanks again to the respectedVice- Chancellor of IUBAT, Prof. Dr.

M Alimullah Miyan because he designated such an environment for learning through which I

got the opportunity to acquire knowledge under BSCE program, and that will be very helpful for

my prospective career.

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A Study on Manufacturing Process of Centrifugal Pumps at Milnars Pumps Ltd.

Md. Mehedi Hasan A S M Sayeam

ID # 12207070 Internal Supervisor

Department of Mechanical Engineering

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Table of Contents

A. Title fly…………………………………………………………………………. i

B. Cover page………………………………………….…………...…....................ii

C. Student declaration …………………………………......…................................ x

D. Acknowledgement …………………………………………………...................xi

E. Supervisor’s comments…………………………………………………………xii

F. Abstract………………………………………………………………...……… xiii

Chapter: One (Introductory Part)

1.1 General..........................................................................................................................2

1.2 Objectives......................................................................................................................2

1.3 Scope.............................................................................................................................3

1.4 Methodology.................................................................................................................3

1.5Limitations.....................................................................................................................3

Chapter: Two (Company Overview)

2.1 Introduction..................................................................................................................5

2.1.1Company Location......................................................................................................7

2.1.3Mission Vision ...........................................................................................................8

2.1.4Social commitment.....................................................................................................8

2.1.5 MPL Code of Conduct...............................................................................................9

2.1.6 Management structure................................................................................................9

2.2 Company product profile and their detail...................................................................10

2.2.1 Product Profile:........................................................................................................10

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2.2.2Product Details of MPL............................................................................................11

2.5Production Capacity of Milnars Pumps Ltd.................................................................15

2.6Commitment to Customer............................................................................................15

2.7 Certificate and Award and Social Activities...............................................................15

2.8Organizational activities analysis.................................................................................16

2.8.1 Marketing Mix.........................................................................................................16

2.8.2 Analysis of products of MPL:..................................................................................16

Chapter: Three (Pumping Terminology)

3.1 Valves..........................................................................................................................19

3.2 Pump Installation Information....................................................................................21

Chapter: Four (The centrifugal Pump)

4.1 Definition of Centrifugal Pump..................................................................................23

4.2 Working Mechanism of a Centrifugal Pump..............................................................23

4.3 Different Types of Centifrugal Pump.........................................................................25

4.4Different parts of Centrifugal Pump:..........................................................................26

4.5 Pump Efficiency..........................................................................................................35

4.6 Problems of centrifugal pumps...................................................................................37

4.7 Centrifugal pumps for solids control..........................................................................37

4.8 Magnetically coupled pumps......................................................................................38

4.9 Priming........................................................................................................................38

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Chapter: Five (Manufacturing Process of Centrifugal Pump)

5.1 Foundry shop...................................................................................................................41

5.1.1 Metal casting work.......................................................................................................42

5.1.2 Pouring.........................................................................................................................49

5.1.3Degassing......................................................................................................................50

5.1.4Shakeout........................................................................................................................50

5.1.5Degating........................................................................................................................50

5.1.6 Heat treating.................................................................................................................51

5.1.7Surface cleaning............................................................................................................52

5.1.8 Finishing.......................................................................................................................52

5.2 Defects of casting............................................................................................................53

5.3Machine operation............................................................................................................54

Chapter: Six (Pump Assembly Section)

6.1 Bearing assembly........................................................................................................73

6.2 Seal assembly..............................................................................................................74

6.3 Impeller and casing assembly.....................................................................................74

Pump Testing Section

7.1 Performance monitoring.............................................................................................78

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7.2 Required Equations.....................................................................................................79

7.3 Requirements..............................................................................................................79

7.4 Quality Assurance.......................................................................................................83

7.5.1 Statistical control......................................................................................................83

7.5.22 Total quality management......................................................................................76

7.5.3 MPL Assured Quality..............................................................................................76

Chapter: Seven (Problems and Solution)

8.1 LOCATION LOGIC…………………….…………………………………………….86

8.2 SUCTION PIPING…………………………………………………………………….87

8.3 PUMP MOTOR FAILS TO START………….……………………………………..88

Recommendations & Conclusion..........................................................................................85

