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Six Months Industrial Training Report Dec. -- May

ESS ESS KAY CO. LTD.Post Box no-8, Factory area, Kapurthala (ISO 9001:2000)

Submitted by: -SAVYASACHI 90210718927 B.Tech, EEE 2009 - 2013

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INTRODUCTION TO COMPANY

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MAIN DEPARTMENTS

• Sheet metal shop• Paint shop• Electroplating shop• Moulding shop • Switchgear assembly Shop• Panel shop• Quality assurance department/Test Labs

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SHEET METAL SHOP/DEPARTMENTC.R.C.A sheet (ESSAR STEEL INDIA LTD.)

(60 sheets, Wt. 2.8MT,(2/1.5*1250*2500mm)

Shearing Machine(Mechanical cutter)

(HH, 415V, 6200kg,6mm,3Φ,working area 3100mm)Bending machine

(HH,415V,8700kg,6mm,w.a.3100mm,10 ton, DELEM)

(AMADA,5100kg,w.a.2505mm,80 ton)Punching machine

(VIPROS 225,9800kg,50-60hz,196KN,27kva)

(HH, 3Φ,9000kg,2000KN,415V,3.8A,DELEM)

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Welding machine(Sunrise , Spot/Projection,pf-0.4,415V,50hz,3Φ,1.5litre)

(MIG welding, copper electrode)

(Gas welding, O2,Acetylene)

Drilling machine

(Sunrise,pf-0.6,415V,50-60hz,3Φ)

Power press

(Sunrise,415V,50-60hz,pf-0.4,3Φ,14.gauge2100Kg)

(18.gauge,2300Kg)(20 gauge,2500Kg)

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PAINT SHOP/DEPARTMENT

Power Coating Gun

(Based on electrostatic charging,0.5-1A,230V) Paint Process Phosphating

(Degreasing Tank- Caustic soda & Soda ash,10 PH,75-850C,10min)

(Derusting Tank-Acid,1 PH,50-600C,5min)

(Phosphating Tank- Zinc Phosphate,1 PH,30-350C,3min)

(Water rinsing Tank- Water,7 PH,270C,1min)

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Painting(Coating) (2 pipes,-vely charged powder, +vely charged body) (Thermoplastic/Thermoses polymer )

(NUT WHITE SEMI GLOSSY) Baking (182-2200C, 4-5A, 350V, 55μns layer, 15min)

Sealing (Sodium dichromate,4 PH ,70-800 C, 5min)

Test Applied After Coating the Body

o Scratch Test:- (with cello tape)

o Bend Test:- (bend it up to 900)

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ELECTROPLATING SHOP Types Of Electroplating• Acid Zinc Electroplating (for ‘Iron’)

(24-270C, 9-12V,15μns, Anode:- Zinc, Cathode:- Iron)

• Acid Tin Electroplating(for ‘Brass’)

(24-270C, 5-8V,12μns, Anode:-Tin, Cathode:- Brass )• Silver Electroplating(for Brass & Cu)

(24-270C, 1.5V,4μns, Anode:- Silver, Cathode:-Brass or Cu)• Copper Electroplating (for ‘mild steel’)

(500C, 7-8V,6ns,Anode:-Cupper, Cathode:-Steel) Inspection• Coating Thickness• Surface Finish

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MOULDING SHOP

Raw Materials• (Polycarbonate resin/granules,

Heated at 400C in preheater

then fed to barrel of Molding machine)• PBT:- used in high rating switch & socket.

(high tensile strength due to glass fibre) Moulding Machine

(L & T, 5000*1400*2000mm,

locking force-440KN,

Ejection force-28KN,

Oil tank-180L,

Injection pressure -50bar,

415V, 3Φ, 0.45pf, 50-60hz)

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Molds/Dye

(Mainly frames, Two plates, injection mold, ejector mold, silicon spray for

cooling)

All types of frames of household electrical accessories are prepared by this type of machine by changing Dye.

e.g. Batten holder, Ceiling rose, Sockets, Switches, Regulators, Bell push,switch socket combined, Plugs, Indicator, Telephone jack, Angle lamp holder, TV socket, Computer jack, foot light, cage frame. e.t.c

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Waste Grinder Machine

Dharma engg. works,

Size of grinder :- 9”

Size of blade :- 6*4

Connecting load :- 5HP

Max o/p :- 50-70 kg

Voltage 415V

Current rating;- 1.5-2A

Frequency:- 50-60hz

phase:- 3

Wt of machine:- 2400kg

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SWITCHGEAR ASSEMBLY SHOP

Rewirable Fuse & HBC fuse• Base:- Porcelain, Bakelite• Contacts:-Electrolytic copper

Silver plated• Screw:-Brass• Screw insulating material:- Wet ceramic Cubicle Fuse Switch

Fuses are placed in enclosure.

