INTRODUCTION

DEFINITION

In-plant training by the term means training for a short period of time in an industry to
gain the knowledge of the work culture. It is beneficial for students to gain a upper hand when
they work in the company after graduates.
They will be acquainted with the industry and help them to work better in the
environment. It is done by pre or final year students.

MEANING
Training programme at the factory premises.

SUMMARY
In Plant Training (IPT)

In Plant Training will provide an industrial exposure to the students as well as to develop
their career in the high tech industrial requirements. Reputed companies are providing in plant
training to Students. Here students are initially get counseled in order to emerge out their interest
in various streams and what are all the basic concepts they know on that domain.

After the successful completion of studies students has to face this competitive world
with this knowledge to face many problems and to find the right solutions which is to be solved
in the minimum duration of time. The in-plant training is get totally different from the class
environments.

OBJECTIVES
 This training enables us to acquire more practical knowledge.
 The In-plant training totally different from the class environments.

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  To learn real life application of Management.
 To relate theoretical concepts and organizational functioning
 Training will provide an industrial exposure.
 To study the production level and various stages of production.
 To learn the company and industrial polices.
 To study various functions of departments.

SRI LAKSHMI PVC PIPE INDUSTRY

SRI LAKSHMI PVC PIPE INDUSTRY is an Indian PVC pipe manufacturing company
based in DHARMAPURI, TAMIL NADU, INDIA. Founded in 2009.

Around 75 members are working in this company and they manufacture PVC pipes under
customers demand. They manufacture pipes ranging from ½ inch to 7 inches which include
ISI certified water pipes and also strong electrical wire fencing plastic tubes from the old,
waste plastic PVC materials.

They recycle 90% of used and waste PVC materials to manufacture a completely
dependable pipe material. They import mixtures from Malaysia and collect the used PVC
materials from various parts of Karnataka, Kerala and Tamil Nadu.

In 2009 SRI LAKSHMI PVC PIPES INDUSTRY had only 5 employees and now they
have got more than 75 employees and most of their manufacturing machines are automatic
machines. Their machines are manufactured in such a way that they do not pollute the
environment. Water used inside the coolant chambers are properly recycled for later use and
no wastes are dumped in the farm or barren lands instead they are properly recycled.

Raw materials used are ordered in MALAYSIAN regions and that include pure form of
Calcium Carbonate, CPW oil, Oil wax, button wax and Timonium.

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ADDRESS OF SRI LAKSHMI PVC PIPE INDUSTRY;
SF No. 766/A,
KALLUKADAI (Bharathipuram),
BANDHARAHALLI (vill) & (Po),
KARIMANGALAM BLOCK,
PALACODE (Tk),
DHARMAPURI (Dt),Pin-635 123, TN.
Contact no: +91 99437 26133 +91 97867 1031

POLYVINYL CHLORIDE

Polyvinyl chloride, more correctly but unusually poly(vinyl chloride), commonly

abbreviated PVC, is the third-most widely produced synthetic plastic polymer, after
polyethylene and polypropylene.

PVC comes in two basic forms: rigid (sometimes abbreviated as RPVC) and flexible. The
rigid form of PVC is used in construction for pipe and in profile applications such as doors and
windows. It is also used for bottles, other non-food packaging, and cards (such as bank or
membership cards). It can be made softer and more flexible by the addition of plasticizers, the
most widely used being phthalates. In this form, it is also used in plumbing, electrical cable
insulation, imitation leather, signage, inflatable products, and many applications where it
replaces rubber.

Pure poly (vinyl chloride) is a white, brittle solid. It is insoluble in alcohol but slightly
soluble in tetrahydrofuran.

