Project Report

A PROJECT REPORT ON

MARKET POTENTIAL FOR ACOUSTIC SYSTEM FOR DG SET IN PUNE REGION

FOR J.P. SYNERGY CONSULTANTS, PUNE

BY ANKUSH M. AHIRE (M.B.A 2004-2006)

SUBMITTED IN THE PARTIAL FULFILLMENT OF MASTER OF BUSINESS ADMINISTRATION TO THE UNIVERSITY OF PUNE

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ACKNOWLEDGEMENT
Any accomplishment requires the effort of many people and this work is not different. I wish to express my deep sense to gratitude and profound thanks to Prof. Pushkar Phadatare for giving me the opportunity to work with J.P.Synergy consultants, Pune on this project.

I would like to express my heartfelt gratitude to my project guide Prof. Phadatare without whom this project would not have been a success. From the very beginning till the end of completion of this report he was the main source of guidance and motivation for me. He made me aware of the Diesel Generator sets, market trends and business practices and business practices at large.

Grateful acknowledgement is made to all the staff of Newtech Engineering Company, Pune for supporting me in this project.

I also want to place my gratitude to my internal project guide Prof. A.M. Nene for his help and cooperation throughout the project.

I also express my deep senses of gratitude to my Director Dr. Sharad Joshi of Vishwakarma Institute of Management, Pune for allowing me to carry out this project in this prestigious institute.

Ankush M. Ahire

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CONTENTS

S. No. 1 2 3 4 5 6 7 8 9 10 11

Title Executive Summary Company Profile Product Profile Objective of the Study Research Methodology Limitation of the Study Data analysis and Interpretation Conclusions Recommendations Annexure Bibliography

Page No. 1 2 3 11 12 14 15 22 23 24 27

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Project Report EXECUTIVE SUMMARY

Every business organization big or small has its own sets of problems. Sometimes they enjoy advantages over others; sometimes they also have to bear the heat of the competition. They are not above the ups and downs of the business. Newtech Engineering Company deals in DG sets and acoustic system. As recently CPCB and Ministry of forest and environment has implemented guidelines for noise pollution. As per the regulation it is mandatory for all DG set users to have noise limit up to 75 dBA.The main objectives of this study is to find the potential for acoustic system for DG set in pune region also to find level of awareness of pollution control norms for noise pollution among the users. For this purpose we have prepared a questionnaire targeting the industrial users. I have visited the maintenance in charge of the company to find out the details of DG set and awareness of pollution control norms for noise pollution. The data collected from the survey was scientifically analyzed and implemented by company. Based on these conclusions and managerial theory we recommend a set of activities to be implemented by Newtech Engineering Company to be the market leader in acoustic.

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COMPANY PROFILE JP Synergy Consultants is a firm promoted in the year 2002 by professionals having wide experience in the industry. This is a consultancy firm engaged in providing consultancy services to the industry. The areas of operation are: Marketing Manufacturing Human resources development Project Management Marketing Consultancy includes market development, channel partner identification, evaluating distribution network, strategy formulation and implementation, customer satisfaction index studies, market research and training. Manufacturing Consultancy includes productivity improvement, quality enhancement programs and management effectiveness and measurement modules. Project management includes evaluation and value estimation of plants, facilitating the process of takeovers, facilitating production process. Human resource Development consultancy includes managerial effectiveness, goal setting and evaluation, role of organization and its different focal functions. The firm is broadly divided into three functional areas namely consultancy & project management, training and market research. The firm s customers include Kirloskar Oil Engines Ltd. Tata Motors Bharat Vikas Group Coca-Cola Bank of Maharashtra Niranjan Polymers Etc. To name few.

