SUMMER TRAINING REPORT - 2019

"PYROTECH ELECTRONICS PVT LTD"

SUBMITTED BY

Ansh Bharadwaj

Department of Electrical Engineering

COLLEGE OF TECHNOLOGY AND ENGINEERING, UDAIPUR

(2018-19)

SUBMITTED TO: Mr. SOURABH JOSHI

(Executive HR & Welfare Department

Pyrotech Electronics Pvt. Ltd.)

 Acknowledgment

It is my great pleasure and privilege to present this practical training report

prepared under ‘One month training program’ carried out at “Pyrotech

Electronics Pt ltd Unit-(ii)” and submitted in partial fulfilment of the requirement

for the award of the degree of the Bachelor of Technology in Electrical

Engineering to “Maharana Pratap Unviversity of Agriculture and

Technology”.

I express my sincere thanks to “R.R. Joshi Sir” (H.O.D. Electrical Engineering

Department) of our college for his kind co-operation and valuable suggestions.

I am very much thankful to Mr. Sourabh Joshi Sir (Executive HR & Welfare

Department Pyrotech Electronics Pvt. Ltd. (Unit 2) for his encouragement and

co-operation at every step.

Finally, I am very much obliged to “Pyrotech Electronics Pvt. Ltd” for giving

me this opportunity to gain technical exposure in their highly productive

environment.

(Ansh Bharadwaj)

College ID: C.T.A.E./040/2017

Candidates Declaration

I hereby declare that the work, which is being presented in this practical
training report carried out at Pyrotech Electronics Pvt. Ltd and
submitted in partial fulfilment of the requirement for the award of the
degree of the Bachelor of Technology in Electrical Engineering to ”
Maharana Pratap University of Agriculture and Technology” is a
record of my one month training (dated from 26th of May 2019 to 28th
of June 2019) at Pyrotech Electronics Pvt. Ltd Unit- (ii), Udaipur
(Rajasthan).

(Ansh Bharadwaj)

College ID.: C.T.A.E./040/2017

Mr. Sourabh Joshi

Executive HR & Welfare of Company
Pyrotech Electronics Pvt. Ltd Unit-(ii), Udaipur (Rajasthan)
 Contents

1) Acknowledgement
2) Candidate Declaration
3) Contents
4) Company Profile
4.1) Introduction
4.2) Products
4.3) Departments’ list
4.4) Major machines used in production
5) Department Details
(5.1) Purchase
(5.2) Large Video Screens
(5.3)Marketing
(5.4) Local Instrument Enclosures and Local Instrument Racks
(5.5)Sales and Excise
(5.6)Production
(5.7)Electrical Design
(5.8)Quality
(5.9)HT Department
(5.10)Mechanical Design
(5.11)CNC Design
(5.12)Store
INTRODUCTION
Pyrotech is industry manufactures various products in field of Electronics &
Electrical control Equipment. The company is ISO9001, EMS14001 &
OHSAS18001 certified company and recipient of Rajiv Gandhi National
Quality Award -1999 and Jamnalal Bajaj Award for Fair Business practices-
2007 and D&B Axis Bank Gaurav Award-2011. We have mastered the
engineering of various products in the field of Electronics & Electrical
Control equipment.
Pyrotech Group was established by four technocrats in 1976 with its first
products Thermocouple and Resistance temperature detector. The word
Pyro is a Greek word which means fire and name of company is kept Pyrotech
means fire in technology that meant to be technology which can work in fire
like RTD and thermocouple which can be used to detect temperature in high
temperature region like burner, furnace etc. without any damage to it as it
made of platinum and nickel which come with high melting point. In 1998 a
new factory space of 50,000 sq. ft set up at Udaipur named Pyrotech
Electronics Pvt. Ltd. Unit 2.
 Pyrotech Electronics Pvt. Ltd - Unit-2

Pyrotech Group

Pyrotech serve various electronics and electrical equipment and

also provides workspace solution. The various business bodies are

Pyrotech
Group

Electronics Sensor Panel Workspace

Division Division Division solution

(i) Pyrotech Electronics Pvt. Ltd. Unit-1

(ii) Tempsens Instrument India Pvt. Ltd. & Marathon Heater India Pvt. Ltd.

(iii) Pyrotech Electronics Pvt. Ltd. Unit-2 & Pyrotech Electronics Pvt. Ltd. Unit-
4
(iv) Pyrotech Workspace Solution Pvt. Ltd.

Leadership
• Mr. P.S. Talesara – Managing Director & President
• Mr. N.K. Pande – Director (Marketing)
• Mr. Amit Talesara – Director & Vice President
• Mr. Pradeep Kothari – Executive Director (Operations)
• Mr. Amrit Mehta – Chief Executive Officer
• Mr. Ashok Mehta – Chief Financial Officer
 Products of Pyrotech Electronics Pvt. Ltd. Unit-II

• Shelter
• Mosaic desk
• Console desk
• Bare Panel IP-65
• Mosaic Mimic Panel
• Local Control Station
• LIE (Local Instrumentation Enclosure)
• LIR (Local Instrumentation Rack)
• Power Distribution Box
• Purge & Ex-proof
• Acrylic Mimic
• NG/LAVT Cubicle
• Generator Power Control Panel
• MCC/PCC/IMCC
• CT Box
• APEC Panel
• Control & Relay Panel
• Bus Duct (NSPD)
• Soft Starter Panel
• Synchronization Panel
• HT Panel
• Video wall
• Networking Panel
• Bare Panel IP-55
• Junction Box
• Alcosy Control desk
• Metering Panel
• Metering Box
• Marshalling Panel
• EMIRFI Complaint Panel
• Universal test bench
• Push button station
• 19’ Rack
Department

• Purchase
• Large Video Screen(LVS)
• CRP(Control Relay Panel)
• Production
• Electrical Design(ED)
• LIE/LIR (Local Instrumentation Enclosure/ Local Instrumentation Rack)
• Marketing
• Sale & Excise
• Internal
• HT (High tension panel)
• Quality
• Store
MAJOR MACHINERIES INSTALLED IN THE PRODUCTION AREA
PURCHASE DEPARTMENT
HOD (U-2): Kirti Jain ma’am

PURCHASE DEPARTMENT

Purchase Department is the department which deals with buying raw material, spare parts,
services etc. as required by the company‘s production needs. The purchasing management
department ensures that all goods, supplies and inventory needed to operate the business are
ordered and kept in stock. It is also responsible for controlling the cost of the goods ordered,
controlling inventory levels and building strong relationships with suppliers.