References.............................................................................................................................89

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Table of Figures

Figure 1: Management Structure ..............................................................................................08

Figure 2: Different types of heads.............................................................................................21

Figure 3: A centrifugal pump....................................................................................................22

Figure 4: Main components of a centrifugal pump...................................................................24

Figure 5: Main components of a centrifugal pump...................................................................26

Figure 6: Impeller......................................................................................................................27

Figure 7: Volute Casing............................................................................................................28

Figure 8:Discharge Nozzle.…………………..…………………………………………….……………………............29

Figure 9: Break bearing stool....................................................................................................30

Figure 10: Pump Shaft Sleeve ..................................................................................................31

Figure 11: Wear Ring................................................................................................................32

Figure 12: Ball Bearing.............................................................................................................33

Figure 13: Gaskets....................................................................................................................34

Figure 14: Priming....................................................................................................................39

Figure 15: Machine shop of MPL.............................................................................................41

Figure 16: Pattern of Volute casing..........................................................................................43

Figure 17: Core making............................................................................................................44

Figure 18: Induction furnace.....................................................................................................46

Figure 19: Coreless induction furnace.....................................................................................48

Figure 20: Induction Furnace....................................................................................................49

Figure 21:Pouring molten metal...............................................................................................49

Figure 22:Heat Treating............................................................................................................51

Figure 23: After Casating..........................................................................................................53

Figure 24: Lathe operation........................................................................................................55

Figure 25: Lathe operation........................................................................................................57

Figure 26: Dead Center.............................................................................................................58

Figure 27: Lathe........................................................................................................................59

Figure 28: Turrent Lathe...........................................................................................................58

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Figure 29: Milling cutter...........................................................................................................62

Figure 30: Various types of milling cutter................................................................................65

Figure 31:Taper used in milling machine.................................................................................66

Figure 32: Woodruff key slot cutter..........................................................................................67

Figure 33: Shaper Machine.......................................................................................................68

Figure 34: A pressure Gauge....................................................................................................80

Figure 35: Pump test branch.....................................................................................................82

Abbreviations

B

BWDB- Bangladesh Water Development Board

D

DIN-Deutsches Institutfür Normung

E

ETA-Engine Turnover Assembly

H

H-Head

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I.H.P-Indicated Hours Power

ISO-International Organization for Standardization

M

MPL-Milnars Pump Limited

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NPSH-Net positive suction head

P

P- Pressure

PPM-Predictive and Preventative Maintenance

Q

Q-Discharge

R

R.P.M-Revolutions Per Minute

S

SS-Stainless steel

SG- Sherardized Graphite

T

QA- Quality Assurance

TQM- Total Quality Management

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Abstract:

Milnars Pumps Limited (MPL) is well known for its sales and after sales or servicing. It is one of

the largest manufacturers of pumps in the country. It was originally founded in 1961 in the name

of KSB Pumps Company Limited, During my internship period, as a Trainee Engineer, my

responsibilities were to check and troubleshoot the manufacturing process of centrifugal pump in

the workshop. The company underwent extensive and exhaustive program. Under the program,

Induction Furnace has been installed with well-equipped laboratory for casting of quality

stainless steel (SS), other alloy steel and sherardized graphite iron (SG) products. This modern

plant is the only and first of its kind in Bangladesh and can meet the demand of casting of

different type of products of different qualitative specification required in pump valve and other

machine part/component manufacturing. MPL pumps and its other products are manufactured

according to DIN standard and to highest design meeting international quality. So I hope my

report in the centrifugal pump is based on theoretical knowledge and as well as practical

knowledge. This report contains the basic parts and accessories of the Centrifugal pumps. The

total shop of milners pumps shop divided into five different shops those are Foundry shop,

Machine shop, Assembly Section, Testing Section. All this parts are described by the things they

are made and their working procedure. It is also about keeping the pumps in good situation and

when to check for maintenance and servicing. I hope I was able to include all the parts and its

description in this report.

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