Fecal Sludge Management Challenge in Bidibidi Refugee Settlement
BUDNI__INSTITUTE
1. BUDNI
INSTITUTE
GOVERNMENT OF INDIA
CENTRAL FARM MACHINERY
TRAINING & TESTING INSTITUTE
TRACTOR NAGAR, BUDNI (M.P.) 466- 445,
INDIA
PROJECT REPORT ON
SUMMER PRACTICAL
TRAINING
SUBMITTED BY:
MOHIT CHHABRA
L-2K8-AE-29-BIV
PUNJAB AGRICULTURAL UNIVERSITY
LUDHIANA PUNJAB INDIA. PIN CODE: 141 004
2. INTRODUCTION
Central Farm Machinery Training & Testing Institute, Budni is not
only a name but a living culture, a culture that has been developed, as a
result of untiring efforts of a team of men by their selfless and dedicated
work. The Institute made a modest beginning in 1955 with a skeleton
staff and meagre resources . The assistance made available under the
Technical Co-operation Mission of the United States gave a boosting
effect in developing the needed infrastructure to run the initial activities.
Activities first started at the periphery of the forest. Available
army barracks were renovated to use as office, staff residence and
trainees hostel. Forest land was cleared for use as farm. The centre was
surrounded by reserved forest and occasionally , the official estate used
to be visited by wild animals. In the initial period there was no proper
road communication. The nearest district town Hoshangabad was not
linked by road as there was no road bridge over the Narmada River
during that period. Road bridge over Narmada was constructed only in
the later part of the sixties. The only link was the rail . The local railway
station had stoppageof only a passenger train in the morning and
evening. There was no medical facility available. For medical facility
the staff had to go to Bhopal , some seventy kilometer away.
The centre in its years of growth got new buildings replacing the
weather beaten shed-like buildings and developed the needed
infrastructure. This includes separate training labs for I.C. engines, auto-
electrical and farm motors, hydraulic system, irrigation pumps, plant
protection equipments, test laboratories etc. It attained the status of an
institute in 1983. Today the Institute provides facility and guidance for
project work to the M.Tech and above level students of Agricultural
Universities, including I.I.T. Kharagpur etc.
In its testing activity, the first tractor was tested in 1961
manufactured by Renault Tractor Company, France . At that time India
had no test codes ofits own. Test codes for testing of different machines
were evolved by the Centre based on BS, ISO and SAE codes. Drawbar
performance test on tractors used to be conducted with gadgets
fabricated by the centre locally. It was in the later part of the sixties that
a tractor drawbar test load car was received under Colombo Plan Aid
from U.K. and then a concrete test track was constructed. Todaythis test
facility exists in the form of most modern tractor test load car with
3. computer based instrumentation and measurements, which was also
supplied by the Govt. of U.K. under aid programme.
The OECD recognition of the Institute in the year 1988, for tractor
test, in accordancewith their standard test code, brought the Institute to
International status. This type of test has helped the Indian Tractor
Industry to boosttheir export potential.
In the farm, development continued to take place from 1956
onwards with the centre’s own resources. Later-on properlevelling of the
farm was taken up in 1980 as a project. Out of 476 acres of land, the
Institute has 176 acres of land suitable for cultivation. A tar macadam
road around the farm was made in 1999 for haulage test, besides for
security purposes. Thefarm has two natural ponds, and an irrigation
system supported bythree tube wells and one open well. Water is also
lifted from the perennial rivulet passing through eastern side of the farm.
Electrification of a part of the farm roads has also been done, a farm
house with threshing floor has also been constructed.
The selfless and dedicated services rendered by Shri P.John
Zachariah, the first Director and founder of the Testing Wing and his
successor Director Shri O. S. Gupta, are worth to remember for
posterity. Shri Gupta during his stewardship brought the Station to
International acclaim. The editors shall fail in their efforts if a word of
special appreciation to Mr. H.M. Jones, the Farm Machinery Advisor of
the Centre( 1955-60) is not recorded. His contribution to put the centre in
the desired momentum, in the initial stages of its establishment, shall be
ever remembered.