Procurement cycle refers to a term used to describe the actions, procedures, systems and
methods used to purchase and obtain the goods and services and required to execute a project.

Protocol followed for material procurement

1) Indent
2) Purchase Requisition
3) Purchase Quotation
4) Purchase Order
5) Goods Receipt
6) Purchase Invoice
7) Payment out
8) Goods Issue
9) Approval to manager

TYPE OF PURCHASING
According type purchase purchasing categorized into two type

i) 4D Purchase
ii) 5D Purchase
Purchase

4 D Purchase 5 D Purchase
(Generally Requirements used in (Special material
Most of the projects ) requirements
purchased for
project specific)
INDENTS

An official order or requisition for goods. Indent is given by engineer, to the purchase department
for materials require in a project.

Dead Indent

It is material already available in store which might not have been used completely in some
previous projects.

Rate Contract

A Rate Contract or a Rate Agreement is a procurement cost reduction strategy aimed at

standardizing procurement prices for commonly procured, homogenous prices varying inputs.

Purchase Order

Purchase order (PO) is a commercial document and first official issued by a buyer to a seller,
indicating types, quantity and agreed prices for the products or services. It is used to control
the purchasing of products from the external suppliers.

Material Receipt Note (MRN)

Material Receipt Note (MRN) is a written record that indicates the receiving detail of material
from supplier to the inventory location.

Negotiation

It is discount to the product by the make to company which decided with company.

Procedure of Procurement

Indent/ Requirement
Getting the material
Re

Enquiry offer negotiation

Follow -up for expedition of
the material

Placing Purchase Order Finalization of terms and

condition

Order Confirmation
Terms and Condition while placing Purchase Order

1. Price Basis

(i) Ex- works (ii) FOR (Free on Road)

2. Payment terms
(i) Cash (ii) Credit (iii) Advance (iv) PDC (Post Dated
Cheese)
3. Packing (i) Included
(ii) Extra (special (a) Wooden (b) Sea Worthy)
4. GST (As applicable) IGST or CGST+SGST
5. Freight (i) Included (ii) Extra
6. Insurance (i) Included (ii) Extra

4D v/s 5D Electrical and Mechanical items:

4D ITEMS 5D ITEMS
Items which are regularly used in Items which are procured project to
every project project basis
They are Standard Products They are non Standards Products
Ex: ( Mechanical) Ex( Mechanical)
Sheets , fasteners, bolts etc. Sheets, fasteners, paints etc.

Ex:(Electrical) Ex:( Electrical)

Wire, MCB, indication lamp etc.
Wires ( Depending on the size,
colour etc.)
MCB's (Depending on the rating,
curve etc.)
Indication lamp(Depending on the
make, rating etc.)
LARGE VIDEO SCREENS
HOD (U-2)-: Akilesh Mogra Sir

Large Video Screen

A Large video Screen or video wall or Digital wall or large video display is a special multi-
monitor setup that consists of multiple computer monitors, video projectors, or television sets
tiled together contiguously or overlapped in order to form one large screen.

VIDEO WALL

Why a Video Wall System?

For most organizations, a video wall system is a considerable investment. So why spend the
extra money when you could just use a single large display, a front projector, or a set of
individual monitors?

It’s important to understand that a video wall system is an integrated solution: an array of
high- resolution displays driven by a powerful processing and computing system called a video
wall controller. So while a video wall behaves like a single display, the technology behind it is
far more complex and powerful. A complete video wall system can deliver performance,
flexibility, and interactivity that simply not possible with more basic solutions.

DISPLAY

A display device is an output device for presentation of information in visual or tactile form
(the latter used for example in tactile electronic displays for blind people). When the input
information that is supplied has an electrical signal, the display is called an electronic display.
Type of Display

i) Plasma

ii) LCD (Liquid crystal Display)

iii) LED (Light emitting Display)

iv) DLP Projection (Digital Light Process)

i) Plasma Display

A plasma display panel (PDP) is a type of flat panel display common to large TV displays 30
inches (76 cm) or larger. They are called "plasma" displays because they use small cells
containing electrically charged ionized gases, which are plasmas.

ii) LCD (Liquid Crystal Display)

A liquid-crystal display (LCD) is a flat-panel display or other electronically modulated optical

device that uses the light-modulating properties of liquid crystals. Liquid crystals do not emit
light directly, instead using a backlight or reflector to produce images in color or monochrome.

iii) LED (Liquid Emitting Display)

An LED display is a flat panel display, which uses an array of light-emitting diodes as pixels for a
video display. Their brightness allows them to be used outdoors where they are visible in the
sun for store signs and billboards.

iv) DLP Projection (Digital Light Process)

Digital Light Processing (DLP) is a display device based on optical micro-electro-mechanical

technology that uses a digital micro-mirror device.

Some technical term related to Display

 Resolution

Resolution is the no. of Pixels(individual points of color) contained on a display monitor,

expressed in the term of the no. of pixels on the horizontal axis and the no. of pixel on
vertical axis. Different types of resolutions are:-
  XGA (Extended Graphics Array)

It is a high-resolution video display mode that provides screen pixel resolution of 1,024
by 768 in 256 colors or 640 by 480 in high (16-bit) color.