Discovery

PVC was accidentally synthesized in 1872 by German chemist Eugen Baumann. The
polymer appeared as a white solid inside a flask of vinyl chloride that had been left exposed to
sunlight. In the early 20th century the Russian chemist Ivan Ostromislensky and Fritz Klatte of
the German chemical company Griesheim-Elektron both attempted to use PVC in commercial
products, but difficulties in processing the rigid, sometimes brittle polymer thwarted their efforts.
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Waldo Semon and the B.F. Goodrich Company developed a method in 1926 to plasticize PVC
by blending it with various additives. The result was a more flexible and more easily processed
material that soon achieved widespread commercial use.

Production

Polyvinyl chloride is produced by polymerization of the vinyl chloride monomer (VCM),

as shown.

About 80% of production involves suspension polymerization. Emulsion polymerization

accounts for about 12% and bulk polymerization accounts for 8%. Suspension polymerizations
affords particles with average diameters of 100–180 μm, whereas emulsion polymerization gives
much smaller particles of average size around 0.2 μm. VCM and water are introduced into the
reactor and a polymerization initiator, along with other additives. The reaction vessel is pressure
tight to contain the VCM. The contents of the reaction vessel are continually mixed to maintain
the suspension and ensure a uniform particle size of the PVC resin. The reaction is exothermic,
and thus requires cooling. As the volume is reduced during the reaction (PVC is denser than
VCM), water is continually added to the mixture to maintain the suspension.

The polymerization of VCM is started by compounds called initiators that are mixed into
the droplets. These compounds break down to start the radical chain reaction. Typical initiators
include dioctanoyl peroxide and dicetyl peroxydicarbonate, both of which have fragile O-O
bonds. Some initiators start the reaction rapidly but decay quickly and other initiators have the
opposite effect. A combination of two different

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 Initiators is often used to give a uniform rate of polymerization. After the polymer has
grown by about 10x, the short polymer precipitates inside the droplet of VCM, and
polymerization continues with the precipitated, solvent-swollen particles. The weight average
molecular weights of commercial polymers range from 100,000 to 200,000 and the number
average molecular weights range from 45,000 to 64,000.

Once the reaction has run its course, the resulting PVC slurry is degassed and stripped to
remove excess VCM, which is recycled. The polymer is then passed through a centrifuge to
remove water. The slurry is further dried in a hot air bed, and the resulting powder sieved before
storage or pillarization. Normally, the resulting PVC has a VCM content of less than 1 part per
million. Other production processes, such as micro-suspension polymerization and emulsion
polymer.

PIPES:

Roughly half of the world's polyvinyl chloride resin manufactured annually is used for
producing pipes for municipal and industrial applications. In the water distribution market it
accounts for 66% of the market in the US, and in sanitary sewer pipe applications, it accounts for
75%. Its light weight, low cost, and low maintenance make it attractive. However, it must be
carefully installed and bedded to ensure longitudinal cracking and overbelling does not occur.
Additionally, PVC pipes can be fused together using various solvent cements, or heat-fused
(butt-fusion process, similar to joining HDPE pipe), creating permanent joints that are virtually
impervious to leakage.

In February, 2007 the California Building Standards Code was updated to approve the
use of chlorinated polyvinyl chloride (CPVC) pipe for use in residential water supply piping
systems. CPVC has been a nationally accepted material in the US since 1982; California,
however, has permitted only limited use since 2001. The Department of Housing and
Community Development prepared and certified an environmental impact statement resulting in

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a recommendation that the Commission adopt and approve the use of CPVC. The Commission's
vote was unanimous and CPVC has been placed in the 2007 California Plumbing Code.

In the United States and Canada, PVC pipes account for the largest majority of pipe
materials used in buried municipal applications for drinking water distribution and wastewater
mains. Buried PVC pipes in both water and sanitary sewer applications that are 4 inches
(100 mm) in diameter and larger are typically joined by means of a gasket-sealed joint. The most
common type of gasket utilized in North America is a metal reinforced elastomer, commonly
referred to as a Rieber sealing system.