On a visit to the farm machinery museum of the Institute, one can
see, that each machine in fact tells a story, a story of success, astory of
dedication of its engineers, technicians and all others of the institute.
In the back drop ofthe story , it will not be an exaggeration to say
that the Institute has made a commendable contribution for modernization
of Indian Agriculture in the four and half decades of its existence.
4. INFRASTRUCTURE
Training System
The training system has demonstration-cum- training laboratories
for tractors, engines, irrigation pumps, hydraulics, auto electricals, plant
protection equipments and improved bullock drawn implements.
There is a repair shop for on the job training. The Institute has a
large collection of farm implements ranging from the early ‘stump
jump plow’ manufactured in Australia in the early sixties to the
modern day implements. It has a large number of tractors, stationery
engines, irrigation pumps, plant protection equipments, harvesting &
threshing machines. A Museum of tractors & farm machinery is also
maintained by the Institute.
Testing System
The test system of the Institute has two test laboratories equipped
with modern sophisticated Instrumentation for conducting tests on
tractors and other farm machines. It has a computerized tractor PTO
and engine test set-up under controlled environmental conditions.
There is a computerized drawbar test load vehicle, apart from another
hydraulic load car. The test system also has test rigs, test set-ups,
dynamometers and other most modern sophisticated test
instrumentation. Simulated test rig for wet land cultivation is also
available
Instrumentation Cell
The Instrumentation Cell provides necessary assistance related to
Instrumentation needs of the testing process.
Library
The Institute maintains a well equipped library to cater the need of
nascent information required by the engineers, technologists, trainees
and others of the Institute fraternity. It has a large collection of books
numbering 20,000, on varied technological subjects related to the
activities of the Institute, micro-documents & neo- documents. It
subscribes for a number of periodicals in the subject matter that are
published at home and abroad.
5. Farm
The Institute has 476 acres of farm attached to it. Out of this
cultivated area is 176 acres, where paddy, wheat, soyabean and
gram are cultivated. The Institute maintains this farm as an essential
part of its human resources development and testing activities. Field
practices in mechanized farming techniques are imparted here. Also
it is used for testing purposes. Various field trials of farm machines
are conducted at the farm.
Audio Visual Aids Cell
There is an audio visual aids cell to cater the training needs of the
Institute and from time to time publishes books and bulletins .
Auditorium
The Institute has an auditorium with a capacity of nearly 200 seats
for conducting technical seminars, meetings and conferences. 21
Workshop
A moderate workshop equipped with minimum facilities is
provided for the testing and training needs.
Rest House
The Institute maintains a well furnished rest house to meet the
needs of visiting dignitaries at the centre.
Hostel
There are two hostels at the centre, with dining facilities which can
accommodate200 persons at a time. Facility for extra curricular
activity is also afforded.
Housing For Staff
The Institute has sufficient housing facilities for the staff at present.
6. TRAINING AT BUDNI
1. TRANSMISSION SYSTEM
The topic covered under transmission system are:
- Engine
- Clutch
- Gearbox
- Differential
- Final Drive
- Rear Axle
- Rear Wheels
2. TRACTOR MAINTENANCE
The maintenance covered under the training is done
after some intervals which are:
- At 8-10 engine working hours
- At 50-60 engine working hours
- At 100-120 engine working hours
- At 200-250 engine working hours
- At 480-500 engine working hours
- At 960-1000 engine working hours
3. BRAKE, HYDRAULIC AND STEERING SYSTEM
Topics covered under brake are:
- Types of brakes
- Function of brakes
- Components of brakes
Hydraulic System:
- It is based on the principle of Pascal’s law.
