INDUSTRIAL INTERNSHIP REPORT

DEPARTMENT OF LOGISTICS, OIL INDIA LTD.,

DULIAJAN

DURATION – 1.07.2023 to 31.07.2023

SUBMITTED BY –
NAME UNIVERSITY ROLL NO.
ABHISHEKH SARMAH 200810002001
ABINASH CHETIA 200810002003
ANURAG SAIKIA 200810002010
BISHAL CHANGMAI 200810002016

DEPARTMENT OF MECHANICAL ENGINEERING

JORHAT INSTITUTE OF SCIENCE AND

TECHNOLOGY, JORHAT-10
 ACKNOWLEDGMENT

It is a great pleasure for us to present this report of industrial internship at Oil India
Limited, Duliajan considering ourselves very lucky and honored to have so many
people lead us through the completion of this project. This summer training is a
golden opportunity for learning the things practically and to acquire some technical
skills. It would not have been possible without the kind support and help of many
individuals and organizations. We would like to extend our sincere thanks to all of
them. We would like to take the opportunity for learning to thanks and express our
heartfelt to Mrs. Tutumoni Bora (Manager, HR-Learning). We are highly indebted
to them for their guidance and constant supervision as well as for providing
necessary information regarding the project. We are thankful to Mr. Dipankar Deka
(Chief Engineer, Logistics Department), Mr. Bishwa Bhushan Singh (Deputy Chief
Engineer, Logistics Department) and Mr. Abhijit Paul (Deputy Chief Engineer,
Logistics Department) for their guidance and constant supervision as well as their
kind co-operation and encouragement which helped us in completion of this project
throughout the training period. We would like to express our special gratitude and
thanks to Bonshi Dhar Borah (Supervisor), Suresh Baruah (Assistant Mechanic) of
OIL, Duliajan for giving us such attention and time and sharing their valuable
knowledge without which our training would have been incomplete.
 Contents

1.About OIL 1
1.1.Profile 1
1.2.Vision 2
2.Introduction to Logistics department of OIL India, Duliajan 3
2.1Crane section, Logistics Department OIL India, Duliajan 4
2.2Heavy section, Logistics Department OIL India, Duliajan 5
3. Introduction to Hydraulics 6
3.1 Hydraulic circuit 7
4. Coiled tubing 9
4.1 Uses of coil tubing 10
4.1.1. Circulation 10
4.1.2. Pumping 10
4.1.3. Coiled tubing drilling 10
4.1.4. Logging and perforating 11
4.1.5. Production 11
5. Case study: - Preventive maintenance of the boom assembly of a ‘Nitrogen coil 12
tubing unit’
6. Boom assembly of a nitrogen coiled tubing unit 15
6.1 Winch 15
6.2 Mother boom 16
6.3 Telescopic boom 16
6.4 Lift cylinder 17
6.5 Telescopic hydraulic cylinder 18
7. Internal combustion engine 19
7.1 working of IC engine 19
7.2 Basic components of an IC engine 21
8. Starter 24
8.1 Starter motor definition 24
8.2 Working 24
8.3 Components 25
8.4 How a starting system works 26
9. Gearbox 27
9.1 Introduction 27
9.2 Parts of a gearbox 27
 1.About Oil
1.1.Profile
Oil India Limited (OIL) is a fully
integrated Exploration &
Production company in the
upstream sector, with origin dating
back to the glorious year (1889) of
oil discovery in India. A Navratna
Company, OIL is a state-owned
enterprise of the Government of India, under the administrative control of the
Ministry of Petroleum and Natural Gas and is the second largest national oil and
gas company in India. The story of OIL traces and symbolizes the growth and
development of the Indian petroleum Industry. From the discovery of the crude oil
in the far east of India at Digboi, Assam in 1889 to its present status as a fully
integrated National Exploration and Production company with footprints across
entire E&P value chain. The company is India’s second largest National E&P
Company. Oil India Private Limited was incorporated on 18th February 1959, to
expand and develop the newly discovered oil fields of Naharkatiya and Moran in
the North-Eastern region of India. In 1961, it became a joint venture company of
Government of India and Burmah Oil Company Limited, UK. In 1981, OIL became
a wholly owned Government of India enterprise. The Authorized Share Capital of
the Company is Rs. 2,000 Crore. The Issued, Subscribed and Paid Share Capital of
the Company is Rs. 1,084.41 Crore comprising of 108.44 crore shares of Rs. 10
each. At present, the Government of India, the Promoter of the Company is holding
56.66% of the total Issued & Paid-up Capital of the Company. The balance 43.34%
of the Equity capital is held by Public and others including Bodies Corporate,
Mutual Funds, Banks, FPIs, Resident Individuals etc. OIL is the first oil & gas
company to list its bonds on International Securities Market, London Stock
Exchange in 2019. OIL has carved a niche as a leading oil and gas company in the
upstream sector with a legacy of hydrocarbon exploration for over six decades and
having a share of around 9% of the country’s total crude oil and natural gas