PRODUCT PROFILE

6
QUALITY ASSURANCE

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 We firmly believed that quality helps in forming the backbone of any organization. our
endeavours are directly towards manufacturing optimal quality corrugated packaging boxes we
halved employed well versed quality auditors who strictly monitors ,the enter proceeding of our
manufacturing unit

RESEARCH & DEVELOPMENT

To keep a pace with the emerging market trends, we have employed a diligent team of
R&D personnel ,which conducts rigors and exhaustive research of the market .

Our professionals read each and every facet of the market, which helps us in developing
our research activities are cantered on following parameters :

 Design

 Raw material

 Manufacturing process

After conducting a thorough research, our team offers various implications that might proof

Beneficial for organization .after much planning and scheming viable suggestions of our
researchers are implemented in different units , to kea large client base across ep abreast with
market trends, we constantly develop different units of our organization

Our team

Our competitive team is the leading force which has drived our organization on the path of
success. We have with us a hardworking and sincere team of professionals, who helps us in
serving our clients with world class products

 Engineer

 Technicians

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  R&D executives

 Marketing executives

Due to our professionals innovative approaches. We have managed to make a strong

mark in the industry .further ,we also provide them skills development training on regular
intervals ,so that they can manufacture a range that exceeds that expectations of our reputed
clients

Clientele:

Being a client centric organisation ,we make sure to offer our client customized
solutions so as to garner complete customer satisfaction at client as well as our end.in order to
manufacture an optimum range of products ,we make use of the high quality raw materials and
offer our products at market leading prices due to these reasons ,we have been able to form a
large client base across the giobal the department of housing and community development
prepard and certified an environmental impact statement resulting in a recommendation that the
commission adopt and approve the use of cpvc. The commission ‘s vote was unanimous and
cpvc has been piaced in the 2007california piumbing code

IN the united states and Canada, pvc pipes account for the largest majority of pipe materials
used in burid municipal applications for drinking water distri butions and wastewater mains.[22]
burid PVC pipes in both water and sanitary sewer applications that are 4 inches (100mm) in diameter and
larger are typically joined by means of a gasket-sealed joint .the most common type of gasket utilized in
north America is a metal reinformed elastomer ,commonly reffered to as a rieber sealing system.

MANUFACTURING INDUSTRY

MANUFACTURING DEFINITION

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 The process of converting raw materials, components, or parts into finished goods that
meet a customer's expectations or specifications. Manufacturing commonly employs a man-
machine setup with division of labor in a large scale production.

Manufacturing industry refers to any business that transforms raw materials into finished
or semi-finished goods using machines, tools and labor. Manufacturing sectors include
production of food, chemicals, textiles, machines and equipment.

MEANING

Manufacturing is the production of merchandise for use or sale using labor and machines,
tools, chemical and biological processing, or formulation. The term may refer to a range of
human activity, from handicraft to high tech, but is most commonly applied to industrial
production, in which raw materials are transformed into finished goods on a large scale. Such
finished goods may be used for manufacturing other, more complex products, such as aircraft,
household appliances or automobiles, or sold to wholesalers, who in turn sell them to retailers,
who then sell them to end users – the "consumers".

Manufacturing takes turns under all types of economic systems. In a free market
economy, manufacturing is usually directed toward the mass production of products for sale to
consumers at a profit. In a collectivist economy, manufacturing is more frequently directed by
the state to supply a centrally planned economy. In mixed market economies, manufacturing
occurs under some degree of government regulation.

Modern manufacturing includes all intermediate processes required for the production
and integration of a product's components. Some industries, such as semiconductor and steel
manufacturers use the term fabrication instead.

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 The manufacturing sector is closely connected with engineering and industrial design.
Examples of major manufacturers in North America include General Motors Corporation,
General Electric, Procter & Gamble, General Dynamics, Boeing, Pfizer, and Precision Cast parts.

Industry is the production of a good or service within an economy. Manufacturing

industry became a key sector of production and labor in European and North American countries
during the Industrial Revolution, upsetting previous mercantile and feudal economies. This
occurred through many successive rapid advances in technology, such as the production of steel
and coal.