 SXGA (Super XGA) A screen resolution of 1280x1024 pixels which is higher than
the XGA standard (1024x768).

 HD (high-definition display) containing information about their specific screen

technology, resolution, size and pixel density. It is divided into three categories,
containing display with 720p, 1080p and 1440p displays.

 Full HD (Full high-definition display) with 1080p with resolution of 1980x1080p.

 Luminance

The intensity of light emitted from surface per unit area is referred a luminance.

 Contrast Ratio

The contrast ratio is a property of display system, defined as the ratio of luminance of the
brightest colour (White) to that of the darkest colour (Black) that system is capable of
producing.

 Brightness

Brightness is the perceived intensity of light coming from a screen. On a colour screen, it is
the average of the red, green and blue pixels on the screen. Colour screens use three colours
under the RGB scheme: red, green and blue. The brightness of a screen can be represented
by the sum of the amplitude of red, green and blue pixels divided by three in other words
the average of the three colours.

 Aspect Ratio

The aspect ratio of a computer display is the proportional relationship between its width and
its height. It is expressed as two numbers separated by a colon (x:y). Common aspect ratios
for displays, past and present, include 5:4, 4:3, 16:10 and 16:9.
Digital Micro-mirror device

The digital micro-mirror device,

or DMD, is a micro-opto-
electromechanical system
(MOEMS) that is the core of the
trademarked DLP projection
technology from Texas
Instruments (TI). The DMD was
invented by solid state physicist
and TI Fellow Emeritus Dr Larry
Hornbeck in 1987.

A DMD chip has on its surface

several hundred thousand
microscopic mirrors arranged in
a rectangular array which
correspond to the pixels in the image to be displayed. The mirrors can be individually rotate d
±10-12°, to an on or off state. In the on state, light from the projector bulb is reflected into the
lens making the pixel appear bright on the screen. In the off state, the light is directed
elsewhere (usually onto a heat sink), making the pixel appear dark.

The video wall is formed projecting unit with supply unit connected to it. In front to the
projection unit a mirror diagonally attached to have clear image on the screen. The screen is
formed by balancing the sheet all together in case to attach with a wall. The sheet attach to a
screen are:

Sheet-1 Acrylic Fiber (Size-8mm)

Acrylic fibers are synthetic fibers made from a polymer (polyacrylonitrile) with an average
molecular weight of ~100,000, about 1900 monomer units.

Sheet-2 Freznel (including Sheet-3 Size-6mm)

A lens that has a surface consisting of a concentric series of simple lens sections so that a thin
lens with a short focal length and large diameter is possible and that is used especially for
spotlights.

Sheet-3 Lenticular (including Sheet-3 Size-6mm)

A lenticular plastic sheet is a translucent plastic sheet which has one smooth side (this is the
side you print on) while the other side is made of “lenticules”. These are small convex lenses
that allow the transformation of a 2D image into a variety of visual illusions.
 Video Wall Connected in Local area network

Above fig shows that in a local area network how video wall can be connected for connecting the
video wall there is software VNC (Virtual area network) is used it is a graphical desktop sharing
system that uses the remote frame buffer protocol (RFB) to remotely control another computer as
shown in figure as a controller. It transmits the keyboard and mouse events from one computer to
another, replying the graphical screen updates back in the other direction, over a network.

Video walls are used to display information for:

• Broadcast
• Data monitoring
• Defense
• Energy
• Intelligent traffic systems
• Power and utilities
• Public and emergency services
• Surveillance and security
• Telecommunications
MARKETING
HOD (U-2)-: Anil Parikh Sir

Marketing Department
A marketing department promotes business and drives sales of its products or services. It
provides the necessary research to identify your target customers and other audiences.
Depending on the company's hierarchical organization, a marketing director, manager or vice
president of marketing might be at the helm. Marketing is the backbone of any company.

The Process of Marketing can be explain through Flowchart

Receive enquiry from customer

Give the detail to respective department

Collect offers from the department

Send the offer to customer along with BOM and terms

& condition

Technical Terms

i) Price basis – The amount of money to pay for service or for goods

ii) Good Service Tax - Goods and Service Tax (GST) is an indirect tax levied on the supply of
goods and services. This law has replaced many indirect tax laws that previously existed in
India. GST is one indirect tax for the entire country.

iii) Payment Terms- The conditions under which a seller will complete a sale. Typically, these
terms specify the period allowed to a buyer to pay off the amount due, and may demand
cash in advance, cash on delivery, a deferred payment period of 30 days or more, or other
similar provisions.
iv) Packaging- Packaging can be described as a coordinated system of preparing goods for
transport, warehousing, logistics, sale, and end use. Packaging contains, protects, preserves,
transports, informs, and sells.

v) Freight Charges- A freight charge (historically and in ship chartering simply freight) is a
price at which a certain cargo is delivered from one point to another. The price depends on
 the form of the cargo, the mode of transport, the weight of the cargo, and the distance to
the delivery destination.

vi) Delivery- The action of delivering letters, parcels, or goods.

vii) Order Collection- The order which is placed by the company is collected by the vendor.

Working of Marketing Department

Area Enquiry Offer Offer File

Manager sent to Preparation correction Preparation
headquarter

File File Order Offer Offer sent

checking Preparation generation approval to
customer

Marketing
Associate

Working of Marketing Department Flowchart

Area Manager-

Area Manager or Regional sales manager (RSM) is the person responsible for the sales of the
products, marketing activities and brand awareness in his/her region. This position belongs to
the middle management. It is one of the most crucial position in every organization.