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production. The company has significant presence across the entire value chain in
the hydrocarbon sector, it also produces Liquefied Petroleum Gas (LPG) and
transports crude oil and refined petroleum products through cross country pipelines.
The company’s In-Country operations are spread over the areas in the states of
Assam, Arunachal Pradesh, Mizoram, Tripura, Nagaland, Odisha, Andhra Pradesh
and Rajasthan and offshore areas in Andaman, Kerala-Konkan and KG shallow
waters. The Company is operating in 03 (three) PEL and 25 (twenty-five) PML
areas, allotted under the nomination regime in the States of Assam, Arunachal
Pradesh and Rajasthan. The Company also holds Participating Interest (PI) in 06
(six) NELP Blocks with operatorship in 04 (four) Blocks and as non-operator in the
remaining 02 (two) Blocks as on 31-03-2021. The Company has further expanded
its acreage base through participation under Government of India’s Open Acreage
Licensing Policy (OALP) bid rounds. The company has been awarded 29 blocks
covering 53,859 Sq Km under (OALP) for carrying out E&P activities.

1.2.Vision:
Core Purpose - "The fastest growing energy company with a global presence
providing value to the stakeholders"
OIL's Vision –
• Oil India is the fastest growing Energy Company with highest profitability.
• Oil India delights the customers with quality products and services at
competitive prices.
• Oil India is a Learning Organization, nurturing initiatives, innovations and
aspirations with best practices.
• Oil India is a team, committed to honesty, integrity, transparency and mutual
trust creating employee pride.
• Oil India is fully committed to safety, health and environment.
• Oil India is a responsible corporate citizen deeply committed to socio-
economic development in its areas of operations

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2.Introduction to logistics department of OIL INDIA
LIMITED
Preamble: Logistics Department, erstwhile Transport Department, in Oil India
Limited, since its inception, has been consistently showing high level of
commitment with the entire workforce tirelessly engaged as a dedicated team
facilitating operations in challenging environments, to achieve the organizational
goals.
Mission: To provide logistics support to all around exploration and development
activities of the company by transporting Workforce, Materials and Equipment at
right time at right place in a safe, economical and eco-friendly way.
Activities: The Logistics department of Oil India Limited perform the following
activities on a regular basis:
• Drilling & Work-Over Rig inter location movement and material handling
in rig-up, rig-down jobs.
• Workforce movement through round-the-clock bus service to various
installations in the oilfield.
• Maintenance of all company owned vehicles & mobile equipment.
• Provisioning of passenger and utility vehicles for different departments.
• Contract management of outsourced vehicles & mobile equipment.
• Inspection of hired as well as company owned vehicles for their fitness and
road worthiness.
• Technical Scrutiny of spares and inventory & quality control management
for company owned vehicles & mobile equipment.
• Transfer of well consumables and tubulars. ▪ Tubular handling services at
Materials yard.
• Material handling jobs in connection with maintenance of equipment at
production installations / setups and construction project sites of different
installations.
• Transfer of LWC to drilling location.
• Logistic support to Civil Authorities, Social Organizations, Visiting
dignitaries, etc.
• Documentation of company owned vehicles & mobile equipment.
• Departmental human resource planning & development.
• Arranging skill development training for apprentice and engineering
students.
• Arranging road safety awareness programme and relevant trainings.

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The logistics department comprises of four different workshops, namely –
1. Crane Section
2. Heavy Section
3. Plant and Equipment Section
4. Passenger Vehicle Section
We were given the opportunity to explore, learn, observe the Crane and Heavy
sections.
2.1.Crane Section, Logistics Department, Oil India Limited
This section deals with the maintenance, repair and servicing of all the vehicles
listed below –
Sl. Machine Type Model Capacity Engine
No. OIL ID Model
1 OIL-3506 Nitrogen coil tubing Kenworth Cummins
unit C5508 NTC 350
2 OIL-3507 Nitrogen coil tubing Kenworth Cummins
unit C5508 NTC 350
3 OIL-3509 Nitrogen coil tubing Kenworth Cummins
unit C5508 ISX 475
4 OIL-3515 Nitrogen coil tubing International Cummins
unit 5600i ISX 475
5 OIL-3516 Nitrogen coil tubing International Cummins
unit 5600i ISC 315
6 OIL-3701 Wireline mast unit Peterbilt Tata 697
series 335 TC66
7 OIL-6110 Hyd. Crane loader Tata LPT 8 MT Tata 697
1616/42 TC66
8 OIL-6109 Hyd. Crane loader Tata LPT 8 MT Tata 697
1616/42 TC66
9 OIL-6108 Hyd. Crane loader Tata LPT 8 MT Cummins
1616/42 ISX 430V
10 OIL-3511 Emergency well Kenworth AL
killing unit C500B HA57/165
BSIII
11 OIL-6045 Truck mounted Till TMS 40 MT AL
crane 750B MK-II HA57/165
BSIII
12 OIL-6046 Truck mounted Till TMS 40 MT AL
crane 750B MK-II HA57/165
BSIII
13 OIL-6047 Truck mounted Till TMS 40 MT AL
crane 750B MK-II HA57/165
BSIII