Following the Industrial Revolution, perhaps a third of the world's economic output is
derived from manufacturing industries. Many developed countries and many developing/semi-
developed countries (People's Republic of China, India etc.) depend significantly on
manufacturing industry. Industries, the countries they reside in, and the economies of those
countries are interlinked in a complex web of interdependence.

FUNCTIONS OF DEPARTMENTS

The Major Departments are

1. Finance Department

2. Human Resources Department

3. Production Department

4. Marketing Department

TYPES OF DEPARTMENTS

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Finance Human Marketing
Production
Department Resource Department
Department
Department

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FINANCE DEPARTMENT
Finance

 Finance Department is the activity of managing the money to run out the business in a
proper manner.

Finance Functions

 The financial section of the organisation will keep manual/electronic records of money
received and paid out by the organisation.
 This information will then be used to produce various financial statements for tax
purposes and to comply with legal requirements.
 The information will also be used to produce management accounts to enable senior
managers to plan and review business strategy.
 The finance department or unit may also be responsible for administering employee
expenses and salaries.
 For payment of wages the finance department will need to take into account statutory
deductions such as tax, and employee contributions such as pension or loan repayments.

Finance and Accounting Department Duties

 Preparation of budget,
 Appropriation of accounts
 Re-appropriations,
 Surrender and Savings.
 Control of Expenditure
 Ways & Means position.
 Sales Tax,
 Entertainment Tax,

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  Luxury Tax
 Entry Tax
 Service Conditions
 Resource mobilization through loans,
 Institutional Finance,
 Small Savings,
 Credit and Investment

Finance Department in Organization

 The Finance Department is an organization dedicated to providing quality financial, and

judicial services to other City Departments, the City Council, and the citizens of Abilene.
 These services are intended to be provided in a timely, accurate, and cost efficient
manner by utilizing quality employees, technological advances, and generally accepted
principles while fulfilling legal responsibilities.

The Finance Department continues to respond to organizational and community needs

through development of new programs and modification of existing programs. Issues that
continue to face the organization are heavy reliance on sales tax, lack of significant revenue
growth, and increased expenditure needs to maintain service levels.

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 Working Process in the Finance Department

Office of the Director

General Budget Treasury Risk

Accounting Management
GGGGGGG
GGGGGGG
g

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 HUMAN RESOURCES DEPARTMENT

Involvement of Human Resource Management

 Human Resource Management involves the development of a perfect blend between

traditional administrative functions and the well-being of all employees within an
organization.
 Employee retention ratio is directly proportionate to the manner in which the employees
are treated, in return for their imparted skills and experience.
 A Human Resource Manager ideally empowers inter-departmental employee
relationships and nurtures scope for down-the-rung employee communication at various
levels.
 Every organization now has an exclusive Human Resource Management Department to
interact with representatives of all factors of production.
 The department is responsible for the development and application of ongoing research
on strategic advances while hiring, terminating and training staff.
 The Human Resource management is responsible for Understanding and relating to
employees as individuals, thus identifying individual needs and career goals.
 Developing positive interactions between workers, to ensure collated and constructive
enterprise productivity and development of a uniform organizational culture.
 Identify areas that suffer lack of knowledge and insufficient training, and accordingly
provide remedial measures in the form of workshops and seminars.

Human Resources Planning

1. Forecasting
2. Maintaining personnel inventories
3. Succession planning
4. Modeling career paths

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Training & Development
1. Devising programs
2. Hourly Workers
3. Managerial Staff

