8/6/2015

Internship Report
Gas Geyser Thermostat work shop

TESLA.PV

ISLAMABAD I-10/3 STREET 6

ABSTRACT:................................................................................................................................................. 1

INTRODUCTION: ........................................................................................................................................ 1

STATIONS: ................................................................................................................................................. 1
3.1
MACHINE WORKSHOP: ....................................................................................................................................... 1
3.1.1 Filing: ....................................................................................................................................................... 1
3.1.2 Drilling:..................................................................................................................................................... 1
3.1.3 Threading: ................................................................................................................................................ 2
3.1.4 Washing: .................................................................................................................................................. 3
3.1.5 Pressing: ................................................................................................................................................... 3
3.1.6 Rotor: ....................................................................................................................................................... 3
3.1.7 Rear seat filing: ........................................................................................................................................ 3
3.2
N OPERATION: .................................................................................................................................................. 3
3.2.1 Ring Spring: .............................................................................................................................................. 3
3.2.2 H Ring:...................................................................................................................................................... 3
3.2.3 Ring Spring: .............................................................................................................................................. 3
3.2.4 N spring plus aluminum button plus aluminum pin: ................................................................................ 3
3.2.5 Pressure disc: ........................................................................................................................................... 3
3.2.6 Copper disc:.............................................................................................................................................. 3
3.2.7 Sealing plate plus MS button: .................................................................................................................. 3
3.2.8 Slider pin and sleeve: ............................................................................................................................... 4
3.2.9 Adjuster plate: ......................................................................................................................................... 4
3.2.10
Sensor (thermistor) .............................................................................................................................. 4
3.2.11
Adjuster bolt and nut: .......................................................................................................................... 4
3.2.12
Problems and solutions: ...................................................................................................................... 4
3.3
FRONT SEAT AND FRONT PLATE: ........................................................................................................................... 4
3.3.1 Front seat, seal: ....................................................................................................................................... 4
3.3.2 Glass filter wool: ...................................................................................................................................... 4
3.3.3 Front seat spring: ..................................................................................................................................... 4
3.3.4 Main gasket: ............................................................................................................................................ 4
3.3.5 Front seat cover: ...................................................................................................................................... 4
3.4
FINAL ASSEMBLY: .............................................................................................................................................. 4
3.4.1 Screw:....................................................................................................................................................... 5
3.4.2 Adjuster valve: ......................................................................................................................................... 5
3.4.3 Rotor operation:....................................................................................................................................... 5
3.4.4 Pilot manual: ............................................................................................................................................ 5
3.5
SOLENOID CELL: ................................................................................................................................................ 5
3.6
RETEST:........................................................................................................................................................... 5
3.6.1 Adjuster Cup:............................................................................................................................................ 5
3.6.2 Abbreviations used for defects: ............................................................................................................... 5
3.7
GAS GEYSER THERMOSTAT PACKING: ..................................................................................................................... 6
3.7.1 Thermostat plastic packing: ..................................................................................................................... 6
3.7.2 Adjuster nut: ............................................................................................................................................ 6
3.7.3 In out seals: .............................................................................................................................................. 6
3.7.4 Main knob: ............................................................................................................................................... 6
3.7.5 Rotor knob: .............................................................................................................................................. 6
3.7.6 Connector seal: ........................................................................................................................................ 6

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1 Abstract:
his report covers the details of the processes taking place at the gas geyser
thermostat workshop.

2 Introduction:
The gas geyser thermostat workshop is one of the many workshops located at
Tesla.pv. As its name suggests, this workshop is intended for the production of
thermostats assemblies. I work in this workshop for two days and produced
below is what I learnt.

3 Stations:
A total of seven stations are present in the workshop details of which are below:
1.
2.
3.
4.
5.
6.
7.

Machine workshop.
N operation.
Front seat and front plate.
Final assembly.
Solenoid cell.
Retest.
Packing.

Details of these are below.

3.1 Machine workshop:

3.1.1 Filing:
The process starts with thermostat casting, which comes from Lahore. The
thermostat castings undergo slight filing to remove any nicks and burs.

3.1.2 Drilling:
There are slight sports on the casting, which indicate the places to be drilled.
These spots are drilled using the drill machine.

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3.1.3 Threading:
On the castings there are certain holes which need to be threaded. Drilling
machine modified by a threading assembly is intended to make these threads.

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3.1.4 Washing:
In this process, kerosene oil along with water is used at a high-pressure to wash
this castings.

3.1.5 Pressing:
Using a hand press machine, plug gasket, side hole plug, inlet filter, outlet
washer our pressed at the relevant positions.

3.1.6 Rotor:
Like the thermostat casting, the rotor casting also comes from Lahore. But it
needs machining, which is done on the lathe machine.

3.1.7 Rear seat filing:

The rear seat is filed using a lathe machine. This operation is called rear seat
operation or N operation.

