DESIGN AND FABRICATION OF PORTABLE

OIL SKIMMING MACHINE

PROJECT REPORT 2016-2017

Submitted by:
(team name)

COLLEGE LOGO

Guided by:

Submitted in partial fulfillment of the requirement for the

Award of Diploma in -----------------------------------------
By the State Board of Technical Education Government of
Tamilnadu, Chennai.

Department :
College name:
Place:
 COLLEGE NAME

COIMBATORE

DEPARTMENT

PROJECT REPORT-2016-2017

This Report is certified to be the Bonafide work done by

Selvan/Selvi ---------------- Reg.No.------------ of VI
Semester class of this college.

Guide Head of the Department

Submitter for the Practical Examinations of the board of

Examinations,State Board of Technical Education,Chennai,
TamilNadu.On --------------(date) held at the ------------
(college name),Coimbatore

Internal Examiner External Examiner

DEDICATED TO OUR BELOVED
PARENTS
 ACKNOWLEDGEMENT

At this pleasing movement of having successfully completed our

project, we wish to convey our sincere thanks and gratitude to the
management of our college and our beloved
chairman------------------------.who provided all the facilities to us.

We would like to express our sincere thanks to our principal

------------------for forwarding us to do our project and offering adequate
duration in completing our project.

We are also grateful to the Head of Department prof…………., for

her/him constructive suggestions &encouragement during our project.

With deep sense of gratitude, we extend our earnest &sincere thanks

to our guide --------------------, Department of Mechanical for her/him kind
guidance and encouragement during this project we also express our indebt
thanks to our TEACHING staff of MECHANICAL ENGINEERING
DEPARTMENT, ---------- (college Name).
DESIGN AND FABRICATION OF PORTABLE

OIL SKIMMING MACHINE

CONTENTS
 CONTENTS

CHAPTER NO TITLE
SYNOPSIS
LIST OF FIGURES
NOMENCLATURE
1 Introduction
2 Literature review
3 Description of equipments
3.1 Belt
3.2 Pulley
3.3 Chain
3.4 Worm gear
3.5 Control unit
4 Design and drawing
4.1 Over all diagram
5 Working principle
6 Advantages and disadvantages
7 Application
8 List of materials
9 Cost Estimation
10 Conclusion
Bibliography
photography
 LIST OF FIGURES

LIST OF FIGURES
Figure
Number Title

1 overall Diagram
SYNOPSIS
 SYNOPSIS

During the recent decade, World has witnessed big oil spillage

accidents into ocean and made huge impact to the environment. Apart this,

sometimes Oil is getting spillage through being the results of chronic and

careless habits in the use of oil industries and oil products. It is estimated

that approximately 706 million gallons of waste oil enters the ocean every
year; whereas more than half of that sourced from land drainage and waste

disposal. Offshore drilling & production operations and spills or leaks from

ships or tankers are typically contributing less than 8% of the total whereas

routine maintenance of ships (nearly 20%), onshore air pollution &

hydrocarbon particles (about 13%) and natural seepage from the sea floor

(over 8%). This has caused ever lasting damage to aquatic life. To separate

the mixed oil from the water, industries wide various type of oil skimmers

are getting used. Herewith, the objective of this project is to design and

conduct efficiency studies of belt type oil skimmer by using various

materialzed belts. The belts absorb the oil from water which can be scooped

out and collect into a vessel by providing piping arrangements. The collected

oil can be reused for many purposes.

 CHAPTER-1

INTRODUCTION

CHAPTER-1
INTRODUCTION
The new generation of Megator oil water separators. Lightweight,

stainless steel construction make the Megator oil water separators extremely

resilient to corrosion and portable. The coalescing oil water separators are

the perfect extension of Megator’s recovery systems that have for years

proven their value to our customers.