Employment

1. Recruitment
2. Selection
3. Testing
4. Orientation

Compensation

1. Incentive pay plans

2. Job analysis
3. Job evaluations
4. Wage surveys
5. Performance reviews

Personnel Research

1. Administering opinion surveys

2. Conducting HR audits
3. Publishing statistical analysis

Functions of Human Resource Department

 Getting Paying Employees

 Paying employees (and Providing Benefits)
 Training Employees

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WORKING STRUCTURE IN HUMAN RESOURCE DEPARTMENT

Chief Human Resource Officer

General Manager

Human Resource Manager

Assistance Human Assistance Human

Resource Officer-I Resource Officer-II

Supervisor-I Supervisor-II Supervisor-I Supervisor-II

Employees Employees Employees Employees

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 PRODUCTION DEPARTMENT

Role of Production Department

 The main role of production is to turn inputs (raw materials) into outputs (finished
goods).
 Outputs refer to a finished product or service and inputs are the materials that are needed
to manufacture certain goods.
 When a business completes this process they are able to achieve customer satisfaction by
producing products that are ready to be used and fit for purpose.

The function of the production department is to produce our products on time, to the required
quality levels, at the defined product cost.

Component and materials procurement is another factor that strongly influences production,
production targets and delivery. If components cannot be purchased at the target price, profits are
down. If components arrive late at our factory production targets may not be met and customers
may experience late delivery. Purchasing of components and materials is carried out by the
Purchasing section of Production.

Features of Production Department

Creation
 The foundation of every production and operations department is the creation
of goods or services.
 Traditionally, production included the physical assembly of goods, but
production can also include data-based goods such as websites, analysis
services and order processing services.

Customer Service
 The production and operations department contains the customer-facing
customer service department that addresses the needs of the customer after the
purchase of goods or services.
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  The support function usually is served through phone, online or mail based
support.

Profit
 The main function of the production and operations department is to produce a
product or service that creates profit and revenue for the company.
 Actualization of profit requires close monitoring of expenses, production
methodology and cost of inputs.

Evaluation
 Every production and operations department must function as self-evaluating
entity that monitors the quality, quantity, and cost of goods produced.
 Analysis usually takes the form of statistical metrics, production evaluation
and routine reporting.

FUNCTIONS OF PRODUCTION DEPARTMENT

Materials:

 The selection of materials for the product. Production manager must have sound
Knowledge of materials and their properties, so that he can select appropriate materials
for his product.
 Research on materials is necessary to find alternatives to satisfy the changing needs of the
design in the product and availability of material resumes.

Methods:

 Finding the best method for the process, to search for the methods to suit the available
resources, identifying the sequence of process are some of the activities of Production
Management.
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Machines and Equipment:

 Selection of suitable machinery for the process desired, designing the maintenance policy
and design of layout of machines are taken care of by the Production Management
department.

Estimating:

 To fix up the Production targets and delivery dates and to keep the production costs at
minimum, production management department does a thorough estimation of Production
times and production costs.
 In competitive situation this will help the management to decide what Should be done in
arresting the costs at desired level.

Loading and Scheduling:

 The Production Management department has to draw the time table for various
production activities, specifying when to start and when to finish the process required.
 It also has to draw the timings of materials movement and plan the activities of man
power.
 The scheduling is to be done keeping in mind the loads on hand and capacities of
facilities available.

Routing:

 This is the most important function of Production Management department.

 The Routing consists of fixing the flow lines for various raw materials, components etc.,
 From the stores to the packing of finished product, so that all concerned knows what
exactly is happening on the shop floor

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Dispatching:

 The Production Management department has to prepare various documents such as Job
Cards, Route sheets, Move Cards, Inspection Cards for each and every component of the
product.
 These are prepared in a set of five copies.
 These documents are to be released from Production Management department to give
green signal for starting the production.
 The activities of the shop floor will follow the instructions given in these documents.
Activity of releasing the document is known as dispatching.

Inspection:

 Here inspection is generally concerned with the inspection activities during production,
but a separate quality control department does the quality inspection, which is not under
the control of Production Management.
 This is true because, if the quality inspection is given to production Management, then
there is a chance of qualifying the defective products also.

Working process in Production Department

Production Manager

Assistance Production Manager

Supervisor- I Supervisor- II

Employees Employees
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 MARKETING DEPARTMENT

 Ascent circuits Company growing in the market size and in its product exports in both the
national level and international level.
 The company having many competitors in the inner and outer of the nation.
 The market position of the Ascent Company growing day to day in a systematic order.
 Some of the companies that are in the competition view towards Ascent Company are
stated below.