Work of area manager is

• To visit a customer
• To generate an enquiry for product requirement
• To approve product to the vendor.
• After approval provide product detail to customer To prepare the payment record
preparation To generate the order. Terms & Condition for marketing

Payment Term:

(a) 80%value of each equipment and the accessories and 100% Excise duty and full
concessional ST/CST along with 100% transportation & Insurance charges will be paid within
21 days after delivery of the equipment and receipt and acceptance of performance bank
guarantee. The equipment should be accompanied with relevant dispatch documents like
Challan, Maker’s Test Cum Inspection Certificate Warranty Certificate, Pre dispatch
inspection certificate wherever applicable etc.

(b) Balance 20% payment shall be made after successful completion of erection
testing, commissioning and final acceptance of the equipment (along with accessories) at
site upon presentation of a certificate from the project Officer the effect that the equipment
has been erected and commissioned to their entire satisfaction.
LOCAL INSRUMENT ENCLOSER/LOCAL INSTRUMENT RACK
(LIE/LIR)
HOD (U-2) -:S.K. Roy Sir

LOCAL INSRUMENT ENCLOSER

A Local Instrument enclosure is a cabinet for electrical or electronic equipment to mount
switches, knobs and displays and to prevent electrical shock to equipment users and protect the
contents from the environment.

Local Instrument Enclosure (LIE)

The enclosure is the only part of the equipment which is seen by users; in many cases it is
designed not only for its utilitarian requirements, but also to be pleasing to the eye. Regulations
may dictate the features and performance of enclosures for electrical equipment in hazardous
areas, such as petrochemical plants or coal mines. Electronic packaging may place many demands
on an enclosure for heat dissipation, radio frequency interference and electrostatic discharge
protection, as well as functional, esthetic and commercial constraints.

Electrical enclosures are usually made from rigid plastics, metals, particularly stainless steel, carbon
steel, and aluminum. Steel cabinets may be painted or galvanized.

Construction features related LIE

• LIE normally constructed of 3mm CRCA and are made in standard ALOCOSY-30 system.
• Enclosures have access doors on both front and the back sides.
• Double interlocking doors are provided and are arranged for maximum possible access to
the module interior.
 • IP-65: IP rated as "dust tight" and protected against water projected from a nozzle. Lifting
bolt provided as standard for higher load carrying capacity

Advantage of LIE

• Easy to maintenance.
• Durability and improved aesthetics.
• Time consuming assembly work at site is greatly reduced.
• Reduces cabling work & thus reduce the cost

Used in

• Open area EX. Boiler, Cement factory etc.

Local Instrument Rack (LIR)

A Local Instrument Rack (LIR) panel do Pressure measurement of fluid. Pressure measurement
is the analysis of an applied force by a fluid (liquid or gas) on a surface. Pressure is typically
measured in units of force per unit of surface area. Many techniques have been developed for

the measurement of pressure and vacuum.

Local Instrument Rack (LIR)

Construction features of LIR

• Instrument racks are free standing type.

• LIR are normally constructed of suitable 6mm thick channel frame of steel.
• The canopy is constructed of 3mm CRCA sheet.
• The rack also comply to the other requirements of the enclosure.
• Lifting bolt provided as standard for higher load carrying capacity.
Advantage of LIR

• Easy to maintenance.
• Durability and improved aesthetics.
• Time consuming assembly work at site is greatly reduced.
• Reduces cabling work & thus reduce the cost

Used in

• Closed Area
• Industrial Area

Monometer

Manometers are devices in which columns of a suitable liquid are used to measure the
difference in pressure between two points or between a certain point and the atmosphere.
Manometer is needed for measuring large gauge pressures. It is basically the modified form of
the piezometric tube.

Pressure and force are related, and so you can calculate one if you know the other by using the
physics equation, P = F/A. Because pressure is force divided by area, its meter-kilogram-second
(MKS) units are newtons per square meter, or N/m2. ... Air exerts pressure, too, due to the
weight of the air above you.

It sensing range in between 4mA to 20mA which further converted into range of reading for
example at 0-200 N/m2 can be expressed in range of 4mA-20mA.

Testing

A hydrostatic test is a way in which pressure vessels such as pipelines, plumbing, gas cylinders,
boilers and fuel tanks can be tested for strength and leaks. Hydrostatic testing is the most
common method employed for testing pipes and pressure vessels.

Hydrostatic testing

IP-55 and IP-65

IP-55 and IP-65 is are protection against dust, moisture and water. Basically IP65 Protected
from total dust ingress. Protected from low pressure water jets from any direction, limited
ingress protection And IP-55 are used to define levels of sealing effectiveness of electrical
enclosures against intrusion from foreign bodies (tools, dirt etc.) and moisture.
Types of pipe

• A106nB,C (Carbon steel) for 100’C

• A335P11 (Alloy steel) 300-350’C
• A335P12 (Alloy steel) 300-350’C
• A335P974 (Alloy steel) for high temperature & high pressure A269 (stainless steel)

For Measurement
RTD (Resistance temperature Detector)

RTDs work on a basic correlation between metals and temperature. As the temperature of a
metal increases, the metal's resistance to the flow of electricity increases. Similarly, as the
temperature of the RTD resistance element increases, the electrical resistance, measured in
ohms (Ω), increases.

Thermocouple

A thermocouple is a device used extensively for measuring temperature. Learn how the device
works here. A thermocouple is comprised of at least two metals joined together to form two
junctions. One is connected to the body whose temperature is to be measured; this is the hot
or measuring junction.
SALES & EXICISE

HOD (U-2): Prasanna Vijay Ma’am

Sales & Exicise

The purpose of sales and dispatch department is the safe and beneficial approach to sales and
delivery of goods that are manufactured in the company.

