training report

INDUSTRIAL TRAINING REPORT – LEVEL 3 DIPPED PRODUCTS LIMITED

i R. S. V. PIYASENA 080362G DEPARTMENT OF MECHANICAL ENGINEERING

PREFACE

Actually I’m glad to say, during the industrial training period of the 3rd year of my B. Sc

Engineering degree program I was selected as a trainee for Dipped products Ltd. The period of

training was 28th February of 2011 to 12th August of 2011 (24 weeks).So I was based at Dipped

products Ltd, 400, Deans road , Colombo 10.

So they have three major factories located at three different places which are at

Weliweriya – Venigross ltd , Kottawa – Grossart ltd , Hanwella – HRPL(Hanwella rubber

products ltd). I stayed venigross limited and HRPL at Hanwella. Further it was a great

opportunity for me to improve and gain practical knowledge about mechanical engineering, By

working with machines, plants mechanics, fabricators and metal workers, technicians. So not

only those things sometimes I was able to visit outside metal fabricators and contractors to see

the progress of ongoing projects and give some contribution and instructions to do those things

properly.

I was able to develop my communication skills with the technical knowledge by working

with Engineers and technicians. So those practical things and knowledge I obtained from this

implant training are explained and described briefly in different segments in this report.


ii R. S. V. PIYASENA 080362G DEPARTMENT OF MECHANICAL ENGINEERING

ACKNOWLEDGEMENT

I worked and well trained in Dipped products limited as a undergraduate mechanical

engineer for my level 3 industrial training session. I’m glad to say it was a great and memorable

opportunity to me to practice and get vast knowledge about mechanical engineering and related

other engineering applications. So I have to give my thank to

• Mr. N. Y. Fernando (Director- Projects, Dipped products limited)

• Mr. Nilantha Warusawithana (Senior projects engineer)

• Mr. Janaka Abeyerathna (Projects Manager),

• Mr. W.A. Dilhara (Projects Engineer)

• Mr. Anil Premachandra (Project Implementation Manager)

• Mr. Chandika Rathnasiri (Goup Engineering Manager - DPL)

• Mr. Namal Dharmarathne (factory manager –Venigross ltd)

• Mr.S. P. C. Pathirana (Excecutive engineer – Venigross ltd)

• Mr. Narangoda (Excecutive engineer – Venigross ltd)

• Mr. Charith (Production manager – Venigross ltd)

• and all other staff members of all the factories of DPL

• Dr. Palitha Dsanayaka (Head, Department of mechanical Engineering)

• Mr. N.A.Wijeyewickrame (Director, Industrial training)

• Mr. P. Gunawardena (Senior lecturer, Industrial training)

• Mr. S.A.S. Punchihewa (Senior lecturer, Industrial training)

• and all staff members of the industrial training division of University of Moratuwa