Role of Marketing Department

 The marketing department will research customer needs to develop strategy and product
to satisfy that customer need.
 In its research, the marketing department will investigate the market they are aiming at;
the type of consumer making up the market (age, background sex etc) and the preferences
of the consumer within that market.
 The marketing department will then need to marry consumer preferences with producing
a product that is profitable.
 Once the product has been designed by the production department marketing will then
need to package, advertise, and promote the product.
 Sales are responsible for persuading the consumer to purchase the end product,
manufactured through marketing’s research.
 The Sales Department’s selling strategy could involve mail shots, travelling sales
representatives, telephone sales and devising the sales interview.

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Overview

 Small companies may consist of one or two marketing employees, and larger
organizations may have dozens of marketing employees.
 The organizational structure of the marketing department of a company can vary
according to the individual company

Marketing Manager

 Marketing manager and marketing director are often interchangeable in the world of
marketing.
 A marketing manager typically has the responsibility of carrying out the marketing
strategy for the company.
 This includes creating marketing messages, choosing mediums such as website
advertising and print advertising, and carrying out other marketing campaigns and
programs to reach the target audience of the company.
 The marketing manager reports to the vice president and generally manages the rest of
the marketing employees.
 In product-based companies that have different product lines, a marketing manager may
exist for each product line.

Market Researchers

 Market researchers can employ tools, such as surveys and focus groups to help them
uncover information and statistic or use publications, such as the U.S. Census to obtain
information.
 The research, information and statistics found by the market researchers are used by the
marketing manager to create the programs and messaging.

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  Small- to medium-size companies tend to hire a third-party source for market research
rather than have a full-time market research staff. Large organizations employ its own
market researchers.

PURCHASE DEPARTMENT

Role of Purchase Department

 It is policy to maintain a reputation for fairness and integrity in its dealings with
legitimate and reliable firms and to promote sound relationships with such firms.
 By maximizing competition among reputable firms, an impartial selection of qualified
sources for materials, equipment, supplies and services can be attained and still merit the
continuing confidence of suppliers, customers and the public while maintaining high
ethical standards.
 The expenditures for materials, equipment, goods and services
 Each Strategic Business Unit and facility shall establish a written purchasing policy and
procedure to insure that adequate controls are in effect to assure that purchases are
properly authorized before orders are placed with vendors.
 Also, such policy must insure that adequate documentation is requested from vendors to
describe goods and/or services rendered. Purchasing, in the broadest sense, involves
every organizational unit which participates in the planning, design or use of materials,
equipment, supplies and services required in ERL operations.

Activities of Purchase Department

 Through coordination of purchasing activities in all of these organizational units, and

cooperation between such units, the Company will receive the desired value of needed
materials, equipment, supplies and services at the lowest possible cost.
 Supply Chain Management personnel of each major operating business unit have the
primary responsibility for
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  Purchasing all materials, equipment, supplies and services at the best possible prices,
 Maintaining confidence of suppliers and the public.

Functions of Purchase Department

 Procurement of stores through indigenous and foreign sources as required in accordance

with the rules in force.
 Checking of requisitions/purchase indents.
 Selection of suppliers for issue of enquiries.
 Issuing enquiries/tenders and obtaining quotations.
 Negotiating contracts.
 Checking legal conditions of contracts.
 Issue of Purchase Orders.
 Follow-up of purchase orders for delivery in due time
 Maintenance of purchase records.
 Maintenance of progressive expenditure statement, sub-head wise.
 Maintenance of vendor performance records/data.
 Arrangement for Insurance Surveys, as and when necessary.
 Clearance of foreign consignments.

MANUFACTURING PROCESS
For more than 50 years, PVC has been very successful throughout the world. Today, this
versatile material is one of the most important plastic materials recognised internationally and
proven on the market.

