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A STUDY ON
INTERNSHIP AT WATERMAN PUMPSET
INDUSTRIAL REPORT ON WATERMAN PUMPSET
A PROJECT REPORT
Submitted by
BHAGYARAJSINH VAGHELA
[211080119513]
In partial fulfillment for the award of the degree of
BACHELOR OF ENGINEERING
In
Mechanical Department
Amiraj College of Engineering and Technology, Sanand
Gujarat Technological University, Ahmadabad
June-July 2023
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Amiraj College of Engineering and Technology
Opp. Virochannagar Bus Stop Nr. Tata Nano Plant Village Khoraj, Sanand -
Viramgam Hwy, Ahmadabad, Gujarat 382170
CERTIFICATE
This is to certify that the project report submitted along with the project
entitled INTERNSHIP AT WATERMAN PUMPSET INDUSTRIAL
REPORT ON WATERMAN PUMPSET has been carried out by
BHAGYARAJSINH VAGHELA under my guidance in partial
fulfillment for the degree of Bachelor of Engineering in Mechanical, 7th
Semester(3170001) of Gujarat Technological University, Ahmadabad during
the academic year 2023.
Prof. Keval Suthar Prof. Keval Suthar
Internal Guide Head of the Department
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Industrial Report on Waterman Pumpset
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Amiraj College of Engineering and Technology
DECLARATION
I hereby declare that the internship report submitted along with the internship
entitled Internship in Waterman Pumpset submitted in partial fulfilment for
the degree of Bachelor of Engineering in Mechanical To Gujarat
Technological University, Ahmedabad, is a bonafide record of original project
work carried out by me at Waterman Industries PVT. LTD. under the
supervision by Rahul Prajapati and that no part of these report has been
directly copied from any student’s reports or taken from any other source,
without providing due reference.
NAME OF STUDENT SIGN OF STUDENT
BHAGYARAJSINH VAGHELA
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ACKNOWLEDGEMENT
The internship opportunity I had with Waterman Pumpset was a great chance for
learning and professional development. Therefore, I consider myself as a very lucky
individual as I was provided with an opportunity to be a part of it.
I am also grateful for having a chance to meet so many wonderful and
professionals who led me through this internship period. Bearing in mind previous I am
using this opportunity to express my deepest gratitude and special thanks to the mentor of
Waterman Pumpset Mr. RAHUL PRAJAPATI
Despite being extraordinarily busy with his duties, took time out to hear, guide
and keep me on the correct path and allowing me to carry out my project at their esteemed
organization and extending during the internship. I am also thankful to my HOD and
Mentor for providing guidelines regarding this internship.
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ABSTRACT
Industrial internship is an important phase of student’s life. A Well planned, properly
executed and evaluated industrial training helps a lot in developing a professional attitude.
It developed and awareness of industrial approach to problem solving, based on a broad
understanding of process and mode of operations of organization the aim end the
motivation of this industrial internship is to receive discipline, skills, team work, and
technical knowledge through proper training environment which will help me as a student
in the field of mechanical engineering to developed a responsiveness of the self-disciplinary
nature of problems in manufacturing, management and quality control.
During a period of 2 weeks internship at Waterman Pumpset I was assigned to
analysis there working method, do research about machinery, participate in working of
Testing section. Throughout this industrial internship I have learn about Assembly process,
inspection and testing of submersible pumps and motors. I had learned how to use
instruments like vernier calliper, micrometre, height gauge, and many types of go-no go
gauges. Apart from these study manufacturing submersible pumps and motors. I also learnt
rules and safety instruction, inventory, management, quality control.
I realize the responsibility of supervisor and worker who working on system. So, this
new knowledge and skills and met many new people. Working together with people having
different background and education was great experience. I also accompanied by 4
apprentice who were also on industrial training, so it was nice knowledge sharing. I
achieved many of my learning goals. I got insight into the work of the organization. At last,
this internship has me given new insights and motivation to pursue a career in my goal.