 In refineries, chemical plants, electric power plants and many other

industrial facilities the separation of various oil and water mixtures can

cause problems. These problems are often the result of imperfect

understanding of the nature of the mixtures and how to take advantage of

their properties to accomplish the required separations. In addition, many

states and cities require treatment of stormwater from parking lots and

other facilities where cars and trucks may be present to treat stormwater to

ensure the oil and fuel that may have leaked from the vehicles does not enter

the rivers, streams and lakes.

This course will give an overview of many of the industrial and also

stormwater processing situations that may arise and also some of the means

for solving the problems with pros and cons of many possible designs as

well as some suggestions on determining the nature and extent of the

problems and possible solutions. For purposes of this discussion,

oil means hydrocarbons except where specifically noted otherwise.

TYPES OF SEPARATIONS:

Four main types of separations are likely in industrial plants and

numerous more similar situations exist from time to time. The four most

common are: Water from Oil where main flow is Mostly Oil Oil from Water

where main flow is Mostly Water Emulsions Non-Hydrocarbon oils WATER

FROM OIL WHERE MAIN FLOW IS MOSTLY OIL Separating water from

continuous flows of oil is commonly required in oil production applications,

oil refineries and chemical plants as well as some places where it is essential

that the hydrocarbons not be contaminated with water. The possible

problems with water contamination were first emphasized during the last

part of World War II when it was found that airplanes could fly high enough

to cause the water to freeze in the fuel lines. The pilots found this

unreasonably inconvenient because it caused the engines to stop, so

equipment was designed to ensure that only tiny amounts of water were

allowed to remain in the aviation fuel.

CHAPTER-2

LITERATURE SURVEY
 CHAPTER-2

LITERATURE SURVEY

It was also found that refinery processes operated easier and better

and corrosion problems were avoided by removing the water from the

hydrocarbons. Numerous types of equipment have been designed to cope

with the widely varying problems of removing the water from the oil and

several of these are discussed below. The problems in removing water from

oil vary widely mostly because of the widely varying viscosity of

hydrocarbons that must be treated.

OIL FROM WATER WHERE MAIN FLOW IS MOSTLY WATER

Separating oil from a continuous stream of water is commonly done in oil

refineries, chemical plants, and other industrial facilities for resource

recovery as well as environmental reasons. It is also practiced in some oil

field situations where the flow from the wells is primarily water. The

beginnings of the application of scientific principles to these separations

began in 1948 when the American Petroleum Institute (API) commissioned a

study by the University of Wisconsin to prepare a method for designing

separators to recover oil from the m in refinery wastewater streams. This

design is still used, but it was not originally designed for environmental

purposes and does not generally produce an effluent suitable for discharge to

rivers, streams or lakes. This method requires a large residence time and is

therefore bulky and costly, so modified design “API Type” systems are often

used. Since the 1948 study2, numerous designs have been used to remove oil

from water and several are discussed below. The newer designs make it

possible to remove oil from the water down to less than 10 mg/l.

EMULSIONS:

An emulsion is a mechanical mixture, not a solution, consisting of droplets

of one immiscible fluid dispersed in another continuous fluid. A good

definition, offered by is: "An emuls on is an apparently homogenous

mixture in which one liquid is dispersed as droplets throughout a second

immiscible liquid." In the case of water and oil, two types of emulsion are

common, depending on which is the continuous phase.

1. Oil in water emulsions.

2. Water in oil emulsions.

A third type, water in oil in water, is possible but very uncommon.

Emulsions can be very difficult to separate and because of the extreme

variations in type, causes, and treatment are outside the scope of this

discussion.
 CHAPTER-3

DESCRIPTION OF EQUIPMENT
 CHAPTER-III

DESCRIPTION OFEQUIPMENT

3.1 PULLEY

A pulley is a wheel with a groove along its edge, also called a sheave,

for holding a rope or cable. Pulleys are usually used in sets designed to

reduce the amount of force needed to lift a load. The same amount of work

is necessary for the load to reach the same height as it would without the

pulleys. The magnitude of the force is reduced, but it must act through a

longer distance. The effort needed to pull a load up is roughly the weight of

the load divided by the number of wheels. The more wheels there are, the

less efficient a system is, because of more friction between the rope and the

wheels.