Range :16-100A

No of poles :SPN,DP,TPN

Rated voltage :240,415V

Insulation Voltage: 660V

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Metal clad plugs & sockets Molded Polyester compound,Deep recessed socket contact tubes & surrounded plug pins to avoid accidental contacts.Range 1.5A,3A,6A/230V

Cubical Isolator Switch Range 16A to 200A,220v-415V Poles:- SP, DP, TP, TPN

Double Break Switch Fuse Incoming supply can either be connected Top & Bottom Range : 63 – 400A Poles : TP,TPN,FP

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Change over switch 63 A, 415 V

Asbestos sheet

Metal clad change over switch

range:- 32A- 200A

220V-415V

TPN

Insulated Iron rod Bakelite case

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Element names of change over

Silver cupper bimetal rivets

Wooden block

Holding spring

Brass clamp

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TESTING LIST Heating Oven Test

for switches & holders

kept on 800C for 8hrs. Mechanical Strength test

for lamp holders

1 kg wt. hanged for hrs. Tumbling barrel test

checks mech. Strength of plug socket.

wire tightened to socket & whole

combination is put in tumbling barrel,

it revolves & mechanical strength is checked

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Endurance test for switches

general operation 4000 times

in test lab 3 times more i.e. 12000 operations

Ampere test

tested for 6A when rating is 2A

30 sec

Conditional Wire test

cu wire, placed at 150C.

1 min.

twisted & checked for cracks

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Short circuit test for change over

done at 3KV-4KV.

contacts are touched for 5 sec.

0KV shows short circuit.

Milli volt drop test

done for checking gap b/w

contacts while closed

Making & Breaking Capacity

tested at 130% of rated current

& 110% at rated voltage.

500 operations, interval 30 sec.

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SSK COOL PACK AC SYSTEM

• Capacity-1 ton

• Temp range:- 100C to 450C

• Refrigerant :- R22,400 gm

• Voltage 230VA, 50HZ, 3.5 FLA

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PANEL SHOP

Assembling of Panel for AC coach of Indian railways. Enclosure or Cabinet a/c to design.

Wire needed near about 6Km in one panel 70 sq mm, 2.5 sq mm for dc, 1.5 sq mm for acClipping tool(multi cutter) clipping of wire is done range 1.5mm-6mmWire Ducts (Halogen free pvc material)

22Outer Left side of panel

shell type(3 phase, p-750V,s-415-110V,0.3kva)

core type(1 phase, p-750V,s-24V, 200va)

Residual Current transformers 690V- 12KV

ACB(ABB company) 4 pole, 7 NO/NC, for relay operation, 800A, 415V, 50/60 hz

AEL(Alternator earth leakage) operating voltage:- 110V

Contactor (ABB Company) 415 V, 2 NO/NC

UVR(under voltage relay) 25VA@750V/AC/50Hz

23 Front view of panel

Pilot lights (indicators) operates at 24V

Buzzer 24 V dc, 96-104Db range:- 50m

Push buttons

Selector switch (4 way selector switch)

Ammeter(0-800A)

Voltmeter(0-800V)

Frequency meter 45-55Hz

Socomec kilowatt meter

kit Kat fuse (L & T, 32A,220V)

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Inner view of panel

Wago terminals

OVR (over voltage relay)

DC Time Delay Relay

OSR(over speed relay)

LOP(low oil pressure)

AFR(alternator fault relay)

Bus bar (woehner)

Ground wire 70 sq mm, 100A

Generator protection relay current range(4.0-10.3A) max gen. voltage 1000V ac aux voltage 24 V dc

ATS(auto transfer switch)

25FINAL PRODUCT

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Any Queries