3.2 N operation:
N operation means all those operations which take place on the rear seat. These
operations are explained below, these operations take place in sequence and are
placed one above the other:

3.2.1 Ring Spring:

Ring Spring is made of an elastic wire.

3.2.2 H Ring:
It is called so because a figure like the alphabet H is engraved in it.

3.2.3 Ring Spring:

Same as above.

3.2.4 N spring plus aluminum button plus aluminum pin:

Its called N Spring because of its shape. They are placed at the relevant places.

3.2.5 Pressure disc:

3.2.6 Copper disc:
3.2.7 Sealing plate plus MS button:
These two are pressed.

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After these steps apply grease to bolts and tighten using a gas pressure adjuster.

3.2.8 Slider pin and sleeve:

3.2.9 Adjuster plate:
3.2.10
Sensor (thermistor)
3.2.11
Adjuster bolt and nut:
When we turn the main adjusting knob actually we are turning this adjuster bolt.
Its angle should be between 35 to 45.

3.2.12

Problems and solutions:

problem
Angle not correct.
Rear seat leak.
No off on sound.

cause
Change then N Spring.
Again, press it.
H Spring change.

3.3 Front seat and front plate:

Following operations take place in sequence, in this station:

3.3.1 Front seat, seal:

Front seat and its seal are meant to overlap each other, accurately, if not, they are
filed and compared to do so.

3.3.2 Glass filter wool:

The purpose of this wool is to prevent any solid particles from entering into the
thermostat body.

3.3.3 Front seat spring:

3.3.4 Main gasket:
This is to ensure the sealing of the main thermostat body.

3.3.5 Front seat cover:

3.4 Final assembly:

As its name suggests, here the thermostat is made ready to be tested. A number
of operations take place here. All these operations take place on the top plate:

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3.4.1 Screw:
3.4.2 Adjuster valve:
Adjuster valve is mounted into its correct place. Its purpose is to control the
flame. Greece is also used to produce is in its rotation.

3.4.3 Rotor operation:

Black grease is used for the rotor. Rotor Spring plus washer is mounted on its top
upon which the top plate is screwed. The rotor should rotate about 180.

3.4.4 Pilot manual 1:

Pilot manual plus gasket are pressed intact by Hammer.

3.5 Solenoid cell:

The solenoid cell is the heart of this thermostat. The solenoid cell is made in
China, grease is applied to it and it is inserted into its correct place in the
thermostat casting.

3.6 Retest:
The whole assembly is retested using the flame for any leakage or any other fault.
Its then using a potential difference to take place of the thermocouple. Solenoid
cell and the thermocouple are internally linked. They use their own notation to
denote what the defect is.

3.6.1 Adjuster Cup:

This cup is used to prevent from adjusting the pilot adjuster knob.

3.6.2 Abbreviations used for defects:

abbreviations used
PML
HA
LA
HC
RSL
FSL

What they denote

Pilot manual leaked
High angle
Low angle
H Spring change
Rear seat leak
Front seat leak

, the pilot manual is also manufactured in this workshop. It consists of a few washers, rubber sealing, springs,
mounted on a single aluminum nail like structure.

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RL
BD

Rotor leak
Burner direct 2

After this, these pieces with abbreviations written on them are sent back to the
respective sections because assembling the thermostats is a very sensitive task.
So mostly problems come and there are more assembled parts which need
rework than correct ones.

3.7 Gas geyser thermostat packing:

Gas geyser thermostats are packed with in groups of five by casing. And per
carton is 25 thermostats that is five casings per carton.

3.7.1 Thermostat plastic packing:

Using heat the thermostat is packed using a plastic sheet.

3.7.2 Adjuster nut:

3.7.3 In out seals:
Theyre made of rubber.

3.7.4 Main knob:

Theyre made of plastic. They are the knobs which we rotate.

3.7.5 Rotor knob:

It should rotate 180.

3.7.6 Connector seal:

After these operations, the thermostats are stamped indicating the necessary
precautions, and the company logo.

4 Accompanying parts:
Apart from these, using the auto lathe machine and the CNC machine, following
parts are also made in the other section of workshop:

In this situation, the burner keeps burning no matter we turn it on or off.

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4.1 Sleeve pin:

Made on auto lathe machine.

4.2 Adjuster nut:

Made on auto lathe machine.

4.3 Outlet washer:

Made on auto lathe machine.

4.4 CNC pressure disc:

On CNC machine.

4.5 Aluminum button:

On auto lathe machine.

4.6 Adjuster cup:

On auto lathe machine.

Adjuster nut

Outlet washer

Pressure disc

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Aluminum button

Sleeve pin

Sealing plate

MS button

5 Conclusion:
In short, the workshop was create. The QC was very good. Every step and every
measure is well calculated. Owing to sensitivity of this product, mostly most of
the parts show faults, these faulty parts are resent for rework.