iii R. S. V. PIYASENA 080362G DEPARTMENT OF MECHANICAL ENGINEERING

CONTENTS

CHAPTER 1

1.1 Introduction…………………………………………………………………………………………1

1.2 DPL Products……………………………………………………………………………………….1

1.3 Vision of the company……………………………………………………………………………...2

1.4 Mission of the company…………………………………………………………………………….2

1.5 History of the company……………………………………………………………………………..2

1.6 Factories and establishments………………………………………………………………………..3

1.7 Organizational structure…………………………………………………………………………….4

1.8 Production capacity…………………………………………………………………………………5

1.9 Performance of productions of DPL………………………………………………………….……..5

1.10 Countries who imports DPL gloves………………………………………………………….…….5

1.11 Resources and supplies…………………………………………………………………….………5

1.12 Process cycle……………………………………………………………………………………..…6

1.13 Company Financial Values………………………………………………………………………...6

1.14 Quality assurance……………………………………………………………………………….….7

1.15 Environmental policy………………………………………………………………………….…...7

CHAPTER 2…………………………………………………………………………………………….….8

2.1 WORKSHOP PRACTICE………………………………………………………………………….….8

2.1.1 Workshop machineries………………………………………………………………………….…8

2.1.2Welding ……………………………………………………………………………………….……8

2.1.2.1Shielded Metal Arc Welding (SMAW)…………………………………………………….….9

2.1.2.2 Welding electrode identification code…………………………………………………….…10

2.1.2.3 Oxy fuel welding……………………………………………………………………...…..…10

2.1.2.4 Oxy fuel cutting……………………………………………………………………………...11

2.1.2.5 Flames and types…………………………………………………………………………….12

2.1.3 Grinding…………………………………………………………………………………………..12


iv R. S. V. PIYASENA 080362G DEPARTMENT OF MECHANICAL ENGINEERING

2.2 Maintenance department……………………………………………………………………………...13

2.2.1 Schedules and periods of maintenance………………………..………………………………….13

2.2.2 Preventive Maintenance ………………………………………………………………………….14

2.2.2.1Basic steps of preventive maintenance……………………………………………………….15

2.2.3 Maintenance in Shutdowns…………………………………………………………….………...16

2.2.4Corrective Maintenance………………………………………………………………….………..16

2.3 Production Department………………………………………………………………………………..16

2.3.1 Glove making general process……………………………………………………………………16

2.3.1.1 Cuff cleaning / washing……………………………………………………………………...17

2.3.1.2 Coagulation / Coagulant dipping…………………………………………………………….17

2.3.1.3 Glove dipping/Latex dipping………………………………………………………………...17

2.3.1.4 Precise dipping levels on glove formers……………………………………………………..17

2.3.1.5 Adhesive dipping…………………………………………………………………………….18

2.3.1.6 Flocking……………………………………………………………………………………...18

2.3.1.7 Fixing………………………………………………………………………………………...18

2.3.1.8 Leaching……………………………………………………………………………………...18

2.3.1.9Vulcanization /curing…………………………………………………………………………18

2.3.1.10 Post cure leaching…………………………………………………………………………..19

2.3.1.11Stripping…………………………………………………………………………………….19

2.3.1.12 Drying of produced gloves………………………………………………………………….19

2.3.1.13 Chlorinization………………………………………………………………………………19

2.3.1.14 Quality control methods……………………………………………………………………19

2.3.2 Trimming , sorting and packing /TSP……………………………………………………………19

2.3.2.1 Glove identification codes…………………………………………………………………...20

2.3.3 Parts and important machineries of the plants……………………………………………………20

2.3.3.1 Formers………………………………………………………………………………………20

2.3.3.2 Chariots……………………………………………………………………………………....21

2.3.3.3 Sprockets and chains…………………………………………………………………………22

2.3.3.4 Cyclone separator…………………………………………………………………………….22


v R. S. V. PIYASENA 080362G DEPARTMENT OF MECHANICAL ENGINEERING

2.3.3.5 Dipping tracks………………………………………………………………………………..23

2.4 Compounding section…………………………………………………………………………………23

2.4.1 Diaphragm pumps / membrane pump……………………………………………………………23

2.4.2 Ball Mills…………………………………………………………………………………………24

2.4.2.1 Ball Mill Working Principle …………………………………………………………………25

2.4.2.2 Details of ball mills which are used in industry……………………………………………..25

2.4.2.3 Grinding media………………………………………………………………………………25

2.4.3Feed tanks…………………………………………………………………………………………26

2.4.3.1 Feed tank to dipping tank latex distribution arrangement………………………………..…27

2.4.3.2 Feed tank motors and gearbox specifications ………………………………………………..27

2.4.4 Compounding section electrical hoists…………………………………………………………...28

2.5 Fire protection and safety……………………………………………………………………………...28

2.5.1 Classes of fire……………………………………………………………………………………..28

2.5.2 Fire alarm system…………………………………………………………………………………29

2.5.2.1Notification methods………………………………………………………………………….29

2.5.3 Fire extinguishers………………………………………………………………………………....29

2.5.4 Heat and smoke sensors…………………………………………………………………………..30

2.5.5 Fire assembly point……………………………………………………………………………….31

2.5.6 Pressurized water supply / Fire hydrant system…………………………………………………..31

2.5.7 Fire blankets………………………………………………………………………………………32

2.6 Water treatment plants………………………………………………………………………………...32

2.6.1 Water treatment plant arrangement………………………………………………………………32

2.7 Thermal oil heater, furnace, thermal oil distribution lines and chillers……………………………….33

2.7.1 Thermal oil heating system…………………………………………………………………….…33

2.7.1.1 Thermal oil distribution system…………………………………………………………… ..34

2.7.1.2 Specification of pumps and motors used in system………………………………………….35