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 14 OIL-6048 Truck mounted Till TMS 40 MT AL
crane 750B MK-II HA57/165
BSIII
15 OIL-6049 Truck mounted Till TMS 40 MT AL
crane 750B MK-II HA57/165
BSIII
16 OIL-6050 Truck mounted Till TMS 40 MT AL
crane 750B MK-II HA57/165
BSIII
17 OIL-6051 Truck mounted Till TMS 40 MT AL
crane 750B MK-II HA57/165
BSIII
18 OIL-3512 Hot oil circulation Kenworth CAT C-
unit K-500 13
19 OIL-3513 Hot oil circulation Kenworth CAT C-
unit K-500 13
20 OIL-3517 Nitrogen pumping Kenworth
unit K-500
21 OIL-3518 Nitrogen pumping Kenworth
unit K-500
22 OIL-3520 Coiled tubing unit Mercedes Actros
Benz Actros 4146K
23 OIL-3521 Coiled tubing unit Mercedes Actros
Benz Actros 4146K

2.2.Heavy Section, Logistics Department, Oil India Limited

The Heavy Section Logistics Department of Oil India Limited, Duliajan, plays a
critical role in managing the transportation and logistics of heavy and oversized
equipment, machinery, and materials required for the company's oil and gas
operations. Given the nature of the oil and gas industry, Oil India Limited deals
with various heavy components, such as drilling rigs, wellheads, pipelines, and
other large-scale equipment that require specialized handling and transportation.

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 3.Introduction to Hydraulics

Hydraulics, an essential branch of science and engineering, lies at the heart of

countless industries and applications, enabling the precise and efficient control of
forces and motions using the power of fluids. Derived from the Greek words
"hydor" (meaning water) and "aulos" (meaning pipe), hydraulics originally focused
on the study of water's behavior in pipes. However, over time, its scope expanded
to encompass a broader range of fluid dynamics, including the use of various liquids
and gases.

At its core, hydraulics delves into the mechanical properties of fluids, particularly
liquids, and the fundamental principles that govern their behavior under pressure.
By understanding how fluids transmit force and energy, engineers have harnessed
this knowledge to develop sophisticated hydraulic systems that drive machinery,
operate heavy equipment, control aircraft, facilitate automobile braking systems,
and much more.

The key principle driving hydraulic systems is Pascal's principle, which states that
any change in pressure applied to a confined fluid is transmitted undiminished
throughout the fluid in all directions. This fundamental concept forms the basis for
the operation of hydraulic components like cylinders, motors, pumps, and valves.

In this exploration of hydraulics, we will uncover the basic principles that underpin
this field, explore the fundamental components of hydraulic systems, learn about
the advantages and limitations of hydraulics, and delve into the diverse applications
across various industries. Whether you are an engineering enthusiast, a student, or
simply curious about the wonders of fluid mechanics, the world of hydraulics
promises to be an enlightening journey through the mechanics of liquids and their
role in powering the modern world.

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3.1. Hydraulic circuit

Fig 1: Hydraulic circuit

Basic components of a hydraulic circuit -

Reservoir (Oil tank) – It stores the used and unused hydraulic oil.
Pump - The pump in a hydraulic circuit is a vital component that converts
mechanical energy into hydraulic energy. It serves as the heart of the system,
responsible for generating fluid flow and creating the necessary pressure to
transmit force through the hydraulic fluid. When the pump is activated, it draws
hydraulic fluid from a reservoir and pushes it through the system, providing power
to various hydraulic actuators, such as cylinders and motors.
Pressure relief valve - The pressure relief valve is a critical safety component in a
hydraulic circuit. Its main function is to protect the system from excessive
pressure buildup, which can lead to equipment damage or failure. The pressure
relief valve is designed to open when the hydraulic system's pressure exceeds a
predetermined limit, allowing excess fluid to bypass the circuit and return to the
reservoir.

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Direction control valve - The Direction Control Valve (DCV) is a fundamental
component in a hydraulic circuit responsible for controlling the direction of fluid
flow within the system. It determines the path the hydraulic fluid takes to actuate
various hydraulic actuators, such as cylinders and motors, enabling precise control
over the movement and operation of machinery and equipment.
Flow control valve (Holding valve) - The Flow Control Valve (FCV) is a vital
component in a hydraulic circuit that regulates the flow rate of hydraulic fluid
passing through it. Its main function is to control the speed of hydraulic actuators,
such as cylinders and motors, to achieve precise and controlled movement in
various applications.
Check valve - The Check Valve, also known as a non-return valve or one-way
valve, is a fundamental component in a hydraulic circuit that allows fluid flow in
one direction while preventing backflow in the opposite direction. Its primary
function is to ensure that hydraulic fluid flows in the intended direction and
prevents undesired reverse flow or pressure surges.
Actuator - The actuator in a hydraulic circuit is a mechanical device that converts
hydraulic energy into mechanical force or motion. It serves as the "muscle" of the
system, responsible for performing various tasks and operations based on the
controlled flow and pressure of hydraulic fluid. It consists mostly of a cylinder,
piston which performs the task of providing work while oil is being pumped to it
accordingly.
Oil Filter - The oil filter in a hydraulic circuit is a crucial component responsible
for removing contaminants and impurities from the hydraulic fluid. It plays a vital
role in maintaining the cleanliness of the fluid, ensuring the smooth and efficient
operation of the hydraulic system.