Process Chart of Sales and Dispatch

1. PURPOSE: this procedure outlines the sales and dispatch activity for finished goods.

2. SCOPE: all the ordered items and materials that are to be transported.

3. DEFINITION: 1 PO: purchase order

2 FOLIO: FILE

3 GR: Goods Receipt

4 IOC: Inter Office Communication

Duties of different

Sales assistant

• To prepare commercial invoices and all supplementary invoices

• To send BG/CG along with invoices to customer
• To prepare debit note/credit notes
• To send CRC with invoices to customer
• Follow-up
• To prepare major documentation

Assistant sales officer

• To prepare excise invoices

• To prepare documentation and sent to customer after dispatch
• To prepare packing list
• To prepare fax for transit insurance
• To prepare delivery challans
• Attending dispatches
• Contact with transporter
 • Letter to customer for complaints and other matters

Dispatch assistant

• Truck loading
• To take measurement of lorries
• To take measurement of packed material
• To book the orders in order booking register
• To prepare sales folio
• To help in documentation

Assistant Commercial Officer

• To prepare excise invoices

• To documentation
• To prepare packing list
• To attend late hours dispatch
• Contact project engineering- For proper dispatch information.

INSPECTION STAGE AND DISPATCH : -

LOADING

1. Recheck the cases

2. Check loading should be careful
3. Check position of cases after loading
4. Check there may be no gap between the case

AFTER LOADING

5. Confirm the loaded no. of case

6. Check the cases that it should be tightened
7. Check the truck may be covered with tripal
8. Confirm without gate pass, truck should not go out

SECURITY
The security will be confirmed by the quality of the cases loaded in the trucks covered with tripal
and entry should be done in register.
Terms and Conditions
In any industry commercial terms and conditions play a very important role.

1. FRIEGHT:

• Ex-worker
• For Udaipur
• For destination
• To pay
• Pre-Paid

2. PAYMENT TERMS FOR ELECTRICAL /MCC/LIE-LIR/CRP

The company takes at least 20%advance and balance 80% payment against delivery or 100%
payment against performance invoices /POC for 30/40/60maximum before dispatch.

3. ABG/PBG/CPBG and warrantee

The company doesn’t accept ABG for value less than that 50k/1 lac.

There are some hidden costs which company don’t consider at the time of negotiation.

Following are the cost whom company issue the ABG/PBG/CPBG

ABG - 2.25% per annum +ST

PBG - 1.75% per annum +ST

CBG - 1.75%per annum +ST

 PRODUCTION

HOD (U-2): KS Rao sir

CNC DESIGN

Powder
CNC Fabrication Seven Tank Painting
Coating

This department makes use of Computer Numerically Controlled CNC) or Numerically Controlled
(NC) machines to carry out four important processes of shearing, bending, punching and notching.

The inputs to the CNC department are CNC Drawings and Sheets. Spacing between title of
subsection and first line of text is 1.5 lines. The first paragraph in a subsection should align with left
margin. General alignment for texts in paragraph should be “justified”.

 Fabrication
This is an important Stage in the manufacturing process wherein four important processes are
followed which are given as follows: Welding, Grinding, Riveting and Drilling.

PANEL FABRICATION (WELDING)

  7- Tank Process
After the process of fabrication, the fabricated material is sent for the 7-tank treatment
wherein it is protected from the chemical phenomenon of corrosion and rusting. A "7tank
process" is simply a process where parts are immersed in seven tanks sequentially.
Normally, a zinc phosphating process is done in 7 steps while the simpler iron phosphating
pretreatment process is done in 3 steps or sometimes 5 steps.

The various processes are depicted as follows:-

Sr. No. Process Involved Function

1 Degreasing To remove oil and grease
from the surface of metal
sheet.

2 Derusting To remove the rust from the

surface & to prevent the sheet
from pits.

3 Activation Provides surface conditioning

and prepares the sheet
for the next process.

4 Phosphating Produces a fine and smooth

film of phosphorous to cover
the anodic and cathodic areas
of the metal surface making it
non conductive. This prevents
the electrochemical
 corrosion and enhances the
adhesion of powder or paint
by 6-8 times.

5 Passivation Forms a layer of metal oxide

or
Polymolecular oxide on the
metal surface.
6 Chromatising Prevents metal dissolution
and enhances the strength
of powder coat.

7 Tank process

Powder Coating
Powder coating is a type of coating that is applied as a free-flowing, dry powder. The main difference
between a conventional liquid paint and a powder coating is that the powder coating does not
require a solvent to keep the binder and filler parts in a liquid suspension form.

Powder coating electrical panels

Types of powder coatings

There are two main categories of powder coatings: Thermosets and thermoplastics. The
thermosetting variety incorporates a cross-linker into the formulation. When the powder is baked, it
reacts with other chemical groups in the powder polymer and increases the molecular weight and
improves the performance properties. The thermoplastic variety does not undergo any additional
reactions during the baking process, but rather only flows out into the final coating. The most
common polymers used are polyester, polyester-epoxy (known as hybrid), straight epoxy (Fusion
bonded epoxy) and acrylics.
Process of powder coating
The powder coating process involves three basic steps:
1. Part Preparation Processes & Equipment
Removal of oil, soil, lubrication greases, metal oxides, welding scales etc. is essential prior to the
powder coating process. It can be done by a variety of chemical and mechanical methods. The
selection of the method depends on the size and the material of the part to be powder coated, the
type of soil to be removed and the performance requirement of the finished product.

Painting
It is defined as a type of coating process that is applied in the form of a free flowing, wet or
powdered paint. It is done with the PU and Epoxy paint. Painted objects are suitable for interior as
well as exterior use also. Since, in this process PU (poly urethane resin) is added in the epoxy paint
which protects the object’s surface from sunlight, rain etc.

Steps involved in the painting process

After the 7- tank treatment the material goes to the painting section wherein the following
processes are followed.