2.7.1.3 General detail of cost for thermal oil heaters……………………………………………… ..36

2.7.2 Chillers………………………………………………………………………………………………36

2.7.2.1 Counter flow cooling tower…………………………………………………………………….36


vi R. S. V. PIYASENA 080362G DEPARTMENT OF MECHANICAL ENGINEERING

2.8 Former cleaning room and former stores……………………………………………………………..37

2.9 Electrical distribution system and generators ………………………………………………………...38

2.9.1 Specifications of two generators which are located in the factory……………………………….39

2.9.2 Power factor correction and the capacitor bank………………………………………………….39

2.9.3 Main electricity distribution arrangement………………………………………………………..40

2.10 Industrial vehicles……………………………………………………………………………………41

2.10.1 Fork lift………………………………………………………………………………………….41

2.11 Firewood storage and wood chippers………………………………………………………….……43

2.13 5S concept and operations………………………………………………………………….…….….45

2.13.1 5S Guidelines…………………………………………………………………………….….…..45

2.14 PROJECTS………………………………………………………………………………….….……46

2.14.1 Increasing the efficiency of Tumbler dryers………………………………………….…….…...46

2.14.1.1 Basic operation of a tumbler dryer……………………………………………………….....46

2.14.1.2 Nameplate details………………………………………………………………………...…47

2.14.1.3 Our model for solution of tumbler dryer heating system to increase the efficiency……..…48

2.14.2 Calculations of loadings and drawing of existing structure of feed tanks at Venigross ltd……..48

2.14.3 Develop and modify a scroll pump for circulating latex inside dipping tanks 50

2.14.4 Plant shifting project at plant W , HRPL , Hanwella (Applying of new flocking unit)……......54

2.14.5 Structural design for feed tanks of compounding section at Venigross ltd, Weliveriya………...57

2.14.6 A new mechanism for bead opening of gloves at sorting lines – TSP department……………..59

2.14.6.1First trial……………………………………………………………………………………..60

2.14.6.2 Second trial project…………………………………………………………………………62

2.14.7 Water purification plant – Load , torque and power calculations………………………………63

2.14.8 Modeling of existing dipping tracks……………………………………………………………63

2.14.9 Washing tank replacement project……………………………………………………………..65

2.14.10 Modeling of new door designs for drying and curing ovens………………………………….65

2.14.11 Modeling of existing sprocket and chain links at plan T………………………………………68

2.14.12 Production building heating sources and airflow direction analysis…………………………..68

2.14.13 Coagulant / chemical solutions barrel heating project…………………………………………69


vii R. S. V. PIYASENA 080362G DEPARTMENT OF MECHANICAL ENGINEERING

2.14.14 Modifying of new arrangement of ovens………………………………………………………70

2.14.15 Tensile strength and tension calculations for plant Q…………………………………………71

CHAPTER 3………………………………………………………………………………………………73

CONCLUTION …………………………………………………………………………………………...73

3.1 Conclusion………………………………………………………………………………………….73

3.2 Industrial training programme……………………………………………………………………...74

3.3 Few words about the training establishment………………………………………………………75

Annex……………………………………………………………………………………………….. i

A.1 5S concept……………………………………………………………………………………………i

A.2 Classes of fires………………………………………………………………………………………ii

A.2.1 Ordinary combustible type……………………………………………………………………..ii

A.2.2 Flammable or combustible liquid or gas……………………………………………………….ii

A.2.2 Electrical fires………………………………………………………………………………….iii

A.2.3 Combustible metals……………………………………………………………………………iii

A.3 Further details of Forklift ……………………………………………………………………….….iv

A.3.1 Forklift classes and lift codes…………………………………………………………….…….iv

A.3.2 Power or energy Source………………………………………………………………….…….iv

A.3.3 Counterweight……………………………………………………………………………….…v

A.3.4 Tilt Cylinders………………………………………………………………………………......v

A.3.5 Mast ………………………………………………………………………………………….…v

A.3.6 Carriage………………………………………………………………………………………...v

A.3.7 Load Back Rest…………………………………………………………………………………v

A.3.8 Forkliift attachments. …………………………………………………………………………...v

A.4 Safety precautions for Oxy-fuel Gas welding and cutting………………………………………….vi

A.5 Production details of Venigross ltd……………………………………………………………….vii

A.6 Further details of cooling tower used in the factory………………………………………………viii

A.7 Safety precautions when working with chemicals…………………………………………………..x

A.8 Approved raw materials stores……………………………………………………………………..xi

A.8.1 Centrifuging of latex……………………………………………………………………………..xii


viii R. S. V. PIYASENA 080362G DEPARTMENT OF MECHANICAL ENGINEERING

LIST OF FIGURES

Figure 1.1: Company Group Structure……………………………………………………………………...2

Figure 1.2: Management Structure………………………………………………………………………….3

Figure 1.3: Process Cycle…………………………………………………………………………………...4

Figure 2.1: code Welding electrode identification………………………………………………………...10

Figure 2.2: Proper arrangement of Oxy fuel welding……………………………………………………..10

Figure 2.3: Welding and cutting torch……………………………………………………………….……11

Figure 2.4: Preventive maintenance schedule – VL………………………………………………………15

Figure 2.5: Glove making general process Chain plant – W –HRPL……………………………….….…16

Figure 2.6: Precision dipping levels on gloves formers..............................................................................17