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ACOUSTIC ENCLOSURE/ CANOPY

The DG Set shall be installed in an integral acoustic enclosure, suitable for emitting a maximum noise level of 75 dB(A) at one meter from the external wall of enclosure. on all four sides, roof and exhaust silencer (if mounted outside of enclosure). The enclosure shall be totally weather proof, ingress proof detachable modular type acoustic enclosure suitable for outdoor application and deigned to meet I54 standards. The enclosure should be constructed on the skid base of DG set and should have suitable openings /doors for easy access to engine accessories like radiator filling cap, engine V belts, charging alternator, oil drain plug and engine breather. The canopies/enclosures shall be base frame mounted and made from sheet metal steel and lined with fire proof sound absorbing materials retained by perforated zinc sheet .The canopy shall be designed with a pitched roof, guttering and a panel viewing window. Side opening access doors shall be provided either side with lockable recessed handles. Cable and fuel line gland plates shall be provided to avoid the necessarily to cut he canopy. The enclosure shall be constructed out of 10/12 SWG CRCA sheet steel as per IS 513 and ISMC for vertical and horizontal framework and base frame. The roof shall be formed out of modular panels built at an angle on a horizontal framework fastened to the vertical members. There shall be no chance of water accumulation on the roof .The sides, roof and the doors should be of bolted assembly for easy dismantling during overhauls/major repairs. The complete enclosure metal work shall be treated with 7 tank process and the enclosure surface shall be protected with zinc chromate primer and two coats of chlorinated rubber or Epoxy paint to approved colour to withstand the weather conditions, prevent rusting and finished with paint to approved shade. The canopy is to be finished in synthetic enamel paint or epoxy two pack paint, The silencer shall be aluminum sprayed. The enclosure shall be provided with suitable air intake openings lined with noise attenuators and louvers designed to maintain steady air flow in to the enclosure and prevent ingress of rainwater and any other external foreign matter. Attenuators shall be placed on the hot air outlet and cooling air inlet. Exhaust silencers of residential /hospital type as required shall be mounted either on the top of, or inside the enclosure, exhausting to atmosphere and the enclosure to be equipped with all outlet baffles /attenuators shall be with corresponding weather louvers and bird mesh to allow sufficient airflow for the set to operate even under the harshest ambient conditions whilst maintaining specified noise levels .The

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Project Report louvers and attenuators should be so designed that maximum temperature difference between the ambient and inside of the enclosure is maintained at 10 deg C.

The enclosure walls shall be lined with polyurethane fire retardant insulated acoustic foam, of adequate thickness acoustic insulation boards bonded with suitable thermosetting resins. The density shall be > 64 kg/cub M. The enclosure shall be provided with high performance noise reduction, fire resistant and airtight doors with EPDM gaskets, robust hinges, door locks with keys and handles. A battery rack should be provided inside the enclosure to hold the batteries in place. The above specifications are indicative and vendor shall guarantee that the enclosure is so specified and constructed to achieve a sound attenuation of 75 dB(A) at one meter distance from the enclosure to be measured as per BS 5615. Also the air circulation /distribution shall be driven by the radiator fan of DG set only, no other fan shall be provided.

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TECHNICAL SPECIFICATIONS OF ACOUSTIC CANOPY

General Specifications: Acoustic canopy is of modular construction with provision to assemble and dismantle easily as per site conditions. There are no protruding parts The container is fabricated out of CRCA sheet of Different sizes as mentioned below The sheet metal components are hot dip seven tank pretreated To have long life the canopy is P P based powder coated (inside as well as outside) All nuts and bolts/ hardware are zinc coated The doors are sliding type which give more space for maintenance and gasketed with high quality EDPN gaskets to avoid leakage of sound Sound proofing is done with high quality rock wool/ fire retardant foam of suitable thickness and density Specially designed attenuators are provided to control sound at entry to canopy and exit from the canopy Adequate ventilation is provided to meet the air requirement of engine and alternator Adequate lighting is provided in the canopy Sound level will be maximum 72 db at three meters. Specific Particulars: 1] Acoustic panels & Insulation: Panels are made of CRCA sheets of 16 gauges as an outer cover with arrangement to fill up acoustic material. High quality, 64-density, 75 mm thick rock wool slabs are put from inside. On these slabs, specially made fire retardant foam 32 density, 25 mm thick is applied to give better sound absorption. Over all thickness of panels is 100 mm. Size of panels depends on suitability of fabrication. These panels are used for all sidewalls, top, doors and partitions as shown in the drawing. 2] Base Frame: Base frame is made out of 12 gauge sheet and reinforced at suitable intervals Typical base frame drawing is shown. This base frame is used for mounting of Canopy on all four sided of DG set.