The pulleys and lines are weightless, and that there is no energy loss

due to friction. It is also assumed that the lines do not stretch. With this

assumption, it follows that, in equilibrium, the total force on the pulley must

be zero. This means that the force on the axle of the pulley is shared equally

by the two lines looping through the pulley. The lines are not parallel, the

tensions in each line are still equal, but now the vector sum of all forces is

zero.
 A second basic equation for the pulley follows from the conservation

of energy the product of the weight lifted times the distance it is moved is

equal to the product of the lifting force times the distance the lifting line is

moved. The weight lifted divided by the lifting force is defined as the

advantage of the pulley system. It is important to notice that the amount of

work done in an ideal pulley is always the same. The work is given by the

effort times the distance moved. The pulley simply allows trading effort for

distance.

BELT

Belts are used to mechanically link two or more rotating items. They

may be used as a source of motion, to transmit power at up to 98%

efficiency between two points, or to track relative movement.

As a source of motion, a conveyor belt is one application where the

belt is adapted to continually carry a load between two points. A belt may

also be looped between two points so that the direction of rotation is

reversed at the other point. Power transmission is achieved by specially

designed belts and pulleys. The demands on a belt drive transmission

system.

Belts normally transmit power only on the tension side of the loop.

Designs for continuously variable transmissions exist that use belts that are a

series of solid metal blocks, linked together as in a chain, transmitting power

on the compression side of the loop.

3.2. CHAIN:
A chain is a series of connected links which are typically made

of metal. A chain may consist of two or more links.

 Those designed for lifting, such as when used with a hoist; for pulling;

or for securing, such as with a bicycle lock, have links that

are torus shaped, which make the chain flexible in two dimensions (The

fixed third dimension being a chain's length.)

 Those designed for transferring power in machines have links

designed to mesh with the teeth of the sprockets of the machine, and are

flexible in only one dimension. They are known as roller chains, though

there are also non-roller chains such as block chain.

3.3 MOTOR

PRINCIPLES OF OPERATION

In any electric motor, operation is based on simple electromagnetism.

A current-carrying conductor generates a magnetic field; when this is then

placed in an external magnetic field, it will experience a force proportional

to the current in the conductor, and to the strength of the external magnetic

field. As you are well aware of from playing with magnets as a kid, opposite

(North and South) polarities attract, while like polarities (North and North,

South and South) repel. The internal configuration of a DC motor is

designed to harness the magnetic interaction between a current-carrying

conductor and an external magnetic field to generate rotational motion.

 Let's start by looking at a simple 2-pole DC electric motor (here red

represents a magnet or winding with a "North" polarization, while green

represents a magnet or winding with a "South" polarization).

Every DC motor has six basic parts -- axle, rotor (armature), stator,

commutator, field magnet(s), and brushes. In most common DC motors, the

external magnetic field is produced by high-strength permanent magnets.

The stator is the stationary part of the motor -- this includes the motor

casing, as well as two or more permanent magnet pole pieces. The rotor

(together with the axle and attached commutator) rotates with respect to the

stator. The rotor consists of windings (generally on a core), the windings

being electrically connected to the commutator. The above diagram shows a

common motor layout -- with the rotor inside the stator (field) magnets.
 The geometry of the brushes, commutator contacts, and rotor

windings are such that when power is applied, the polarities of the energized

winding and the stator magnet(s) are misaligned, and the rotor will rotate

until it is almost aligned with the stator's field magnets. As the rotor reaches

alignment, the brushes move to the next commutator contacts, and energize

the next winding. Given our example two-pole motor, the rotation reverses

the direction of current through the rotor winding, leading to a "flip" of the

rotor's magnetic field, driving it to continue rotating.