Figure 2.7: Glove identification codes….....................................................................................................20

Figure 2.8: gloves formers and former arrangement on chains…………………………………………...21

Figure 2.9: Chariots......................................................................................................................................21

Figure 2.10: Cyclone separator....................................................................................................................22

Figure 2.11: Ball mill……………………………………………………………………………………...24

Figure 2.12: Ball mill inside operation……………………………………………………………………24

Figure 2.13: Feed tank arrangement………………………………………………………………………26

Figure 2.14: Feed tank to dipping tank latex distribution arrangement………………………….………..27

Figure 2.15: various types of fire extinguishers…………………………………………………………..30

Figure 2.16: Fire blanket………………………………………………………………………………….32

Figure 2.17: Water treatment plant arrangement…………………………………………………………32

Figure 2.18: Thermal oil distribution system……………………………………………………….…….34

Figure 2.19: Counter flow cooling tower and its operation………………………………………………37

Figure 2.20: Operation of the cooling tower………………………………………………………………37

Figure 2.21: Main electricity distribution arrangement…………………………………………………..40

Figure 2.22: Fork lift and its basic components…………………………………………………………..42

Figure 2.23: Tumbler dryer ……………………………………………………………………………….46


ix R. S. V. PIYASENA 080362G DEPARTMENT OF MECHANICAL ENGINEERING

Figure 2.24: Designed LP gas burning unit……………………………………………………………….48

Figure 2.25 Arrangement of feed tank on structure ……………………………………………………..50

Figure 2.26 Ecentric part…………………………………………………………………………………50

Figure 2.27: Modified bottom plate………………………………………………………………………51

Figure 2.28: Modified bottom plate………………………………………………………………………53

Figure 2.29: Scroll pump …………………………………………………………………………………53

Figure 2.30: Cross section of croll pump …………………………………………………………………53

Figure 2.31: Cross section of croll pump with bearing ball arrangement………………………………...54

Figure 2.32: Bottom scroll member……………………………………………………………………….54

Figure 2.33: Bottom plate of eccentric parts……………………………………………………………...54

Figure 2.34: large sprocket at Plant W – HRPL…………………………………………………………..57

Figure 2.35: Brush roller with fixed rollers………………………………………………………………60

Figure 2.36: Glove with opened bead……………………………………………………………………..60

Figure 2.37: Feeding glove to the rollers for bead opening process………………………………………61

Figure 2.38: Adhesive tank plant S – Dipping track………………………………………………………63

Figure 2.39: Adhesive tank plant S – Dipping track………………………………………………………64

Figure 2.40: 3D model of a dipping track – glove tank no 2 – plant……………………………………...65

Figure 2.41: 3D model of oven door 1 …………………………………………………………………....66

Figure 2.42: Complete drawing of door 1 ………………………………………………………………...67

Figure 2.43: Complete drawing of a chain link…………………………………………………………..68

Figure 2.44: Drawing of production floor…………………………………………………………………69

Figure 2.45: 3D drawing of modified oven………………………………………………………………..71

LIST OF TABLES

Table 1.1: Production capacity………………………………………………………………………….…5

Table 1.2: Company financial values………………………………………………………………….…..6

Table 2.1: Details of ball mills……………………………………………………………………………25


x R. S. V. PIYASENA 080362G DEPARTMENT OF MECHANICAL ENGINEERING

Table 2.2: Feed tank motors and gear box specifications………………………………………………..27

Table 2.3: Name plate details of electrical hoist………………………………………………………….28

Table 2.4: Classes of fire………………………………………………………………………………….28

Table 2.5: Specification of pumps and motors used in system……………………………………………35

Table 2.6: Details of the alternative diesel engine for circulation pump………………………………….35

Table 2.7: Wood fired heater maintenance plan…………………………………………………………..35

Table 2.8: General detail of cost for thermal oil heaters………………………………………………….36

Table 2.9: Generator details……………………………………………………………………………….39

Table 2.10: capacitor bank details………………………………………………………………………...40

Table 2.11: Wood chipper motor details………………………………………………………………….44

Table 2.12: Wood chipper blower details…………………………………………………………………45

Table 1.13: Nameplate details of tumbler dryer…………………………………………………………..47

Table 1.14: Nameplate details of main blower……………………………………………………………56

Table 2.15: Nameplate details of main blower motor……………………………………………………..56

Table 2.16: Nameplate details of small blowers…………………………………………………………..56

Table 2.17: Nameplate details of small blowers motors…………………………………………………..56

training report

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