Proposed List of Instrument for Common Testing Facility -II

8/12/2019 Proposed List of Instrument for Common Testing Facility -II

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Rajkot Pump & Foundry Cluster

Common Facility Center, Rajkot

Prepared by: K.H.Kakkad, Consultant

R.S.Panchal, Project Officer

K.N.Chudasama, Project Officer

Gujarat Industrial & Technical Consultancy Organization Ltd.(GITCO), Ahmedabad


2/20

Role of GITCO

TERI-SIDBI Cluster Development Program.

To understand the Pump Industry Cluster & test

requirement for pumps as per BIS,GEDA & BEEstandard.

To Draw up Preliminary Project Scheme,

Enlisting the test required as well as list of

Instruments.

Assess the Commercial & Financial Viability of

Common Facility Center.


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Methodology

Conduct the Survey to find out requirement ofManufacturing Units.

Study the BIS Standard for Pump & Its Testing

requirement. Approach to Laboratory in this Field ERDA-

Vadodra,NSIC-Rajkot, CFER-Ahmedabad (EQDC &SITARC yet remain) etc.

Contacting Pump manufacturing Units in as well asOutside the Rajkot.

To meet Technocrats of Pump Design, Manufacturing& Quality control & Cluster members.


4/20

Findings of Survey Conduct by GITCO

30%

68% 67%

94%

0%

50%

100%

IS 8034 IS

14220

ISO BEE

Unit Not Having Certificate

No. of Unit

In House Testing Facility

13%

87%

Yes

No


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Testing Related Problem face by Unit

38%

62%

Yes

No

Need for Technical Training

19%

81%

Yes

No


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Testing Expenses of Pump Units

32%

68%

Less than Rs.

5000

More than Rs.5000

Testing Cost

No. of Pump

Unit In

Cluster

Testing Cost

in RS.

Less than Rs.

500052 154560

More than

Rs.5000109 875840

Total 1030400

Calibration Cost of Pump Units

10%

90%

Less than Rs.

5000

More than

Rs.5000

Calibration

Cost

No. of Pump

Unit In

Cluster

Calibration

Cost in

RS

Less than Rs.

500016 64400

More than

Rs.5000145 1738800

Total 1803200

No. of pump units =161,As perTERI Diagnostics Report


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Lab related problems explained by cluster

members

Testing lab take very much time for testing.

Delay in certification.

Testing charges are high.

Priority charges to get early turn in test.

ISI and BEE both required independent laboratory

report.


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Cost Structure Comparison of Pump Testing

Rating of Pump

ERDA, VadodaraEQDC,

Gandhinagar

NSIC,

Rajkot

Cost for Testing of Submersible Pump Set (in RS.)

Upto 3.7kw 4425 2350 3420

3.7kw-7.5kw 4655 2500 39607.5kw-11kw 6260 3600 4500

11kw-20kw 6560 3925 5220

20kw-45kw 9175 5750 6200

45kw-50kw - - 7650

50kw-60kw - - 828060kw-70kw - - 9000

70kw-100kw - - 11250

Source:NABL


9/20

Proposed Testing Facility at CFC, Rajkot

Testing Facility for Submersible/Centrifugal

Pump.

Mechanical/Physical Testing Facility

Chemical Testing Facility

Metallurgical/Non Destructive Testing Facility

Simulation/Design center


10/20

Testing Facility for

Submersible/Centrifugal Pump

Flow Measurement

Pressure Measurement

Performance Characteristics

Temperature Measurement

Insulation resistance

Motor Speed Vibration


11/20

List of Equipments for Pump testingSr.