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PLASTIC PIPES
Plastic pipes are produced by extrusion process followed by calibration to ensure
maintenance of accurate internal dia with smooth internal boxes. These pipes generally come in
lengths of 6 meters. A wide range of injection moulded fittings, including tees, elbows, reducers,
caps, pipes saddles, inserts and threaded adaptors for pipe sizes 15-150mm are available.

PVC Pipes The chief advantage of PVC are:

Resistance to corrosion
Light weight
Toughness
Rigidity
Economical in laying, jointing and maintenance
Ease of fabrication

The PVC pipes are much lighter than cast iron or A.C pipes. Because of their light weight
PVC pipes are easy to handle, transport, and install. Solvent cementing techniques for
jointing
PVC pipe lengths are cheaper, more efficient and far simpler. PVC pipes do not become
pitted or tuberculated and are unaffected by fungi and bacteria and are resistant to a wide range
of chemcials. They are immune to galvanic and electrolytic attack, a problem frequently
encountered in metal pipes especially when buried in corrosive soils or near brackish waters.
PVC pipes have elastic properties and their resistance to deformation resulting from earth
movements is superior compared to conventional pipe materials especially asbestos. Thermal
conductivity of PVC is very low compared to metals. Consequently water transported in these
pipes remain at a more uniform .
Rigid PVC pipes weighs only 1/5 of conventional steel pipes of comparable sizes. PVC
pipes are available in sizes of outer dia20,25,32,50,63,75,90,110,140,160,250,290,315mm at
working pressure of2,5,4,6,10Kg/cm2. Since deterioration and decomposition of plastics are
accelerated by ultraviolet light and frequent changes in temperature which are particularly severe
in our country if is not advisable to use PVC pipes above ground.

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 The deterioration starts with Discolouration, surface cracking and ultimately ends with
brittleness and the life of the pipe may be reduced to 15-20 years.

Precautions in Handling and storage

Because of their light weight, there may be a tendency for a PVC pipes to be thrown
much more than their metal counterparts. This should be discoursed and reasonable care should
be taken in handling and storage to prevent damage to the pipes. On no account should pipes be
dragged along the ground pipes should be given adequate support at all times. These pipes
should not be stacked in large piles, especially under warm temperature conditions, as the bottom
pipes may be distorted thus giving rise to difficulty in pipe alignment and jointing.
For temporary storage in the field, where racks are not provided, care should be taken
that ground is level, free from loose stones. Pipes stored thus should not exceed three layers and
should be stacked as to prevent movement. It is also recommended not to store one pipe inside
another.

Laying and Jointing Procedures

Trench Preparation:
The trench bed must be free from any rock projections. The trench bottom where it
isrocky and uneven a layer of sand or alluvial earth equal to 1/3 dia of pipe or 100mm whichever
is less should be provided under the pipes.
The trench bottom should be carefully examined for the presence of hard objects suchas
flints, rock, projections or tree roots. In uniform, relatively soft fine grained soils found to be free
of such objects and where the trench bottom can readily be brought to an even finish providing a
uniform support for the pipes over their lengths, the pipes may normally directly on the trench
bottom. In other cases the trench should be cut correspondingly deeper and the pipes laid on a
prepared under biding, which may be drawn from the excavated material if suitable.