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3] Front and rear side / Doors: All front sections are made of 100 mm thick panels as mentioned above.Sliding doors are provided on each side. For this also thickness of CRCA Sheet will be 16 guage. These doors are provided suitable locks to withstand Vibrations etc. 4] Partitions: There will total 2 partitions in the canopy as under: Vertical partitions at alternator end and engine end: - This partition will be Fixed at rear & front of DG set to facilitate path of fresh air into canopy and hot air out of canopy via louvers. All the partitions will be made of panels as described above but with 75 mm thickness. 5] Reinforcement: All the panels will be mounted on structure with suitable reinforcements. 6] Ventilation: Ventilation will be achieved by two means: a] Louvers at alternator end & b] Louvers at radiator end c] One number fan One number digital thermometer will be provided to monitor temperature inside the canopy. 7] Illumination: Suitable tube lights will be fixed at different locations and wiring will be done inside the canopy. 8] Painting: All the panels will be Powder coated. Color shed can be as per customer s request. Base frame will be painted with black color. 9] Walk around Space: Canopy will have around 300 to 500 mm space on all sides for maintenance.

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Project Report NOTIFICATION OF CPCB

Copy of notification Dt.17.05.02 issued by Ministry of Environment & Forests (MOEF) related to1) Noise Norms for Diesel Gensets. GSR NO .371 (E). F.NO.8-15022/2/2001-CPA In exercise of Powers conferred by sections 6&25 of the environment (protection) Act, 1986 (29 of 1986) the central government thereby makes the following rules further amended the Environment (protection) rules, 1986 namely 1) These rules may be called the Environment (protection) second amendment rules, 2002. 2) They shall come into force on the date of their publication in the official gazette. In the Environment (protection) Rules, 1986 (hereinafter referred to as the said rules) in schedule 1 [a] Against serial number 47,item (d) relating to Diesel generators for domestic purposes and the entries related thereto shall be omitted. [b] Serial no.83 relating to standards/guidelines for control of noise pollution from stationary Diesel Generator (DG) sets and the entries relating thereto shall be omitted. After serial number 93 relating to primary water quality criteria for bathing waters and the entries relating thereto the following serial numbers and entries shall be inserted, namely: 94, NOISE LIMIT FOR GENERATOR SETS RUN WITH DIESEL Noise limit for diesel generator sets (up to 1000 KVA) Manufactured on or after the 1st July 2003. The maximum permissible sound pressure level for new diesel generator sets with rated capacity up to 1000KVA, manufactured on or after the 1st July 2003 shall be 75dB(A) at 1 meter from the enclosure surface. The diesel generator sets should be provided with integral acoustic enclosure at the manufacturing stage itself. The implementation of noise limit for these diesel generator sets shall be regulated as given in paragraph 3 below. 2.Noise limit for DG sets not covered by paragraph 1.

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Project Report Noise limits for diesel generator sets not covered by paragraph 1 shall be as follows: 2.1 Noise from DG set shall be controlled by providing an acoustic enclosure or by treating the room acoustically, at the users end. 2.2 The acoustic enclosure or acoustic treatment of the room shall be designed for minimum 25 dB (A) insertion loss or for meeting the ambient noise standards, whichever is on the higher side of the actual ambient noise is on the higher side. It may not be possible to check the performance of the acoustic enclosure/acoustic treatment. Under such circumstances the performance may be checked for noise reduction up to actual ambient noise level preferably in the nighttime). The measurement for insertion loss may be done as different points At 0.5 m from the acoustic enclosure /room, and then averaged. 2.3 The DG set shall be provided with proper exhaust muffler with insertion loss of minimum 25 dB (A). 2.4 These limits shall be regulated by the sate pollution control boards and the state pollution control boards. 2.5 Guidelines for the manufacturers /users of Diesel Generator sets shall be as under: 01) The manufacturer shall order to the user a standard acoustic enclosure of 25dB(A) insertion loss and also a suitable exhaust muffler with insertion loss of 25dB(A). 02) The user shall make efforts to bring down the noise level due to the DG set, outside his premises, within the ambient noise requirements by proper sitting and control measures. 03) Installation of a DG set must be strictly in common place with the recommendations of the DG set manufacturer. 04) A proper routine and preventive maintenance procedure for the DG set should be set and followed in consultation with the DG set manufacturer which would help prevent noise levels of the DG set from deteriorating with use