1. Primer-
Epoxy based Red Oxide Zinc Phosphate primer is applicable on CRCA, HRCA & MS sheets and Epoxy
based Zinc Chromate primer for Aluminum. The function of primer is to protect the metal against
highly corrosive environment. Also gives good bonding with Phosphate surface of the object.

2. Surface-
It acts as an intermediate coat between Top coat and primer. Epoxy and polyurethane based surface
are used. Also it improves adhesion between primers and top coat.

3. Epoxy first coat-

It acts as an intermediate coat between Top coat and primer. Epoxy and polyurethane based
surfacer are used. It improves adhesion between primers and top coat.

4. M-Seal and Putty-

To fill up the dents, scratches and reappearing. To make surface free from defects (these
defects may arise during process) and uniformity is maintained throughout the surface.
5. Polyurthane Top Coat-
The distinguishing features of Polyurethane paint provides an excellent anti corrosive properties
acid, alkali, solvents & water resistance.

6. Drying-
Temperature 120°C for 10 Minutes/ 100°C for 20 minutes/ Air
drying - 4 hours.
 ELECTRICAL DESIGNING
HOD (U-2): SS Tripathi Sir

Different kinds of panels:-

There are two types:-
1) CRP (Control Relay Panel )

2) Synchronizing and Control Panels

For the operation distribution and transmission

2.1) Protection Panels:-

For the protection of power system like relays, fuses etc.

2.2) MIMIC Panels:-

Mimic panel is a fire and gas purpose panel on which shows a

geographical layout of the installation and equipment to represent rapid visual
appraisal of any fire and gas hazard.

MIMIC PANEL
2.3) MOSAIC Panels :-

Mosaic based miniature type switches and indicators modules used for
operation. Mosaic tile system is one of the most planner friendly, reliable
and economical approach to process visualization and control. It is Used for
Miniature Control Room..The support grid (mosaic tiles) is made up of modular
24x24, 48x24 or 48x48 and it is supported by a frame and by eventual steel
uprights in the event of large panels

Application :-
Power Plant, Process Plant

MOSAIC Panels

Major Components used in panels:-

Miniature Circuit Breaker (MCB)
Circuit breakers are electrical switching devices for protecting and controlling
the electricity supply to respective electrical circuits. Its basic function is to
detect a fault condition and, by interrupting continuity, to immediately
discontinue electrical flow. Unlike a fuse, which operates once and then has to
be replaced, a circuit breaker can be reset (either manually or automatically) to
resume normal operation. Thus, they protect electrical circuitry from damage
due to an overcurrent condition, such as an overload condition or a relatively
high level short circuit or fault condition.
Electrical systems in residential, commercial and industrial applications usually
include a panelboard for receiving electrical power from a utility source. The
electrical power is then delivered from the panelboard to designated branch
circuits supplying one or more loads. Typically, various types of circuit
interrupters are connected to the branch circuits to reduce the risk of injury,
damage or fires.

Basic Design of Breaker Circuit

The basic circuit breaker consists of a simple switch, connected to either a
bimetallic strip or an electromagnet. The diagram below shows a typical
electromagnet design.
The hot wire in the circuit connects to the two ends of the switch. When the
switch is flipped to the on position, electricity can flow from the bottom
terminal, through the electromagnet, up to the moving contact, across to the
stationary contact and out to the upper terminal.
Construction
Miniature circuit breakers typically include an electrical contact mounted on a
movable contact carrier which rotates away from a stationary contact in order to
interrupt the current path. Also, there is a fixed contact attached to the housing
and a movable contact coupled to an operating mechanism. The operating
mechanism includes a movable handle that extends outside of the housing. The
handle has essentially three stable positions: on, off, and tripped. These three
positions tell the operator what condition the contacts are in when the handle is
viewed. The trip mechanism is automatically releasable to effect tripping
operations and manually resettable following tripping operations. The trip
mechanism may include a thermal trip capability, which responds to persistent
low level overcurrents, and/or a magnetic trip capability, which responds
instantaneously to higher overload currents. The thermal-magnetic device
includes a bimetal which heats up and bends in response to persistent
overcurrent conditions to unlatch a spring powered operating mechanism which
opens the contacts which opens the separable contacts of the circuit breaker to
interrupt current flow in the protected powe r system. For short circuit
protection, an armature, which is attracted by the sizable magnetic forces
generated in a magnetic core by a short circuit, unlatches, or trips, the operating
mechanism.
Function
Circuit Breakers consist of a trip mechanism. For large currents or high voltages
they are usually arranged with pilot devices to sense a fault current and to
operate the trip opening mechanism. This operating mechanism, trip consist of a
thermal trip assembly and/or magnetic trip assembly, which are automatically
releasable and manually/automatically resettable. The trip solenoid that releases
the latch is usually energized by a separate battery, although some high-voltage
circuit breakers are self-contained with current transformers, protection relays,
and an internal control power source.
Once a fault is detected, contacts within the circuit breaker must open to
interrupt the circuit; some mechanically-stored energy (using something such as
springs or compressed air) contained within the breaker is used to separate the
contacts, although some of the energy required may be obtained from the fault
current itself. Small circuit breakers may be manually operated; larger units
have solenoids to trip the mechanism, and electric motors to restore energy to
the springs. The circuit breaker contacts must carry the load current without
excessive heating, and must also withstand the heat of the arc produced when
interrupting the circuit. Contacts are made of copper or copper alloys, silver
alloys, and other materials. In the event of overcurrent, electrical contacts open,
which further stops the flow of electrical current through the circuit breaker and
thus to the equipment. Overload protection is provided by a thermal element
which, when heated by the increased current, will cause the circuit breaker to
trip and interrupt the power. When a current is interrupted, an arc is generated.
This arc must be contained, cooled, and extinguished in a controlled way, so
that the gap between the contacts can again withstand the voltage in the circuit.
Different circuit breakers use vacuum, air, insulating gas, or oil as the medium
in which the arc forms. Different techniques are\ used to extinguish the arc
including:

1) Lengthening of the arc

2) Intensive cooling (in jet chambers)
3) Division into partial arcs
4) Zero point quenching
5) Connecting capacitors in parallel with contacts in DC circuits
Finally, once the fault condition has been cleared, the contacts must again be
closed to restore power to the interrupted circuit.