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 4.Coiled Tubing

In the oil and gas industry, coiled tubing refers to a long metal pipe, normally 1 to
3.25 in (25 to 83 mm) in diameter which is supplied spooled on a large reel. It is
used for interventions in oil and gas wells and sometimes as production tubing in
depleted gas wells. Coiled tubing is often used to carry out operations similar to
wirelining. The main benefits over wireline are the ability to pump chemicals
through the coil and the ability to push it into the hole rather than relying on gravity.
Pumping can be fairly self-contained, almost a closed system, since the tube is
continuous instead of jointed pipe. For offshore operations, the 'footprint' for a
coiled tubing operation is generally larger than a wireline spread, which can limit
the number of installations where coiled tubing can be performed and make the
operation more costly. A coiled tubing operation is normally performed through the
drilling derrick on the oil platform, which is used to support the surface equipment,
although on platforms with no drilling facilities a self-supporting tower can be used
instead. For coiled tubing operations on sub-sea wells a mobile offshore drilling
unit (MODU) e.g. semi-submersible, drillship etc. has to be utilized to support all
the surface equipment and personnel, whereas wireline can be carried out from a
smaller and cheaper intervention vessel. Onshore, they can be run using smaller
service rigs, and for light operations a mobile self-contained coiled tubing rig can
be used.

Coiled tubing has also been used as a budget version of work-over operations. It is
used to perform open hole drilling and milling operations. Common coiled tubing
steels have yield strengths ranging from 55,000 PSI to 120,000 PSI so it can also be
used to fracture the reservoir, a process where fluid is pressurized to thousands of
psi on a specific point in a well to break the rock apart and allow the flow of product.
Coil tubing can perform almost any operation for oil well operations if used
correctly.

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4.1 Uses of coiled tubing:

4.1.1. Circulation - The most typical use for coiled tubing is circulation or
deliquification. A hydrostatic head (a column of fluid in the well bore) may be
inhibiting flow of formation fluids because of its weight (the well is said to have
been killed). The safest (though not the cheapest) solution would be to attempt to
circulate out the fluid, using a gas, frequently nitrogen (Often called a 'Nitrogen
Kick'). By running coiled tubing into the bottom of the hole and pumping in the gas,
the kill fluid can be forced out to production. Circulating can also be used to clean
out light debris, which may have accumulated in the hole. Coiled tubing umbilicals
can convey hydraulic submersible pumps and jet pumps into wells. These pumps
allow for inexpensive and noninvasive well cleanouts on low-pressure CBM (coal
bed methane) gas wells. These umbilicals can also be run into deviated wells and
horizontal laterals.

4.1.2. Pumping - Pumping through coiled tubing can also be used for dispersing
fluids to a specific location in the well such as for cementing perforations or
performing chemical washes of downhole components such as sand screens. In the
former case, coiled tubing is particularly advantageous compared to simply
pumping the cement from surface as allowing it to flow through the entire
completion could potentially damage important components, such as the downhole
safety valve. Coiled tubing umbilical technologies enable the deployment of
complex pumps which require multiple fluid strings on coiled tubing. In many
cases, the use of coiled tubing to deploy a complex pump can greatly reduce the
cost of deployment by eliminating the number of units on site during the deploy.

4.1.3. Coiled Tubing Drilling - A relatively modern drilling technique involves

using coiled tubing instead of conventional drill pipe. This has the advantage of
requiring less effort to trip in and out of the well (the coil can simply be run in and
pulled out while drill pipe must be assembled and dismantled joint by joint while
tripping in and out).

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An additional advantage is that the coiled tubing enters the hole via a stripper,
mounted on the injector, which provides a hydraulic seal around the coil. This
offers well control capabilities beyond those normally possible with drill pipe, and
gives the ability to drill underbalanced.

Instead of rotating the drill bit by using a rotary table or top drive at the surface, it
is turned by a downhole MUD MOTOR, powered by the motion of drilling fluid
pumped from surface. Drilling which is powered by a mud motor instead of a
rotating pipe is generally called slide drilling.

4.1.4. Logging and perforating - These tasks are by default the realm of wireline.
Because coiled tubing is rigid, it can be pushed into the well from the surface. This
is an advantage over wireline, which depends on the weight of the tool string to be
lowered into the well. For highly deviated and horizontal wells, gravity may be
insufficient for wireline logging. Roller stem and tractors can often overcome this
disadvantage at greatly reduced cost, particularly on small platforms and subsea
wells where coiled tubing would require mobilizing an expensive mobile drilling
rig. The use of coiled tubing for these tasks is usually confined to occasions where
it is already on site for another purpose, for example a logging run following a
chemical wash.