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3 LIMITS OF NOISE FOR DG SETS (UPTO 1000KVA) MANUFACTRED ON OR AFTER THE 1ST JULY 2003. 3.1 Applicability 01. These rules apply to DG sets up to 1000KVA rated output manufactured or imported in India ,on or after 1st July 2003. 02. These rules shall not apply to (a) DG sets manufactured or imported for the purpose of exports outside India: and (b) DG sets intended for the purpose of sample and not for sale in India. 3.2 Requirements of Certification Every manufacturer or importer (hereinafter referred to as the supplier) of DG set (herein after mentioned to as product) to which those regulations apply must have valid certificates of type approved and also valid certification of conformity of production for each year, for all the product models being manufactured or imported from 1st July 2003 with the noise limits specified in paragraph 1. 3.3 Sale import or use of DG sets not complying with the rules prohibited. No person shall sell, import or use of a product model, which is not having a valid type approval certificate and conformity of production certificate. 3.4 Requirement of conformance Labeling. (1) The supplier of the product must affix a conformance label on the product meeting the following requirements: -

(a) The label shall be durable and legible. (b) The label shall be affixed on a part necessary for normal operation of the product and not normally requiring replacement during the product life.

(2) The conformance label must contain the following information. (a) Name and address of the supplier (if the address is described on the owners manual. it may not be included in the label.) (b) Statement this product conforms to the environment (Protection) rules, 1986. (c) Noise limit viz, 75dB(A) at 1 m. (d) Type approval certificate number.

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Project Report (e) Date of manufacture of the product. 3.5 Nodal Agency (1) The central pollution Control Board shall be the nodal agency for implantation of these regulations. (2) In case of any dispute or difficulty in implementation of these regulations, the matter shall be referred to the nodal agency. (3) The nodal agency shall constitute a committee to advise on all matters including the disputed matters related to the implementation of these regulations. 3.6 Authorized agencies for certification. The following agencies are authorized to carry out such test as they deem necessary for giving certificates for type approval and conformity of production testing of DG sets to give such certificates: (1) Automotive Research association of India, Pune. (2) National Physical Laboratory, New Delhi. (3) Naval Science &Technology Laboratory, Vishakhapattanam. (4) Fluid Control Research institute, Palghat. (5) National aerospace laboratory, Bangalore.

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Project Report OBJECTIVES

A project will haywire if it does not have its objectives clear. If one knows the goal, only then the right path can be decided and with disciplined work and positive attitude achieving these objectives will be a catwalk. Therefore, we also set down the objectives before starting the project, which are as follows:

1. The basic purpose of the survey was to find out the market potential of acoustic system for DG set. 2. To find out the level of awareness of CPCB norms regarding the noise pollution for the DG set. 3. To find out the market potential for AMF (Automatic Mains Failure) Panel. 4. To find out the market share of Manual DG sets and Automatic DG sets.

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RESEARCH METHODOLOGY
Development of research procedures is another important step in the market research process. Research Design is actually the blue print specifying every stage of action in the course of research. Features Of Research Design: The design was formulated to be a flexible so that changes can be adapted in the execution of the research. Care was taken to minimize the bias at every stage since any research work made untrue information would turn out to be unreliable or worthless. Effort has been taken to collect as many information as possible through the questionnaire so that elaborate analysis can be carried thereafter. The design was closely linked with the objectives set earlier, so that the essence of the information collected and analyzed does not get diluted. Methods Of Data Collection:Sources Of Data A. Secondary data 1. Internal sources Company records Service reports Yellow pages 2. External sources Web pages of organizations and journals Newspapers Magazines B. Primary data Data required for the study is collected first hand from Industrial Users Warehouses

Tools for data collection

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Questionnaire Based Interview Method: The questions are crafted in a way to generate as many information as possible with minimum effort on respondent s part. Type Of Questions Used: Open ended Close ended Multiple choices Sampling: The sample size for users research was 174. The samples were selected randomly to ensure unbiased information. The samples ware selected from all over the city. Analysis Methods And Tools: The entire analysis of data was done with the aid of Microsoft Excel spreadsheet programming. The diagrammatic representation of the data was done through this software. Areas covered under research: 1. Hadapsar Industrial Area. 2. Ramtekadi Industrial Area. 3. Fursungi warehouses. 4. Jejuri MIDC. 5. Baramati MIDC. 6. Ahamednagar Road. 7. Ranjangaon MIDC. 8. Bhosari MIDC. 9. Kurkumbh MIDC. 10. Solapur Road.