Arc interruption
Mechanical low-voltage circuit breakers use air alone to extinguish the arc.
Larger ratings will have metal plates or non-metallic arc chutes to divide and
cool the arc. Magnetic blowout coils deflect the arc into the arc chute. In larger
ratings, oil circuit breakers rely upon vaporization of some of the oil to blast a
jet of oil through the arc.
Gas (usually sulfur hexafluoride) circuit breakers sometimes stretch the arc
using a magnetic field, and then rely upon the dielectric strength of the sulfur
hexafluoride (SF6) to quench the stretched arc. Vacuum circuit breakers have
minimal arcing (as there is nothing to ionize other than the contact material), so
the arc quenches when it is stretched a very small amount (<2–3 mm). Vacuum
circuit breakers are frequently used in modern medium-voltage switchgear to
35,000 volts.
Air circuit breakers may use compressed air to blow out the arc, or alternatively,
the contacts are rapidly swung into a small sealed chamber, the escaping of the
displaced air thus blowing out the arc.
Circuit breakers are usually able to terminate all current very quickly: typically
the arc is extinguished between 30 ms and 150 ms after the mechanism has been
tripped, depending upon age and construction of the device.

Low Voltage circuit breaker

Low voltage (less than 1000 VAC) types are common in domestic, commercial
and industrial application, include:
• MCB (Miniature Circuit Breaker) have current rating up to 100 A. Trip
characteristics are normally not adjustable. Thermal or thermal-magnetic
operation.

MCB

• MCCB (Molded Case Circuit Breaker) have current rating up to 1000 A.

Trip current may be adjustable in larger ratings.

Low-voltage circuit breakers are also made for direct-current (DC) applications.
Special breakers are required for direct current because the arc does not have a
natural tendency to go out on each half cycle as for alternating current. A direct
current circuit breaker will have blow-out coils which generate a magnetic field
that rapidly stretches the arc when interrupting direct current.

MCCB
 CONTACTOR

• Actuator lever - used to manually trip and reset the circuit breaker. Also
indicates the status of the circuit breaker (On or Off/tripped). Most breakers
even if the lever is held or locked in the "on" position. This is sometimes
referred to as "free trip" or "positive trip" operation.

• Actuator mechanism - forces the contacts together or apart.

• Contacts - Allow current when touching and break the current when moved
apart.

• Terminals

• Bimetallic strip

• Calibration screw - allows the manufacturer to precisely adjust the trip current
of the device after assembly.

• Solenoid

Some important terms related with circuit breakers:

Breaking capacity
• The breaking capacity is the maximum current that can safely be interrupted
by the fuse. Generally, this should be higher than the prospective short circuit
current. Miniature fuses may have an interrupting rating only 10 times their
rated current.
Rated current
• Rated current n of a circuit breaker for low voltage distribution applications is
defined as the current that the breaker is designed to carry continuously (at an
ambient air temperature of 30 °C). The commonly-available preferred values
for the rated current are 6 A, 10 A, 13 A, 16 A, 20 A, 25 A, 32 A, 40 A, 50 A,
63 A, 80 A and 100 A.

Procedure followed

ENQUIRY DISPATCH

OFFER QUALITY

PURCHASE ORDER INTERNAL WIRING

DRAWING CNC
(DESIGN+PRODUCTION)
(GA+WIRING)

APPROVAL

INDENT PURCHASE
 QUALITY

HOD (U-2): Santosh Sir

Welding

Checking Dimensions

Powder Coating

Checking Thickness of Colour

Internal

Wiring Department

Continuity

Supply Checking {electrical testing}

BOM { Catalogue No. Ratings,Quantity}

,

Thickness of Wires and makes

 HIGH TESTING DEPARTMENT

HOD (U-2): R.P. Shukla sir

(1) DEPARTMENT OVERVIE :

(1.1) PRODUCTS MAUFACTURED

The two major products manufactured in HT department are:
 Indoor kiosks
 Outdoor kiosks

(1) OUTDOOR KIOSKS

INTRODUCTION

ADVANTAGES:
KIOSK MANUFACTURED (RATING )

TESTS CONUCTED ON 11KV KIOSKS

MAJOR FEATURES AND SPECIFICATIONS

IMPORTANT COMPONENTS USED IN AN OUTOOR KIOSK

The major components used in an outdoor kiosk are :

(1) Indication lamps
(2)Voltmeter
(3)Ammeter
(4)Energy meter
(5)VSS and ASS switch
(6)Push button
(7)Meter TTB
(8)Relay TTB
(9)O/C and E/F Protection relay
(10) TNC switch
(11) Current Transformer
(12) Potential Transformer
(13) Vaccum circuit breaker
(14) Porcelain bushing
(2) Indoor panels

INTRODUCTION

ADVANTAGES

PANEL TYPES (RATINGS)

TESTS CONDUCTED ON THE PANELS

INDOOR PANEL’S MAJOR COMPONENTS
 Mechanical design

HOD (U-2): N.k. Vasisht sir

Department overview

(1) Products manufactured

(1.1) PC Consoles

(1.2) Panels
(1.2.1) Welded

(1.2.2) Folded
(A) 5 Fold Panels
(B) 9 Fold Panels

(1.3) Junction Boxes

(1.4) 19 Inch Racks

(1.4.1) IT Panels
(1.4.2) Defence racks

Types of materials used

(1) Mild Steel

(1.1) CRCA (Cold rolled close annelead steel)
(1.2) HRCA (Hot Rolled Annelead steel)
(2) Stainless Steel
Type of construction