- In addition to towing an implement or supplying
tractive power through the wheels, most tractors
have a means to transfer power to another machine
such as a baler, swather, or mower. Unless it
7. functions solely by pulling it through or over the
ground, a towed implement needs its own power
source (such as a baler or combine with a separate
engine) or else a means of transmitting power from
the tractor to the mechanical operations of the
equipment.
- Early tractors used belts or cables wrapped around
the flywheel or a separate belt pulley to power
stationary equipment, such as a threshing machine,
buzz saw, silage blower, or stationary baler. In most
cases, it was not practical for the tractor and
equipment to move with a flexible belt or cable
between them, so this system necessitated that the
tractor remain in one location with the work
brought to the equipment, or that the tractor be
relocated at each turn and the power set-up
reapplied (as in cable-drawn plowing systems used
in early steam tractor operations).
- Modern tractors use a power take-off (PTO) shaft to
provide rotary power to machinery that may be
stationary or pulled. The PTO shaft generally is at
the rear of the tractor, and can be connected to an
implement that is either towed by a drawbar or a
three-point hitch. This eliminates the need for a
separate implement-mounted power source, which
is almost never seen in modern farm equipment.
- Virtually all modern tractors can also provide
external hydraulic fluid and electrical power to the
equipment they are towing, either by hoses or wires.
Topics covered under Steering System:
- Function of steering
- Types of steering
- Components of steering
- Steering geometry
8. 4. DRIVING PRACTICE
- The same driving techniques as we studied earlier in
our previous course are repeated again.
5. ELECTRICAL SYSTEM
Topics covered under this system are detailed below:
When electrical trouble is experienced in any
circuit it is advisable to start with the battery.
Battery
A visual inspection and a few quick electrical checks
with a voltmeter, ampmeter,
o ohmmeter and hydrometer will reveal the
condition of the power source.
The battery posts and cables must be clean and free of
deposits.
The use of undersize batteries will result in poor
performance or early failure. A new
o battery should be at least of equal ampere-hour
rating to the original battery.
A 12-volt dry charged battery needs to be activated
with electrolytes at a temperature
o under 60 degrees F for a 10-minute period at
warm up charge of 15 amperes.
Always install a battery with the same positive and
negative posts in proper position.
o Hold down bolts should be tight to prevent
movement and damage to the battery case.
The ground strap should be connected last to prevent
arcing. A coating of spray-on
o battery corrosion preventative, petroleum jelly or
grease should be applied to post and
o cable clamps.
For batteries which have discharged and require
charging, a slow charge is best.
o (Example, 4-amps for 24 hours is better than 50
amps for 1 ½ hours.) This is for a 100
o amp/hour capacity battery.
When checking a battery with a hydrometer the
temperature of the electrolyte should
o be considered.
9. When reading a hydrometer the barrel must be held
vertically and just the right
o amount of acid be drawn up into the barrel to
float the tube freely.
The following table illustrates the specific gravity for a
cell in various stages of charge
o to crank an engine at 80 degrees F.1.280 Specific
Gravity 100% charged
o 1.220 " " 50% charged
o 1.190 " " 25% charged
o 1.160 " " very little good
o 1.130 " " discharged
Pouring acid into a discharged battery will cause early
failure.
Generator
The generator supplies electricity when
driven mechanically by the engine. It should
o supply current to the battery, to keep it in a
charged condition and to any connected electrical
o load. However, the regulator and the wiring has
its part to play in the system. If the ampmeter
o gauge is working properly on the tractor it should
indicate the charging rate.
A system that has an overcharge will require excessive
water usage and a high
o ampmeter indication.
Check visually the wiring connections and make sure
they are clean and tight. Repair
o or replace wires that are faulty or bare on
insulation.
Periodically check the fan belt for wear, glazing, or
bottoming on the pulley.
Hold generator pulley with fingers and feel for side play
and freeness of rotation to
o determine condition of bearings.
Each bearing has grease supply which eliminates the
need for periodic lubrication.