In real life, though, DC motors will always have more than two poles

(three is a very common number). In particular, this avoids "dead spots" in

the commutator. You can imagine how with our example two-pole motor, if

the rotor is exactly at the middle of its rotation (perfectly aligned with the

field magnets), it will get "stuck" there. Meanwhile, with a two-pole motor,

there is a moment where the commutator shorts out the power supply. This

would be bad for the power supply, waste energy, and damage motor

components as well. Yet another disadvantage of such a simple motor is that

it would exhibit a high amount of torque "ripple" (the amount of torque it

could produce is cyclic with the position of the rotor).

 A few things from this -- namely, one pole is fully energized at a time

(but two others are "partially" energized). As each brush transitions from one

commutator contact to the next, one coil's field will rapidly collapse, as the

next coil's field will rapidly charge up (this occurs within a few

microsecond). We'll see more about the effects of this later, but in the

meantime you can see that this is a direct result of the coil windings' series

wiring:

There's probably no better way to see how an average DC motor is put

together, than by just opening one up. Unfortunately this is tedious work, as

well as requiring the destruction of a perfectly good motor.

 The guts of a disassembled Mabuchi FF-030-PN motor (the same

model that Solarbotics sells) are available for (on 10 lines / cm graph paper).

This is a basic 3-pole DC motor, with 2 brushes and three commutator

contacts.

The use of an iron core armature (as in the Mabuchi, above) is quite

common, and has a number of advantages. First off, the iron core provides a

strong, rigid support for the windings -- a particularly important

consideration for high-torque motors. The core also conducts heat away

from the rotor windings, allowing the motor to be driven harder than might

otherwise be the case. Iron core construction is also relatively inexpensive

compared with other construction types.

But iron core construction also has several disadvantages. The iron

armature has a relatively high inertia which limits motor acceleration. This

construction also results in high winding inductances which limit brush and

commutator life.

In small motors, an alternative design is often used which features a

'coreless' armature winding. This design depends upon the coil wire itself for

structural integrity. As a result, the armature is hollow, and the permanent

magnet can be mounted inside the rotor coil. Coreless DC motors have
much lower armature inductance than iron-core motors of comparable size,

extending brush and commutator life.

The coreless design also allows manufacturers to build smaller

motors; meanwhile, due to the lack of iron in their rotors, coreless motors

are somewhat prone to overheating. As a result, this design is generally used

just in small, low-power motors. Beamers will most often see coreless DC

motors in the form of pager motors.

Again, disassembling a coreless motor can be instructive -- in this

case, my hapless victim was a cheap pager vibrator motor. The guts of this

disassembled motor are available (on 10 lines / cm graph paper). This is (or

more accurately, was) a 3-pole coreless DC motor.

 CHAPTER-4

DESIGN AND DRAWING

 CHAPTER-IV

DESIGN OF EQUIPMENT AND DRAWING

4.1 COMPONENTS

This project consists of the following components to full fill the

requirements of complete operation of the machine.

1. Motor

2. Worm gear

3. Belt

4. pulley
DRAWING FOR DESIGN AND FABRICATION OF

PORTABLE OIL SKIMMING MACHINE

 SQUARE DC MOTOR CALCULATION

SPECIFICATION:

Speed N = 30 RPM
Voltage V = 12 Volt

Current I = 0.3 A (loading condition)

Current I = 0.06 A (No Load Condition)

Power P =V x I=12x0.3 = 3.6 WATT

1 WATT = 0.00134102HP

3.6 WATT = 3.6 X 0.00134102

P= 0.0048 HP

Motor Efficiency = 36%

FORMULEA

Good science project does not stop with building a motor. It is very

important to measure different electrical and mechanical parameters

of your motor and calculate unknown values using the following

helpful formulas.

This formula could be used in many cases. You may calculate the

resistance of your motor by measuring the consumed current and

applied voltage. For any given resistance (in the motors it is basically
the resistance of the coil) this formula explains that the current can be

controlled by applied voltage.