4.1.5. Production - Coiled tubing is often used as a production string in shallow

gas wells that produce some water. The narrow internal diameter results in a much
higher velocity than would occur inside conventional tubing or inside the casing.
This higher velocity assists in lifting liquids to surface, liquids which might
otherwise accumulate in the wellbore and eventually "kill" the well. The coiled
tubing may be run inside the casing instead or inside conventional tubing.

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 5.Case Study : Preventive maintenance of the boom
assembly of a ‘Nitrogen coil tubing unit’.
A crucial preventive maintenance operation was conducted on the 'International
5600i' nitrogen coil tubing unit, with registration number OIL-3516, owned and
operated by Oil India Limited. The maintenance took place at the ‘Crane Section’
of the logistics department of Oil India Limited, and it was skillfully performed by
the maintenance team led by supervisors Bipin Chutia and Bonshi Dhar Borah,
along with numerous team members. The preventive maintenance tasks included
the replacement of seals in the piston of the hydraulics, thorough cleansing of the
boom with diesel, and the replacement of worn boom wear pads. As part of safety
protocols, all personnel involved were equipped with safety shoes, hard hats, and
protective clothing.

The meticulous preventive maintenance procedures resulted in significant

improvements, and the boom assembly is now operating more smoothly and
efficiently. By replacing the seals in the hydraulic piston and wear pads, the risk of
potential leaks and wear-related issues has been minimized, ensuring the continued
optimal performance of the coiled tubing unit. Oil India Limited's commitment to
preventive maintenance ensures the safety, reliability, and longevity of their
equipment, ultimately contributing to their successful operations in the oil industry.

Fig 2: International 5600i (Nitrogen coil tubing unit)

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 Fig 3: Boom assembly being removed

Fig 4: Mother boom Fig 5: Telescopic boom

Fig 6: Piston seals of telescopic hydraulic cylinder being replaced

13
 Fig 7: Lift Cylinder Fig 8: Backup seal being replaced

Primary steps followed during the whole process –

1. Boom assembly was disassembled.
2. Telescopic boom and Mother boom were cleansed with diesel.
3. Piston seals of telescopic hydraulic cylinder were replaced.
4. Backup seal of the piston in the lift cylinder was replaced as previous one
was damaged.
5. Retraction cables had gone dry, so Cardium oil was applied to it.
6. The parts were reassembled and then fitted back to the Nitrogen coiled
tubing unit.
For this job, a stipulated time of one week was allotted and the task in hand
was completed within this time limit.

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 6.Boom Assembly of a Nitrogen coiled tubing unit
The boom assembly of a nitrogen coiled tubing unit is a critical component that
enables the safe and efficient deployment of coiled tubing operations involving
nitrogen services. Nitrogen coiled tubing units are used in the oil and gas industry
for a variety of applications, such as well stimulation, cleanouts, and other well
intervention activities that require the use of nitrogen gas.

The boom assembly in a nitrogen coiled tubing unit consists of several specialized
parts and features tailored to handle the unique requirements of nitrogen-related
operations. While specific designs may vary among manufacturers, here are some
key components typically found in the boom assembly of a nitrogen coiled tubing
unit:

6.1. Winch - In the context of a boom assembly, the winch serves as the primary
lifting and lowering mechanism. It consists of a drum, around which a cable or rope
is wound. When the winch is engaged, the drum rotates, either winding the cable to
lift the load or unwinding it to lower the load. The winch is equipped with a motor,
gearbox, and braking system to control the speed and direction of the cable. The
winch's lifting capacity and pulling force are crucial considerations in the design of
a boom assembly.

Fig 9: Basic parts of a winch

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6.2. Mother boom - The Mother boom of a crane, is the primary and largest
structural component of the crane responsible for lifting and lowering loads. It is
the central arm that remains fixed to the crane's base or mast and can be raised or
lowered to reach different heights and distances. The Mother boom is typically
composed of one or more sections that telescope in and out to achieve the desired
length. This telescoping feature allows the crane to extend or retract the boom,
providing flexibility in reaching various lifting positions. The length of the main
boom largely determines the crane's maximum lifting capacity and reach.

Fig 10: Mother Boom

6.3. Telescopic boom - The telescopic boom consists of multiple sections that
can extend or retract, allowing the crane to adjust its length and reach based on the
specific lifting requirements. The sections (in this case there are 2 sections) of a
telescopic boom are typically made of high-strength steel and are designed to slide
smoothly into one another. This telescoping feature is achieved through hydraulic
cylinders or cables and sheaves, depending on the crane's design. As the sections
extend, they form a telescopic structure that enables the boom to reach greater
heights and farther distances. The sections are prevented from rubbing against each
other and kept in place with the help of ‘boom wear pads’.