No.Name of Testing Equipments Application Technical Parameter

1 Electromagnetic Flow MeterIt is used for Measurement

of Water flow

0-5lps (25mm),0-

20lps(50mm),0-70lps(100

lps)

2Pressure Gauge/Pressure Transmitter/Pressure

Transducer

For measuring the pressure

of a gas or liquid.0-90mwc,0-300mwc

3 High Voltage TesterTo measure the strength of

insulation material0-5KV,300ma

4 Megger

To measure insulation

resistance of motors, pumps,

cable etc

0-500Mega Ohm, 0-500V

5 Digital Tachometer To measure RPM of Motor 100-30000rpm

6 RTD,ThermocoupleTo measure, record and

control temperature-30 c to 300 c

7 Vibration Sensors

To measure acceleration and

vibration activity -

8 On line Power Analyzer/Power meterFor KW,Volt,Amp & P.F.

Measurement

0-1000v,0-300A. 0.1 to

UPF

9 Water Sump For storing of water 0-5meter

10 V - NotchTo control the flow of the

water out of the basin.0-60lps


12/20

Complete Testing Bed for Pump Testing


13/20

Mechanical/Physical Testing Facility

Tensile Test

Compression Test

Shear Test

Bend Test

Hardness Test

Surface Hardness Test Impact Test


14/20

List of Instruments for Physical testing

Sr.N Name of Testing Equipments Application Testing Parameter

1Computerized Universal Testing

Machine

To perform tensile test on metallic

materials0-100KN

2 Brinell/Vickers Hardness TesterTo test Hardness of Ferrous and Non

Ferrous Samples.HV 5-50, 1 to 250Kg

3 Rockwell Hardness TesterTo test Hardness of Ferrous and Non

Ferrous Samples.

10kgf to 150kgf, HR15N

to HR45T

4 Impact testing MachineTo perform Charpy and Izod Impact

tests on Metallic Materials.168J,300J

5 Surface Roughness TesterTo Measuring Surface Roughness

Parameters

0-4micrometer,0-

400mocrometer

6 Thickness GaugeTo measuring Metallic Coating &

Plating Thickness on Samples

0-1250mm

7 Dial vernier caliberTo measure internal and external

distances0-200mm

8 O.S. Micrometer To measure distances. 0-25mm.0-50mm


15/20

Chemical Testing Facility

All type of Chemical Analysis for Ferrous &

Non-Ferrous Metals


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List of Instruments for Chemical testing

Sr.

No. Name of Testing Equipments Application Technical Parameter

1 Optical Emission SprectometerTo test elements in ferrous

and non ferrous alloys.340-1000mm

2 Spectrometer Sample Preparation Machine

Grinding to ferrous

&Machined on Non -

ferrous material to

prepares sample for

spectro

NA

2 Rapid Carbon Sulphur Analyser

To test Carbon and sulphur

in ferrous and non ferrous

alloys.

0 - 0.5% buretteRdg. 0 - 1.5%burette Rdg. ,from0.001%

3 Microwave Oven System _ 0-300 c

4 Electro AnalyzersTo test copper and lead in

non-ferrous alloys.NA

5 Electronic weighting Balances To weight the Material 0-200gm

6 Muffle Furnaces For combustion of material 40-100 c

7 Digital Thermometer To measure temperature 195 to 200 c


17/20

Non Destructive/Metallographic Testing

Facility

Microstructure Analysis

Radiography Testing

Crack Detection on Surface

Ultrasonic Flaw Detection


18/20

List of Instrument for NDT testing

Sr.N Name of Testing Equipments Application Technical Parameter

1 Metallurgical Microscope with Image Analyzer

It is used for inspecting

Microstructure of

Material.

150X-1000X

2 Techops Gamma ray cameraIt is used to give image of

the material120 curie

3 Ultrasonic testing machine

To detect cracks in the

material by NDT

method

10mm-5000mm

4 Magnetic Particle Detector

To detect magnetic

particle in the

ferrous material.

NA


19/20

Simulation or Design Facility

Auto CAD

ProE

Master E

Unigraphics

Solid Edge

Image ware

Mould Flow

STARD CCD-CED Analysis

Nastran

Ansys

Solid cast/Soft cast


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Documents

Proposed List of Instrument for Common Testing Facility -II