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Table of Contents
Acknowledgement ............................................................................................................... v
ABSTRACT........................................................................................................................ vi
CHAPTER – 1 OVER VIEW OF COMPANY ................................................................. 1
1.1 ABOUT COMPANY ......................................................................................... 1
1.2 HISTORY .......................................................................................................... 1
1.3 DIFFERENT AREA AND DIPARTMENT ...................................................... 2
1.4 DIFFERENT PRODUCT .................................................................................. 3
1.5 ZONE LAYOUT OF COMPANY .................................................................... 4
CHAPTER – 2 COMPONETS OF PUMP ........................................................................ 5
CHAPTER – 3 MANUFACTURING OF PUMP ............................................................. 8
CHAPTER – 4 MEASURING INSRUMENTS .............................................................. 11
SKILLS AND EXPERIENCE THAT I HAVE LEARNED ............................................. 17
CONCUSION .................................................................................................................... 18
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CHAPTER – 1 OVER VIEW OF COMPANY
1.1 ABOUT COMPANY
An innovation spirit that guides and the power of technology that enables,
Waterman Industries Pvt. Ltd. has been a prominent exporter and manufacturer of water
pumps. When it comes to performance, innovation and quality, waterman has constantly
set benchmarks for its competitors, accredited with ISO 9001-2008 by Germany- TUV
NORD, Company manufacture in excess of 3000 variants of water pumps that include but
are not limited to centrifugal pumps, vertical as well as horizontal open-well submersible
motors, submersible pumps, industrial pumps, etc. every product of waterman has been
engineered to perfection by expert hands. Through its expertise and experience spanning
more than four decades, Waterman is committed to became an innovator and standard for
excellence and quality.
1.2 HISTORY
The success story of Waterman Industries began in 1973 when company was
established in Mumbai, Maharashtra and since then, Waterman have never looked back.
Every individual who is employed by company works with the organization with utmost
dedication to provide 100% satisfaction to clients, Waterman have an employee force of
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more than 200 which is spread across different department of company and working
steadfastly to fulfil the requirements of customers in Irrigation, Agriculture, Industrial,
Rural and domestic markets. Waterman’s unwavering determination to be the best has
resulted in its presence in many countries and is counted among the top brands in the world
today.
1973 – Commences with commercial production of submersible pumps.
1973 to 1996 – Starts manufacturing different types of pumps and motors.
1996 – Gets ISI certification for single phase centrifugal pumps.
1999 – Certified as ISO 9001 from TUV Germany.
2002 – August 2002 company shifted to Ahmedabad and cross 15000 pumps per annum.
2004 – Received ISO 9001-2000 certification from TUV Nord, Germany.
2010 – Received star rating in 150 models from bureau of energy efficiency, ministry of
power, government of India.
2010 – Received ISO 9001-2008 certification from TUV Nord, Germany.
1.3 DIFFERENT AREA AND DIPARTMENT
1. Design and Purchase room
2. Meeting and conference room
3. Production office
4. Store, Inward material and first floor packing box
5. C.I. storage
6. Incoming inspection
7. V3 – V4 Pump assembly, Packing and Testing
8. V5 to V10 pump assembly
9. V5 to V10 painting and packing
10. V5 to V10 Testing
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11. Research and Development
12. Finish goods stock
13. Machine shop
14. Filing, Coil making, Cable joining and Winding areas
15. Rotor grinding, balancing and burnishing area
16. Motor assembly and motor stock
17. No load testing, Air cleaning and Red tag area & Retain area
18. Service, Repair, Maintenance Zone
1.4 DIFFERENT PRODUCTS
1. 3” (80 mm) and 4” (100 mm) submersible pump
2. 5” and 6” submersible pump
3. 6” (150 mm) SS submersible pump with SS impeller
4. Vertical open well pump
5. 1 phase and 3 phase horizontal open well submersible pump
6. 8” and 10” submersible pump
7. 1 phase and 3 phase centrifugal mono block pump
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8. 7” and janta model submersible pump
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1.5 Zone layout of company
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CHAPTER – 2 COMPONENTS OF PUMP
- All Components of pump and motor
• Motor: The motor is the primary component of a submersible pump
and is responsible for driving the impeller. It is typically a sealed,
waterproof unit specially designed to operate underwater.
• Impeller: The impeller is a rotating component that consists of curved
blades or vanes. Its main function is to create centrifugal force, which
propels the fluid from the inlet to the outlet of the pump, generating the
pumping action.
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• Diffuser: The diffuser is a stationary component that surrounds the
impeller. Its purpose is to gradually convert the high-speed, low-
pressure flow from the impeller into a high-pressure flow by increasing
the flow area.
• Casing: The casing, also known as the pump housing, is the outer shell
of the pump that encloses the motor and impeller. It provides structural
support and is typically made of durable materials such as stainless steel
or cast iron to withstand the harsh conditions in which submersible
pumps operate.
• Shaft: The shaft connects the motor to the impeller and transfers the
rotational motion from the motor to the impeller. It is usually made of
stainless steel or another corrosion-resistant material to withstand
exposure to fluids.