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LIMITATIONS
Nothing is perfect in this world. The last perfect person was crucified to the cross. This project is not an exception to this rule. Following are the limitations of the project: i. ii. The study is made on the responses to the questionnaire framed. Although utmost care was taken by the researcher to extract data, at times the same may have limitations owing to time constraints of the respondents. Some respondents did not see the project important so they gave exaggerated information that had to be readjusted for our specific queries. By this research a wide crossection of industry segment has been covered. Organizational buying principles remain independent of locations. However researcher does not claim that the results may be applicable to other parts of the country.

iii.

iv.

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ANALYSIS OF THE QUESTIONNAIRE

DISTRIBUTION OF DG SETS AS PER THE KVA RATING

DG Set Rating 1-15 KVA 15-250KVA 250-1000KVA 1000-2000KVA

No of Users 15 69 65 25

Distribution of DG set As per the KVA rating 80 70 60 50 40 30 20 10 0 No of users

No of Users

KV A

0K VA

115

15 -2 5

25 010 0

KVA rating

From the above graph it is observed that for the range of 1-15 KVA the number of users are very few, but for the range of 15-1000KVA the users are maximum. So we can conclude that the potential of acoustic system is maximum in the range for DG set having rating 15-1000KVA.

10 00 -2 0

00 KV A

0K VA

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DISTRIBUTION OF THE DG SETS AS PER THE STARTING SYSTEM

Manual Starting Auto Starting System System 148 26

Total 174

Distribution of the DG set as per the Staring System 15%

Manual Starting system Auto starting System

85%

From the pie chart we can say that maximum DG user i.e.(85%) have manual starting system & (15%) have auto starting system which in turn can provide the potential for AMF panel (AMF: automatic mains Failure System)

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DISTRIBUTION OF DG SET AS PER THE ACOUSTIC SYSTEM

DG set having Acoustic system 64

DG set having no Acoustic system 110

Distribution showing DG sets which have provided Acoustic System

37%
DG set having Acoustic system

63%

DG set having no Acoustic system

From the pie chart we can observe that 37% of the total customers have provided the acoustic system as per the CPCB norm but still there are the 63% customers who have not provided the acoustic system for their DG set which is mandatory as per CPCB norm. We can conclude that there is wide market potential for acoustic system for DG sets.

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DISTRIBUTION OF INDUSTRIES HAVING AWARENESS OF CPCB NORMS FOR NOISE POLLUTION.

Industries which are aware of CPCB norms 88

Industries which are not aware of CPCB Norm 86

Graph shDistribution showing the awareness for CPCB norms 88.5 88 87.5 87 86.5 86 85.5 85 88

no of users

86

Industries which are aware of CPCB norms

Industries which are not aware of CPCB Norm

From above graph we observe that there are 88 industries I.e.50% of total Customers know CPCB norms for noise pollution but still there are 86 industries I.e. 50% of total customers don t no CPCB norms. There is need to create awareness among the DG users to control the noise pollution.

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DISTRIBUTION OF THE INDUSTRIES AS PER THE NOISE PRODUCING MACHINES LIKE DG SET , COMPRESSOR

Industries having DG set 174

Industries having compressor 4

Distribution of industries as per the noise producing machines like DG set ,Compressor
200
no of users

174

150 100 50 4 0 Industries having DG set Industries having compressor

From the pie chart above, it is observed that only four customers have compressor as noise producing machines, there are 174 customers who have DG set as noise producing machine which are the potential customers for acoustic system, so company must focus only on these customers as prime customers.