Electrical power of the motor is defined by the following formula:

Pin = I * V

Where,

Pin – input power, measured in watts (W)

I – current, measured in amperes (A)

V – applied voltage, measured in volts (V)

Motors supposed to do some work and two important values define

how powerful the motor is. It is motor speed and torque – the turning

force of the motor. Output mechanical power of the motor could be

calculated by using the following formula

Pout = Τ * ω

Where,

Pout – output power, measured in watts (W)

τ – torque, measured in Newton meters (Nm)

ω – angular speed, measured in radians per second (rad/s).

Calculate angular speed if you know rotational speed of the motor in

rpm:

ω = N * 2π / 60

Where,

ω – Angular speed, measured in radians per second (rad/s);

rpm – rotational speed in revolutions per minute;

π – Mathematical constant pi (3.14).

60 – Number of seconds in a minute.

Efficiency of the motor is calculated as mechanical output power

divided by electrical input power:

E = Pout / Pin
Therefore

Pout = Pin * E

After substitution we get

Τ*ω=I*V*E

Τ * N * 2π / 60 = I * V * E

Connect the motor to the load. Using the motor from generator kit is

the best way to do it. Why do you need to connect the motor to the

load? Well, if there is no load – there is no torque.

Measure current, voltage and rpm. Now you can calculate the torque

for this load at this speed assuming that you know efficiency of the

motor.

Motor torque changes with the speed. At no load you have maximum

speed and zero torque. Load adds mechanical resistance. The motor

starts to consume more current to overcome this resistance and the

speed decreases. If you increase the load at some point motor stops

(this is called stall). When it occurs the torque is at maximum and it is

called stall torque. While it is hard to measure stall torque without

special tools you can find this value by plotting speed-torque graph.

You need to take at least two measurements with different loads to

find the stall torque.

TORQUE OF THE MOTOR:

And the formula for calculating torque will be

Τ = (I * V * E *60) / (N * 2π)

= (0.3x12x0.36x60)/30x2π

Torque = 0.412 Nm
1Kg-cm = 0.0980665 Nm
1 Nm = (1/.0980665) =10.197 kg-cm
(10.197 x .412) = 4.20 kgcm
Torque (T) = 4.2kgcm
 WORM GEAR CALCULATION
Number of teeth on worm wheel = 30

Outer diameter of worm wheel = 58 mm

Inner diameter of worm wheel = 15 mm

Number of starts on worm = 9

Motor speed = N = 30 rpm

Power of motor = p = 18 watts

Diameter of shaft = 15 mm

Mild steel shaft shear stress = fs = 210 N / mm^2

Torque of the motor = T = p x 60 / 2 x π x N

= 18 x 60 / 2 x π x 30

= 5.729 N - m

The gear ratio of a worm gear is worked out through the following
formula:

number of teeth on wormwheel

number of teeth on worm

= 30 / 9

= 3.333

Gear ratio (i) = n1 / n2

(n1) worm shaft speed = 30 rpm

(n2) worm wheel speed = 30 / 3.333

= 9.00 rpm

Torque of the worm wheel (t2) = p2 x 60 / 2 x π x N2

= 18 x 60 /2 x π x 9.00

= 19.098 N m

Angular velocity of worm wheel = Ɵ = 2 x π x 9.00 / 60

= 0.942 rad

Maximum torque rate of the worm wheel = π/16 x fs x d^3

= π/16 x 210 x 15^3

= 2226.6 N m

Worm wheel torque is limited to the maximum limit. So our design is

safe.

Hence the worm wheel used here rotates at 9.00 rpm

 CHAPTER -5

WORKING PRINCIPLE
 CHAPTER -5

WORKING PRINCIPLE

In our project the tank is placed on the base frame. The tank is filled

with the water and oil mixture. In the above mixture the oil will be floating

on the water. Our aim is to remove the oil from water. Here we use a simple

technique called skimming method. A pulley is allowed to pass inside the

water and oil mixture as shown in the figure to hold the pulley chain is used.