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 Fig 11: Telescopic boom

6.4. Lift cylinder - The lift cylinder is a hydraulic cylinder that operates
using pressurized hydraulic fluid to generate force and motion. It is typically a
robust, cylindrical metal tube with a piston rod extending from one end. Inside
the cylinder, a piston is connected to the piston rod, dividing the cylinder into
two chambers: the rod side and the blind side. When hydraulic pressure is
applied to the rod side of the cylinder, it exerts force on the piston, causing the
piston rod to extend outward. This extension action, in turn, results in the
boom's upward movement, lifting the load or extending the boom arm.
Conversely, when hydraulic pressure is applied to the blind side of the
cylinder, it pushes the piston and piston rod back into the cylinder, causing the
boom to lower or the boom arm to retract.

Fig 12: Lift cylinder

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6.5. Telescopic hydraulic cylinder - A telescopic hydraulic cylinder,
commonly known as a "telescopic cylinder," is a specialized type of hydraulic
cylinder used extensively inside telescopic booms of various heavy equipment
and machinery. A telescopic hydraulic cylinder consists of a series of nested
tubular stages, where each stage is of progressively smaller diameter than the
previous one. The cylinder's design allows it to collapse to a compact length
when fully retracted and extend to a significantly longer length when activated.
The outermost tube, known as the "barrel" or "main tube," encases the other
smaller tubes called "stages" or "plungers." Each stage slides inside the previous
one, and a seal system prevents hydraulic fluid from escaping between the
stages during extension and retraction. The telescopic cylinder operates using
hydraulic pressure to extend and retract the stages. Hydraulic fluid is supplied
to each stage through a network of hoses and valves, and the fluid pressure
pushes the stages outward during extension. The telescopic cylinder is used
along with a system of pulley and retraction cables for proper functioning of the
boom.

Fig 13: Telescopic

hydraullic cylinder

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 7.Internal Combustion Engines
An IC engine is a type of heat engine that converts fuel into useful work through a
series of controlled explosions. The internal combustion engine operates by the
combustion of fuel within a confined space, such as a cylinder, which pushes a
piston, creating motion. This motion is then transformed into rotary motion by a
crankshaft, which can be used to power a wide range of machines and vehicles,
including automobiles, motorcycles, generators, and aircraft. An IC Engine is a
machine that transforms the energy released from the combustion of fuel into
mechanical energy. The motion of the piston is then converted into rotary motion
by a crankshaft, which can be used to drive a wide range of machines and vehicles.
The full form of IC engine is Internal Combustion engine. The combustion of fuel
occurs inside the engine's cylinders, where a mixture of fuel and air is ignited,
creating high-pressure gases that push a piston. They are widely used due to their
high power-to-weight ratio, ease of use, and adaptability to a range of fuels,
including gasoline, diesel, and natural gas. Over the years, IC engines have
undergone significant technological advancements, improving their efficiency,
reducing emissions, and increasing their power output

Fig 14: IC engine components

7.1.Working of IC engine
An IC (Internal Combustion) engine is a heat engine that converts chemical
energy stored in the fuel into mechanical energy. It is used in vehicles, generators,
and various other applications. The working of an IC engine can be explained in
the following steps:

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 Fig 15: 4 strokes of an IC engine.
Intake stroke- The first stroke is called the intake stroke. In this stroke, the fuel-air
mixture is drawn into the engine cylinder through the open intake valve.
Compression stroke- The second stroke is called the compression stroke. In this
stroke, the piston compresses the fuel-air mixture inside the cylinder by moving
upwards.
Power stroke- The third stroke is called the power stroke. In this stroke, the fuel-
air mixture is ignited by a spark plug or a high-pressure injector, causing an
explosion that forces the piston to move downward. This downward motion of the
piston is the source of mechanical energy.
Exhaust stroke-The fourth and final stroke is called the exhaust stroke. In this
stroke, the exhaust valve opens, and the piston moves upward, pushing the exhaust
gases out of the engine through the open exhaust valve.
The above four strokes collectively form a cycle known as the four-stroke cycle,
which is used in most modern IC engines. Some engines, however, use a two-stroke
cycle, which involves only two strokes, i.e., the compression stroke and the power
stroke. In a two-stroke cycle, the fuel-air mixture is drawn into the engine cylinder
and ignited every other stroke.

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7.2.Basic components of a IC engine

Fig 16: Basic components of an IC engine.

Even though there are different types of Internal Combustion Engines and each
engine has hundreds of components, there are some basic components which are
present in almost all the IC Engines. The basic components of IC Engine are as
follows:
Cylinder Block: Cylinder is the main body of IC engine. Cylinder is a part in which
the intake of fuel, compression of fuel and burning of fuel take place. The main
function of cylinder is to guide the piston. It is in direct contact with the products
of combustion so it must be cooled. For cooling of cylinder, a water jacket (for
liquid cooling used in most of cars) or fin (for 18 air cooling used in most of bikes)
are situated at the outer side of cylinder. At the upper end of cylinder, cylinder head
and at the bottom end crank case is bolted. The upper side of cylinder is consisting
a combustion chamber where fuel burns. To handle all this pressure and temperature
generated by combustion of fuel, cylinder material should have high compressive