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DISTRIBUTION OF INDUSTRIES WHICH ARE INTERESTED IN GOING FOR ACOUSTIC SYSTEM

Industries which are interested for acoustic system 35

Industries which are not interested for acoustic system 75

Distribution showing interest for acoustic system

80 70 60 50 40 30 20 10 0

75

no of users

35

Industries which are interested for acoustic system

Industries which are not interested for acoustic system

From above graph we observe that around 32% of total customers which don t have acoustic system for the DG set, are interested for acoustic system but still there are 68%customers are not interested for the acoustic system as acoustic canopy is nonproductive item & one has to invest in lacks for the acoustic canopy as it is costly item .

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DISTRIBUTION OF THE INDUSTRIES WHICH HAVE EXPANSION PLAN FOR THE NEW DG SET WHICH IN TURN WILL HAVE EQUIPPED WITH ACOUSTIC CANOPY.

Industries which have expansion plan for new DG set 45

Industries which have no expansion plan for new DG set 129

Distribution showing the industries which are interested for new DG set which in turn will be potential customer for acoustic system no of users 150 100 50 0 Industries which have expansion plan for new DG set Industries which have no expansion plan new DG set 45 129

From the above graph we observe that there are around 45 existing customers, which are interested for new DG set, can be potential customers for acoustic canopy, company should target them.

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CONCLUSION
The following conclusions are based on the findings from the analysis of data collected through survey.

1. As we are aware of the fact there is acute power shortage (demand 12000 MW and supply 9400 MW in Maharashtra) There is substantial demand for DG sets. Power generated through DG sets is expensive (Rs 12/unit) against (Rs.3/unit) as per state electricity board. Further noise and air pollution goes up due to their use .Awareness about noise is on lower side. 2. From the analysis it is observed that maximum users (77%) are in the range of 15 KVA to 1000 KVA. 3. Maximum users (85%) have DG set of Manual mode as compared to manual mode (15%). 4. As acoustic system is non-productive item which is only mandatory as per Ministry of Environment and Forest (CPCB). 5. Very few (37%) of the total users have acoustic system for their DG set. 6. Maximum users (98%) have DG set as noise producing machine as compare to air compressors. 7. Demand for acoustic system is limited due to the high capital investment in the system.

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RECOMMEDATIONS

1. As recently Ministry Of Environment And Forest (CPCB) has implemented the rules for noise pollution for DG set there is lot of need to create the awareness for noise pollution among the industrial users. 2. As 63 % of the total customers have not provided acoustic system for their DG set. The awareness for noise pollution should be created by sending the notification of CPCB norms to various users. 3. As this is very new concept, customers don t have any idea about the acoustic system for DG set so the company should inform the users through presentations, advertisements, and industrial exhibitions. 4. The prime customers (77%) are in the range of 15 KVA to 1000 KVA so company should focus on these customers. 8. As 35 customers are interested for the acoustic enclosure for their DG set company should target them immediately. 5. Many of the users (85%) are using the DG set of Manual mode, which are the prospective customer for AMF (Automatic Main Failure) panel. So company should target them. 6. As many of the users (26%) are interested for new DG set, they are prospective customers for acoustic system company should give more preference to these customers. 7. As many users (98%) have only DG set as major sound producing machine as compare to air compressor so company should target the DG users. 8. Many users (68%) are not interested for acoustic system for DG set they should be informed about CPCB norms for noise pollution.

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QUESTIONNAIRE
Name of the company Address Contact Person Phone Number Mobile No : : : : :

1. Dose your company own DG set? Yes No

2. DG set is powered by an engine of the make? a) Cummins b) Kirloskar c) Catterpillar d) Any Other(Specify)

3. The type of starting system? Auto Manual

4. What is KVA rating of the set?

5. Approximate year of purchase?

6. Have you provided for acoustic system for the set? Yes No

7. If yes what type? Canopy Room Acoustic

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9. Is there is any other noise making machine? Yes No

10. Is there any expansion plan for new DG set? Yes No

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BIBLIOGRAPHY
BOOKS

AUTHOR

NAME OF BOOK

PUBLICATION

Philip Kotler

Marketing Management Eleventh Edition Marketing Management

Prentice Hall of India Pvt. Ltd, Mumbai. Tata McGraw Hill Publication, New Delhi.

Rajan Saxena

C.R.Kothari

Research Methodology Wishwa Prakashan Methods and Techniques

WEBSITE www.jakson .com www.cumminsindia.com

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