If in doubt of proper operation the alternator may be
taken off and put on a test stand
o to check diodes, starter and rotor.
10. When connecting a booster battery, connect negative
posts together and positive posts
o together. If leads are hooked wrong the diodes
can be damaged. When you have
o sparks and high flow current there is danger of
the wiring harness being burned.
Do not short across or ground any of the terminals on
the regulator. An attempt to
o polarize an alternator can cause damage to the
diodes, wiring harness and other
o components.
Complaints or troubles involving the charging circuit
are either overcharging or
o undercharging of the battery.
An undercharged battery or one that “runs down” is
the fault of a short, heavy usage,
o or faulty battery.
Voltage Regulator
The regulator has a battery, generator, and field
terminal. The operation or rate of
charge is controlled by the cutout relay. The
cutout is a magnetically operated switch
that controls the flow or current.2. Care must be
exercised when cleaning points. Some points are
soft and some very
hard, requiring different methods. All oxides
should be removed so the pure metal is
exposed, although it is not necessary to file the
surface perfectly flat.
Contact points may be cleaned with a strip of 400
silicon carbide paper and then
cleaned with a strip of trichlorethylene paper to
remove foreign material.
Never use emery cloth or sandpaper to clean
contact points.
Cranking Circuits
The cranking motor converts electrical energy
from the battery into mechanical energy
11. which is used to crank the tractor engine for
starting.
The cranking circuit consists of a battery,
cranking motor, wiring and control switches.
The solenoid switch engages the pinion gear to
mesh with the engine flywheel and
reverse the process after the engine has started.
No periodic lubrication is needed and the
cranking motor will have to be disassembled
to inspect brushes and bearings.
The wiring circuit to the starting motor must have
tight fittings and proper size wire to
carry current due to high energy demands during
cranking.
6. TILLAGE, SOWING AND HARVESTING MACHINERY
Tillage is the agricultural preparation of the soil by
mechanical agitation of various types, such as digging,
stirring, and overturning. Examples of human-
powered tilling methods using hand
tools include shovelling, picking, mattock work, hoeing,
and raking. Examples of draft-animal
powered or mechanized work
include ploughing (overturning with moldboards or
chiseling with chisel shanks), rototilling, rolling
withcultipackers or other rollers, harrowing, and
cultivating with cultivator shanks (teeth). Small-scale
gardening and farming, for household food production
or small business production, tends to use the smaller-
scale methods above, whereas medium- to large-scale
farming tends to use the larger-scale methods. There is a
fluid continuum, however. Any type of gardening or
farming, but especially larger-scale commercial types,
may also use low-till or no-till methods as well.
Tillage is often classified into two types, primary and
secondary. There is no strict boundary between them so
much as a loose distinction between tillage that is deeper
and more thorough (primary) and tillage that is shallower
and sometimes more selective of location (secondary).
12. Primary tillage such as ploughing tends to produce a
rough surface finish, whereas secondary tillage tends to
produce a smoother surface finish, such as that required
to make a good seedbed for many crops. Harrowing and
rototilling often combine primary and secondary tillage
into one operation.
Primary tillage equipments:
- MB Plough
- Disc Plough
- Chiesel Plough, etc.
Secondary tillage equipment:
- Disc harrow
- Cultivator
Sowing is the process of planting seeds.
Sowing equipments shown are:
- Seed drill
- Potato Planter
- Zero till drill
- Sugarcane planter
- Transplanter
Harvesting is the process of gathering mature crops from
the fields.
Harvesting equipments shown are:
- Thresher
- Reaper binder
- Rotavator
- Vertical conveyer
- Combine Harvestor.
13. 7. ENGINE
- Study, operation, maintenance and repair of 5 H.P.
Single Cylinder Diesel Engine and also 4 Cylinder
Diesel Engine is covered within 5 days of the
training.
8. TESTING
- Introduction to tractor testing activities, study of
Indian Standards and Testing procedure.