• Seals: Submersible pumps have multiple seals to prevent water from
entering the motor and causing damage. The primary seal is located
between the motor and the impeller, known as the mechanical seal.
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Additional seals may be present in the cable entry and other critical
areas.
• Bearings: Bearings support the rotating shaft within the pump and
reduce friction. They help maintain the alignment and smooth operation
of the pump. Bearings are typically lubricated to ensure optimal
performance and minimize wear.
• Power Cable: The power cable supplies electrical power from the
surface to the submersible pump. It is specially designed to be
waterproof and durable to withstand submersion. The cable is typically
protected by a sheath to ensure electrical safety.
• Control Box: In some cases, submersible pumps
may require a control box on the surface to house
electrical components such as motor starters,
capacitors, and overload protection devices. The
control box allows for convenient control and
protection of the pump.
• Check Valve: A check valve, also known as a
non-return valve, is often installed in the
discharge line of a submersible pump. It allows fluid to flow in one
direction and prevents backflow, ensuring that the pump remains
primed and maintains pressure within the system.
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• Strainer: The strainer is located at the inlet of the pump and serves to
filter out large debris and solids from entering the pump. It typically
consists of a mesh or perforated plate that prevents clogging and
damage to the impeller.
CHAPTER – 3 MANUFACTURING OF PUMP
Step – 1 Making Diffuser Bowels
• They start by making diffuser bowels using urn shaped casings.
• The bowls hold the pump spinning impellers.
• Computerized tools refine their shape so the bowls fit neatly in the pump columns.
Step – 2 Carving the impellers
• Another set of tools carve the impellers.
• They fine tune the casing so that the impellers will fit into the diffuser bowls.
• Here is a look at the manufacturing of impeller.
Step – 3 Balancing
• A technician uses this machine to check for imbalances.
• When sensors locate the problem he send down the metal in that area this balances
the impeller.
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Step – 4 Shaft pipes making
• Next they make the pump shaft pipes.
• Tools work on both the ends of the pipe simultaneously to refine the inner
diameter, the they carve threads into them.
Step – 5 Making rotor and stator
• Rotor of induction motor is made by operations such as rotor pressing, brazing,
turning, CNC turning, grinding and burnishing.
• After this they insert copper coils into the stator.
• A coolant is circulated in the stator winding for cooling of heat generated.
• Separate impellers is provided for circulating the coolant (water or oil).
Step – 6 Motor assembly
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• Before assembling the induction motor they take a inspection of rotor and stator
for checking of electrical connection or any problem.
• Winding :- when the inspection is done they start winding all the electric cables,
wires etc. into the motor.
Step - 7 Pump assembly
• The pump is assembled manually.
• Workers step by step assembles the various parts such as induction motor,
impellers, diffusers, diffuser bowls and shaft into the casing.
• They use bearings, springs, bolts and screws for attaching the different parts into
one an other.
• The assembly process of submersible pump shown in photo.
Step – 8 Testing the pumpset
• Quality control department tests various pump parameters such as volt, current,
power, speed, discharge, head, efficiency, change in head etc.
• After this they take a actual test of pumpset.
• They submerges the pump into the water and record their readings.
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Step – 9 Painting and packaging
• A blue or green colour paint that is sprayed on the pump to protect the pump from
corrosion.
• Finally, the pump is packed and labelled.
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CHAPTER – 4 MEASURING INSTRUMENTS
➢ Length and dimensional measurement is a way to determine the metrics of an
object. Specifically, it quantifies an object's:
• Physical size
• Characteristics of shape and form
• The distances among the object's components
➢ Physical size quantities can be height, depth, or thickness. Characteristics may be
the object's roundness, flatness, or shapeliness. Distances may include the degree
of angles or the length between nodes.
➢ Dimensions measurement tools have various types; major products include vernier
callipers, micrometres, dial gauges, gauges of varied types, protractors, and rulers;
they are tools used in production processes and quality checks. Some of these
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products have inspection certificates or calibration certificates attached to them,
ISO standard, etc.
❖Various dimensions measuring instruments
➢ Digital Vernier Calliper
The Digital Calliper is a precision instrument that can be used to measure
internal and external distances extremely accurately. The figure shown above is a
digital calliper as the distances/measurements, are read from a LCD display.
Earlier versions of this type of measuring instrument had to be read by
looking carefully at the imperial or metric scale and there was a need for very good
eyesight in order to read the small sliding scale. Digital calipers are easier to use as
the measurement is clearly displayed and, by pressing the inch/mm button the
distance can be read as metric or imperial.