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Laying and Jointing:
As a rule trenching should not be carried out too far ahead of pipe laying. The trench
should be as narrow as practicable. This may be kept from 0.30m over the outside diameter of
pipe and depth may be kept at 0.60 - 1.0m depending upon traffic conditions. Pipe lengths are
placed end to end along the trench. The glued spigot and socket jointing technique as mentioned
later is adopted. The jointed lengths are then lowered in the trench and when sufficient length has
been laid the trench is filled.
If trucks, lorries, or other heavy traffic will pass across the pipe line, concrete tiles 600 x
600mm of suitable thickness and reinforcement should be laid about 2m above the pipe to
distribute the load. If the pipe line crosses a river the pipe should be buried at least 2m below bed
level to protect the pipe.
For bending, the cleaned pipe is filled with sand and compacted by tapping with wooden
stick and pipe ends plugged. The pipe section is heated with flame and the portion bent as
required. The bend is then cooled with water, the plug removed, the sand poured out and the pipe
(bend) cooled again. Heating in hot air over hot oil bath, hot gas or other heating devices are also
practiced. Joints may be jet welded, or flamed or with rubber gaskets or made with solvent
cement. Threaded joints are also feasible but are not recommended. Socket and spigot joint is
usually is preferred for all PVC pipes up to 150mm in dia. The socket length should at least be
one and half times the outer dia for sizes up to 100mm dia and equal to the outer dia for larger
sizes.
For pipe installation, solvent gluing is preferable to welding. The glued spigot socket
connection has greater strength than can ever be achieved by welding. The surfaces to be glued
are thoroughly scoured with dry cloth and preferably chamfered to 30 . If the pipes have become
heavily contaminated by grease or oil, methylene cement is applied with a brush evenly to the
outside of the socket on the other. The spigot is then inserted immediately in the socket upto the
shoulder and thereafter a quarter (90 ) turn is given to evenly distribute the cement over the
treated surface. The excess cement which is pushed out of the socket must be removed at once
with a clean cloth. Jointing must be carried out in minimum possible time, time of making
complete joint not being more than one minute. Joints should not be disturbed for at least 5
minutes. Half strength is attained in 30 minutes and full in 24 hours.

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Pre-fabricated connections
In laying, long lengths of pipe, prefabricated double socketed connections are frequently
used to join successive pipe lengths of either the same or one size different. The socket in this
case must be formed over a steel mandrel. A short length of pipe is flared at both ends and used
as a socket connection. The mandrel used in sized such that the internal dia of the flared socket
matches the outer dia of the spigot to be connected. By proper sizing of the two ends of a
connector, it is possible to achieve reduction (or expansion) of pipe size across the connector.

Standard threaded connections

Normally PVC pipes should not be threaded For the connections of PVC pipes to metal
pipes, a piece of a special thick wall PVC connecting tube threaded at one end is used. The other
end is connected to the normal PVC pipe by means of a glued spigot and socket joint. Before
installation the condition of the threads should be carefully examined for cracks and impurities.
Glue can be used for making joints leak proof. Yarn and other materials generally used with
metal pipe and fittings should not be used. Generally, it is advisable to use PVC as the spigot
portion of the joint.

Pressure Testing
The method which is commonly in use is filling the pipe with water, taking care to
evacuate any entrapped air and slowly raising the system to appropriate test pressure. The
pressure testing may be followed as in 6.4.4.2.
After the specified test time has elapsed, usually one hour, measured quantity of water is
pumped into the line to bring it to the original test pressure, if there has been loss of pressure
during the test. The pipe shall be judged to have passed the test satisfactorily if the quantity of
water required to restore the test pressure of 30 m for 24 hours does not exceed 1.5 litres per 10
mm of nominal bore for a length of 1 Km.

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FINDINGS

1. Workers have been provided with aprons, gloves, shoes, head covers and ID cards.

2. 75% of work is done manually and 25% of work is done through automated machines.

3. Hygienic lunches for the employees are provided.

4. Refreshments like tea, coffee, biscuits are also provided.

5. Production processes are highly ECO-FRIENDLY.

6. They recycle 95% of their waste materials.

7. Solar powered generators are being effectively used.

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 CONCLUSION

The In-Plant Training was in fact an eye opening movement for the Trainee. It helped the
Trainee to co-relate the theory into practical aspects. At certain situation Trainee found a wide
gap between Theory & Practical knowledge. This becomes a great challenge for the trainee to
understand deeply. But as a whole, In-Plant Training immensely helped the Trainee to know the
history, working structure, production process, its products, sales and total management of that
particular company.

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