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strength. So, it is made by high grade cast iron. It is made by casting and usually
cast in one piece.
Cylinder Head- The top end of the engine cylinder is closed by means of
removable cylinder head. There are two holes or ports at the cylinder head, one for
intake of fuel and other for exhaust. Both the intake and exhaust ports are closed by
the two valves known as inlet and exhaust valve. The inlet valve, exhaust valve,
spark plug, injector etc. are bolted on the cylinder head. The main function of
cylinder head is to seal the cylinder block and not to permit entry and exit of gases
on cover head valve engine. Cylinder head is usually made by cast iron or
aluminum.
Cylinder - Cylinder is the space or cylindrical vessel supported by cylinder block,
in which the piston makes reciprocating motion. During the operation of engine, the
volume inside the cylinder is filled with working fluid and subjected to different
thermodynamic process.
Piston - Piston is a tubular component that fitted into the engine cylinder. Piston
makes reciprocating motion inside the cylinder. Piston rings and lubricants
provided to make the fit is gas tight. It also acts as link in transmitting gas forces to
rotary motion of output shaft.
Piston Rings - Piston rings are provided on the piston to provide a gas tight seal
between piston and cylinder wall. This is fitted into slots on the outside diameter if
the piston to prevent leakage of combustion gas during engine running.
Connecting Rod - Connecting rod connects the piston to crankshaft and transmits
the motion and thrust of piston to crankshaft. It converts the reciprocating motion
of the piston into rotary motion of crankshaft. There are two ends of connecting rod;
one is known as big end and other as small end. Big end is connected to the
crankshaft and the small end is connected to the piston by use of piston pin.
Crankshaft - The crankshaft of an internal combustion engine receives the efforts
or thrust supplied by piston to the connecting rod and converts the reciprocating
motion of piston into rotary motion of crankshaft. The crankshaft mounts in bearing
so it can rotate freely.
Crankcase -The main body of the engine at which the cylinder are attached and
which contains the crankshaft and crankshaft bearing is called crankcase. It serves

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as the lubricating system too and sometime it is called oil sump. All the oil for
lubrication is placed in it.
Valves - To control the inlet and exhaust of internal combustion engine, valves are
used. The number of valves in an engine depends on the number of cylinders. Two
valves are used for each cylinder one for inlet of air-fuel mixture inside the cylinder
and other for exhaust of combustion gases. The valves are fitted in the port at the
cylinder head by use of strong spring. This spring keep them closed. Both valves
usually open inwards.
Spark Plug - It is used in spark ignition engine. The main function of a spark plug
is to conduct a high potential from the ignition system into the combustion chamber
to ignite the compressed air fuel mixture. It is fitted on cylinder head. The spark
plug consists of a metal shell having two electrodes which are insulated from each
other with an air gap. When high potential current supply to spark plug it jumping
from the supply electrode and produces the necessary spark.
Injector - Injector is usually used in compression ignition engine. It sprays the fuel
into combustion chamber at the end of compression stroke. It is fitted on cylinder
head.
Inlet and Exhaust Manifold - The pipes which connect the inlet system to the inlet
valve is known as Inlet Manifold. The air or air-fuel mixture are drawn into the
cylinder through inlet manifold. Exhaust Manifold is the pipe which connects
exhaust system to the exhaust valves. The products of combustion escape into
atmosphere through exhaust manifold.
Camshaft - Camshaft is used in IC engine to control the opening and closing of
valves at proper timing. For proper engine output inlet valve should open at the end
of exhaust stroke and closed at the end of intake stroke. So, to regulate its timing, a
cam is use which is oval in shape and it exerts a pressure on the valve to open and
release to close. It is drive by the timing belt which drives by crankshaft. It is placed
at the top or at the bottom of cylinder.
Flywheel - A flywheel is secured on the crankshaft. The main function of flywheel
is to rotate the shaft during preparatory stroke. It also makes crankshaft rotation
more uniform.

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 8.Starter

8.1. Starter motor definition

A starter or starter motor is an electrical device that is used to rotate (crank) internal
combustion engines so as to initiate the engine’s operation under its own power. As
soon as the engine begins to run, it got disconnected from the engine, which now
relies on the combustion process. The component is mounted on the engine’s
gearbox housing, and the starter motor gear meets the flywheel’s teeth.
8.2. Working

Fig 17: Starter

The starter motor typically has four field windings (field coils) attached to the starter
motor housing from the inside. The armature (the rotating part) is connected through
the carbon brushes in series with the field coils. On the front end of the armature,
there is a small gear that is attached to the armature through an overrunning clutch.

When the driver turns the key or presses the Start button, the solenoid winding is
energized. The solenoid plunger moves in the direction of the arrow and closes the
solenoid contacts. This connects the battery power to the starter motor (field coils
and armature). At the same time, the plunger pushes the starter gear forward through
the lever. The gear then engages with the ring gear of the flexplate and turns it over.
The flexplate is attached to the engine crankshaft.

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8.3. Components

Armature - An armature is an electromagnet component that is mounted on the

driveshaft or bearings for a guide. It is made of a laminated soft iron core which is
wrapped with numerous conductor loops or windings.

Commutator - A commutator is a section of the shaft at the rear of the housing on

which brushes run to conduct electricity. It is made of two plates mounted to the
axle of the armature, the plates provide connections for the coil of the
electromagnet.