Least Count: 0.01 mm
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➢Digital Micrometre
The digital micrometre is the most recent innovation in micrometre
technology. Digital micrometres can take extremely accurate measurements; most
can measure up to 0.0005 inches and 0.001mm.
Measurements can be taken in both metric and imperial units. At any time,
the user can convert their readings from one system to the other by pressing the “mm
/ inch” or “unit” button. A zero button also allows the unit to be zeroed at any point.
The feature is ideal for comparative and incremental measurements.
Readings provided by digital micrometres are electronically generated and
shown on an LCD display. The LCD display may be instead of, or in addition to, the
scales normally found on a micrometre. The reading is instant and avoids user error
by eliminating the need to interpret the scales. Some micrometres have a data output
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connection which allows them to be connected to a computer. Measurements can
then be stored on a spreadsheet rather than recorded manually.
Least Count: 0.001 m
➢Digital depth gauge
A depth gauge is a precision measuring instrument, designed specifically to
measure the depth of holes, recesses, cavities and distances from a plane surface to
a projection. In other word, a depth gauge is a variation of the ruler. The depth gauge
consists of a ruler—usually a narrow one to measure the depth of holes, counter
bores, etc. There is a base through which the ruler can slide up and down, and a
locking screw on the cover to clamp the ruler in place. The base, which is machined
flat and at right angles to the ruler, is placed on a reference surface and the ruler
lowered into the hole or recess until its bottoms.
Depth gauges comes in various configurations, depending on the specific
application. Depth gauge types include digital tire thread depth gauges, digital depth
gauges, single hook type digital depth gauges, needle digital depth gauges, double
hooks digital depth gauges, digital depth gauges with adjustable base, vernier depth
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gauges, and dial depth gauges. The digital version is capable to output
measurements to a wide variety of peripherals and data collection devices. These
simple, inexpensive tools are typically about 150mm long, and they can even
measure up to longer range, such as 1000mm.
Least Count: 0.01 mm
➢ Plug Gauges
Plug gauges, in some cases called pin gauges, are metrology tools whose
purpose is to gage the inside diameters of holes that have been drilled or machined
into a manufactured part, component, or assembly. They are essential tools for
quality control and enable inspectors, machinists, manufacturing engineers, and
others to quickly obtain a go/no-go decision about whether the characteristic of the
part being gaged falls within the specified dimensional tolerance for the inside
diameter measurement. This gaging process is designed to allow accurate
assessments to be made without the need for production personal to resort to the use
of additional, more sophisticated, and more expensive measuring instruments such
as inside micrometres. In production operations where a large volume of parts is
being produced, plug gauges provide a rapid means of assessing the quality without
taking time to perform actual hole diameter measurements and to set-up
instrumentation.
When using plug gauges, it is important to recognize that the gauge results
in a yes/no condition only – the tool is allowing the quality control inspector to
accept or reject a part. It is not performing an actual measurement of the diameter,
but merely assessing if that diameter is within the tolerance band established for
that parameter.
• Types and Uses of Plug Gauges:
Plug gauges are available in several different types. These include:
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Go plug gauges
No-go plug gauges
Combination go/no-go plug gauges
• Go - No go Thread Gauges
GO - NO GO thread gauge is thread inspection tool for checking thread. the
go end should go through the entire thread; the NO GO end should be stopped
between the thread of workpieces. If not like so, then we can judge that the thread
of workpieces is not well enough.
Thread gauge GO NOGO is measuring tool for checking tool. These gauges
can’t measure out the detailed data of thread. They just can tell a “state”. The thread
tested can be accepted or not. Go NOGO thread gages come from Taylor invention
patent in 1905. GO NOGO ring gage is used to check “screw” external threaded
parts, GO NOGO plug gage is used to check ”nut” internal threaded parts. The Go
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end of plug gauge checks the minimum major diameter and minimum pitch
diameter are not exceeded, and the No-go end of plug gauge checks the maximum
pitch diameter. The go ends of ring gauge checks that the maximum minor diameter
and maximum pitch diameter are not exceeded, The no-go end of ring gauge checks
the minimum pitch diameter. For both ring gauges and plug gauges, The go end
should go into the whole threads of parts, the No-go end should be stopped no more
than three turns.
SKILLS AND EXPERIENCE THAT I HAVE LEARNED:
During these 2 weeks of internship, I have learned different skills and experienced
required in the company. The 2 week’s internship exposed me to the various aspects of
manufacturing company.