This project is done by the dc motor and worm gear which is mounted on the

frame behind the belt and pulley. The oil scrapper is attached with another

frame in a slanted position such that it can wipe out the oil from the belt and

pulley. When the belt rotates the oil will be stick to the belt and the water

will remain in the tank. The oil scrapper removes the oil from the disc. The

removed oil is collected in a container which is arranged separately beside

the setup. A heater can be used under the collecting for better separation.
 CHAPTER -6

ADVANTAGES AND DISADVANTAGES

 CHAPTER - VI

ADVANTAGES AND DISADVANTAGE

ADVANTAGES

 An oil skimmer by itself can achieve the desired level of water purity.
 Easy to operate
 One of the effective ways to separate the oil from water.

DISADVANTAGES

If the floating grease has formed into solid clumps, aerator or

mechanical apparatus can be used to break up grease mats and facilitate

removal.
CHAPTER -7

APPLICATION

CHAPTER –VII
 APPLICATION

APPLICATIONS

It can be used in industries for removing oil or grease from the water.
 CHAPTER-8

LIST OF MATERIALS

CHAPTER-VIII
 LIST OF MATERIALS

FACTORS DETERMINING THE CHOICE OF MATERIALS

The various factors which determine the choice of material are

discussed below.
1. Properties:

The material selected must posses the necessary properties for the

proposed application. The various requirements to be satisfied

could be weight, surface finish, rigidity, ability to withstand

environmental attack from chemicals, service life, reliability etc of the

material.

The following four types of principle properties of materials

decisively affect their selection

a. Physical

b. Mechanical

c. From manufacturing point of view

d. Chemical

The various physical properties concerned are melting point, thermal

Conductivity, specific heat, coefficient of thermal expansion, specific

gravity, electrical conductivity, magnetic purposes etc.

The various Mechanical properties Concerned are strength in tensile,

Compressive shear, bending, torsional and buckling load, fatigue resistance,

impact resistance, elastic limit, endurance limit, and modulus of elasticity,

hardness, wear resistance and sliding properties.

The various properties concerned from the manufacturing point of

view are,

 Cast ability

 Weld ability

 Surface properties

 Shrinkage

 Deep drawing etc.

2. Manufacturing case:

Sometimes the demand for lowest possible manufacturing cost or surface

qualities obtainable by the application of suitable coating substances may

demand the use of special materials.

3. Quality Required:

This generally affects the manufacturing process and ultimately the

material. For example, it would never be desirable to go casting of a less

number of components which can be fabricated much more economically by

welding or hand forging the steel.

4. Availability of Material:
 Some materials may be scarce or in short supply. It then becomes

obligatory for the designer to use some other material which though may not

be a perfect substitute for the material designed. the delivery of materials

and the delivery date of product should also be kept in mind.

5. Space consideration:

Sometimes high strength materials have to be selected because the forces

involved are high and space limitations are there.

6. Cost:

As in any other problem, in selection of material the cost of material

plays an important part and should not be ignored.

Some times factors like scrap utilization, appearance, and non-

maintenance of the designed part are involved in the selection of proper

materials.
 CHAPTER-9

COST ESTIMATION

Chapter-IX

COST ESTIMATION
1. LABOUR COST:

Lathe, drilling, welding, grinding, power hacksaw, gas cutting cost

2. OVERGHEAD CHARGES:

The overhead charges are arrived by”manufacturing cost”

Manufaturing Cost =Material Cost +Labour Cost

Overhead Charges =20%of the manufacturing cost

3.TOTAL COST:

Total cost = Material Cost +Labour Cost +Overhead Charges

Total cost for this project =

CHAPTER-10

CONCLUSION

CHAPTER-X

CONCLUSION
 The project carried out by us made an impressing mark in the field of

marine industries.

This project will reduce the cost involved in the concern. Project has

been designed to perform the entire requirement task at the shortest time

available.
 BIBLIOGRAPHY

BIBLIOGRAPHY

1. Strength of Materials -R.S.Kurmi

2. Manufaturing Technology -M.Haslehurst.
PHOTOGRAPHY