Brushes - Brushes are parts that run on a section of the commutator at the rear of
the housing. it rubs the commutator and conducts electricity.

Solenoid - The solenoid features two coils of wire that are wrapped around the core.
This solenoid serves as a switch that connects and closes the electrical connection
between the starter motor and the vehicle’s battery.

Plunger - The function of a plunger in a starter motor is to push forward so the

pinion can be engaged.

Lever Fork - The lever fork is connected to the plunger which makes them push
forward together to engage the pinion.

Pinion - A pinion is a small mechanism containing gear and springs. It engages

immediately after the engine started, by extending the gear to the flywheel teeth.
The flywheel is the source of engine rotation.

Field Coils - The field coils are held in a housing with screws as it consists of two
or more coils connected in series. These coils receive power from the battery that
converts them into an electromagnet that turns the armature. This creates a magnetic
field around the armature.

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8.4. How a starting system works -

Fig 18: starter circuit diagram

1. When you turn the ignition key to ON position, the engine computer (PCM)
checks if the ignition key security code matches (immobilizer). If yes, the
engine is allowed to start.
2. When you turn the key to the START position, or press the START button,
the engine computer (PCM) checks if the transmission is in Park or Neutral,
if the brake pedal (Automatic) or clutch pedal (Manual) is depressed and if
the steering lock is unlocked (in some cars).
3. If all checks pass, the engine computer activates the starter relay.
4. The starter relay closes the starter control circuit and activates the starter
solenoid.
5. The starter solenoid closes the high-current circuit and sends power to the
starter motor.
6. At the same time, the starter solenoid throws the starter gear forward to mesh
it with the engine flexplate gear (or flywheel gear in a manual transmission).
The flexplate (flywheel) is attached to the engine crankshaft.
7. The starter motor turns over the engine crankshaft fast enough to allow the
engine to start. In cars with a push button start, the system disengages the
starter motor as soon as the engine starts running.

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 9.Gearbox
9.1. Introduction
Gearbox is a contained gear train, or a mechanical unit or component consisting of
a series of integrated gears within a housing. The use of gearbox is to transfer energy
from one rotating power source to another. They are found in automobiles, turbines
and heavy machineries.
In automobiles the gearbox is used in power transmission from the engine, through
the clutch, to the wheels of the vehicles. In general, there are three types of
gearboxes: concentric, parallel and right angles.

9.2. Parts of Gearbox:

Fig 19: Gear Box

Output shaft:An output shaft connects the drive wheels to the automatic gearbox
in our vehicle. The output shaft is the component that carries the power out of the
transmission to the wheels. An output shaft typically consists of several gears which
are connected together by bearings that allow them to rotate as power is transmitted
through them. The number of gears in an output shaft depends on the type of
vehicle. The gears can be either straight cut or helical cut

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Clutch packs: The clutch pack inside of an automatic transmission is comprised of
several discs inside of a drum which facilitates gear shifts in an automatic
transmission, a piston inside the drum squeezes the clutch pack together using oil
pressure, which locks the components of the clutch pack together.

Planetary gear set: A planetary gear is a type of gear system comprised of spur
gears. In planetary gearing a center gear is called a sun gear, serves as the input and
driver of the set. Three or more” driven” gears rotate around the sun gear. Finally,
the planets engage with a ring gear from the inside, which makes an internal spur
gear design. The benefit of planetary gear is to convert to a different ratio by simply
changing out the carrier and sun gears.

Brake band: Brake band is a strip of fabric, leather or metal tightened around a
pulley or shaft to act as a brake. Brake band are used in vehicles and engines to aid
in creating friction which is used to slow down the movement in the vehicles or
engine. When the brake band is applied, hydraulic pressure is applied to the servo
that, in turn, tightens the band around the drum.
Torque converter: A torque converter is a type of fluid couplings, which allows
the engine to spin somewhat independently of the transmission. The function of
torque converter is to transmits the torque from the engine to a rotating driven load.
In an automatic transmission car, the torque converter connects the power source to
the load.
Oil pump: The oil pump is an internal combustion engine part that circulates engine
oil under pressure to the rotating bearings, the sliding pistons and the camshaft of
the engine. This lubricates the bearings, allows the use of higher capacity fluid
bearings and also assists in cooling the engine.
Valve body: The valve body allows the flow of hydraulic fluid to different valves
to direct the right clutch and switch the gear appropriately according to the driving
situation. The vale body is controlled by a solenoid. The materials most frequently
used for valve bodies are bronze, cast iron and steel.
Oil pan: The bottom part of the crankcase of an internal combustion engine in
which the oil used to lubricate the engine accumulates is called the oil pan. The
pump forces the oil from the pan through a filter to remove dirt and other debris
before it circulates through the engine. There are two type of oil pans, these are the
dry and wet type sumps. Dry sump designs have more than one sump per engine;
the secondary sump is separate to the main engine sump. Oil drains from the engine
into a main sump where it is then removed to an additional external sump.

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