I closely coordinated with the company’s engineers who provided the excellent
knowledge of inspection in manufacturing.
The skills I have learned are mentioned below:
Different measuring instruments used in manufacturing and proper setting of them.
To proper reading of Engineering drawing.
To make Bonds between Workers and Professional Employee.
Applying of 6 s’ Concept to the company and always give first priority to Safety.
Working flow of this company.
How to make decision
How to define a problem
How to deal with difficulties
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CONCUSION
1) Corporate world exposure
2) Gaining various industrial information
3) Got to know more about the industrial hydraulics
4) Operation of various machinery
5) Knowledge of different valve
6) Circuit formation of oil hydraulics
7) Attending the training program on industrial hydraulics
8) Data analysis with statistic
During my internship, I had the opportunity to gain exposure to the corporate world
through attending company events and networking with professionals in various
departments. This exposure allowed me to gain insights into the day-to-day operations of
the business, the importance of teamwork and communication, and how to navigate the
professional landscape. I also had the opportunity to participate in team projects, which
gave me hands-on experience in collaborating with team members and contributing to the
success of the project.
One of the most valuable experiences I had during my internship was gaining
various industrial information. I was able to attend industry conferences, read industry
publications, and network with professionals in the field. This allowed me to gain a better
understanding of the industry I was working in and how it operated. I also had the
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opportunity to learn about different manufacturing processes, which was invaluable in my
role as an intern.
During my internship, I also got to know more about industrial hydraulics. I
received training on the principles of hydraulics and how to design and operate hydraulic
systems. I had the opportunity to work closely with experienced professionals who shared
their knowledge and expertise with me. This allowed me to gain a better understanding of
the role of hydraulic systems in the industry and how they were utilized in production
processes.
As part of my responsibilities, I was also responsible for the operation of various
machinery. I received training on how to operate and maintain the machinery, which was
important to ensure production was running efficiently and safely. My supervisor and I also
gained knowledge about different types of valves and their functions. I had the opportunity
to troubles.hoot issues related to valves and learned how to maintain and repair them. This
was valuable in my role as an intern and helped to ensure production was running smoothly.
During my internship, I learned about circuit formation of oil hydraulics, and also
gained experience in data analysis with statistics. I was responsible for collecting and
analysing production data to identify trends and potential areas for improvement. I was
trained in statistical analysis and used various tools such as Excel and R to analyse the data.
This allowed me to gain a better understanding of the production process and how data
analysis can be used to make informed decisions. I had the opportunity to attend a training
program on industrial hydraulics, which provided a more in-depth understanding of
hydraulic systems and their applications in the industry. The training program included
classroom instruction, simulations, and demonstrations, which allowed me to gain hands-
on experience.
Overall, my internship provided me with a wealth of experience and knowledge
related to the industry I was working in. I gained exposure to the corporate world, learned
about industrial hydraulics, operated various machinery gained knowledge of different
valves, learned about the circuit formation of oil hydraulics, and gained experience in data
analysis with statistics. These experiences were invaluable in my personal and professional
growth, and I am grateful for the opportunity to have had them.
• Time management
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As overall technician and programmer are always racing against tight timeline and packed
schedule, a proper time management will minimize facing overdue deadlines. An effective
time management allows us to do our assignment efficiently and meet our schedules.
Scheduling avoids time wastage and allows us to plan and gaining.
• Colleague Interaction
In a working environment, team work is vital in contributing to a strong organisation.
Teamwork is also essential in reaching the goals of the organisation as an entity. Thus,
communicating and sharing is much needed in the working environment. Therefore, we
should be respecting each other in work, and working together as a team, instead of working
alone. This is because working together as a team is easier in reaching our targets, rather
than operating individually.
• Critical And Analytical Thinking
To organize our tasks and assignment, we need to analyse our problems and assignment,
and to formulate a good solution to the problem. I would have to set contingency plan f or
the solution, so that I am well prepared for the unforeseeable situations.
• Goal Management
Opposing to a Herculean goal seemed to be reachable at first sight, it is better to sub - divide
the goals to a few achievable tasks, so that I will be gaining more confidence. In a nutshell,
this internship has been an excellent and rewarding experience. I can conclude that there
have been a lot I’ve learnt from my work at Waterman Engineers. The technical aspects of
the work I’ve done are not flawless and could be improved provided enough time. As
someone with no prior experience with filtrations unit and manufacturing section.
Whatsoever, I believe my time spent in analysis and discovering it was well worth it and
contributed to finding an acceptable solution.
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