(1) Based on construction technique

(1)Welded
(2)Folded

(2)Based on material used

(2.1) FECOSY (Ferrous Construction System)
(2.2) ALCOSY (Aluminium Construction System)

GENERAL PROCUDER FOLLOWED IN THE

DEPARTMENT

Customer Enquiry PRODUCT COMPLETE

(from marketing to MD) AND READY TO DISPATCH

FINAL ORDER CNC DESING AND

PREPARATION PROGGRAMMING

PURCHASE ORDER PROJECT EXECUTION APPROVAL FROM

GENERATION (GA PREPARATION) CUSTOMER
 FIVE FOLD PANELS

FEATURES

(1)Protection
The FeCOSY panels meet the varying protection
requirements up to Ip 55.
(2)Strength
The rigid 5 fold sections provides a very stable
framework, moreover the recessed side sheets
provide extra strength to the cubicle. The folding of
the sheets make the frame structure lighter and
stronger than traditional construction system of
making structure frame with MS angles and Flats.

(3)Flexibility
In Size, mountings, accessibility finish. The cubicles
are made to order, and we do not push standard
products.

(4)Integration
We offer panels integrated with instruments,
elements and wiring, providing complete one stop
solution for panel requirement.
 NINE FOLD PANELS:

FEATURES

(1)Speed:
Quick assembly with comer block and rolled sections.
Uniform slots in frame member ensure flexibility for the
internal arrangement of the instruments.

(2)Strength:
The rigid B fold section provides a very stable framework.
Projected side sheets provides extra strength to the
cubicle. The folding of the sheets make the frame
structure lighter and stronger than traditional
construction system of making structure frame with MS
angles and flats.

(3)Flexibility:
In size, mountings, accessibility, finish. The cubicles can
also be made to order.

(4)Protection:
Specially designed gaskets and multifold enclosure
aperture is angled upwards and provides increased
stability and greater protection against dust and
moisture, meeting the varying protection requirements
upto IP-55.
(5)Stacking :
Any number of panels can be stacked together
horizontally as per lay out and site requirements with
easy and quick fixing hardware.

(6)Interchangeability:
Interchangeability of doors, side sheet, removable cover
and mounting plate.

(7)Integration:
We provide a completely customized solution which
includes providing and fixing of various types of electrical
instruments and their wiring.

FIVE FOLD PANELS

NINE FOLD PANEL

 CNC DESIGN

HOD (U-2): AKHILESH SIR

(1) GENERAL WORK FLOW PROCEDURE

INQURY FROM STARTING

CUSTOMER PRODUCTION

ENQUIRY DRAWING APPROVAL

DISTRIBUTED TO
FROM CUSTOMER
PROJECT ENGINEERS

DRAWING SCHEME
PREPARATION OF
PREPARATION
OFFER
(INCLUDING GA, IGA,
BOM, WIRING)
)SCHEME)

CNC DEPARTMET
This department makes use of Computer Numerically Controlled (CNC) or
Numerically Controlled (NC) machines to carry out four important processes of
shearing, bending, punching and notching.
The inputs to the CNC department are CNC Drawings and Sheets.
1. Design:- drawing

2. Programming ( On AUTOCAD and AUTOCAM)

3. Muratec CNC machine (made in Japan):- swing loader

 54 tools,2 index tool:-

Long, round, rectangle, square, angled.

4. Raw material used
 CRCA(cold rolled cold annealed)

 HRCA(hot rolled cold annealed)

 GI(galvanized iron)

 Alu.(aluminium)

 Alu. Zinc(aluminium-zinc)

 SS(stainless steel)

5. Sheet thickness
 Standard thickness:- 2500x1250mm(all material)

 Alu.:- 2400x1220mm

 0.6mm,0.8mm

 1.0mm,1.2mm,1.6mm

 2.0mm,2.5mm

 3.0mm

7. Machines

 Shearing machine:-NC hydraulic shear machine(2000)

Capacity 4x3000mm, Accuracy up to 0.5mm, Work length4x1000mm

• Procedure
1. Details of sheet received from design dept.

2. study of details of sheet size

3. Programming is made according to the requirement of sheet size.

 4. Cutting of sheets according to requirement

 Bending machine:-power folder future plus-25

Folding length 2600mm

Capacity at 400mm 3.5mm
Weight cap. 4295kg
->It has 500mm bending facility

Notching Machine:-
Machine Specification:- This Machine has only vertical and horizontal
motion no other angular motion is perform during punching Single
tooling process used in machine.
(Manpower-22)

 Punching Machine:-

Punching Capacity: 20 Tons,

Punching Accuracy: 0.1mm,
Working Length: 1250x2500
For Clamping the sheet at clamps, press foot switch the sheet is properly
hold by clamps or reference plugs.
 STORE

HOD (U-2: VIRENDRA SIR

(7) Storage

Raw material is purchased according to the need of the company and after
purchasing the raw material is sent to storage area where it is inspected to
ensure expected weight, height and other physical and electrical parameters.
Main raw material in store is sheet steel.
The storage area is divided majorly into two:
(1) Electrical storage
(2) Mechanical storage
Both mechanical and electrical storage areas are further divided into two:
(1) 4D storage
(2) 5D storage

Working of store

•Product Received from the shipper:

Here invoice is collect by Merchandiser, without invoice it is not possible make
the inventory, because there is a list of Goods In invoice.
•Inventory:
After Comparing invoice with received goods, the goods are placed in
inventory.

•Inspection of Goods:
Generally 10% goods are inspected, if found defects more that tolerance, the lot
will be declared as reject and inform supplier for replace. Trims and accessories
will be inspected 10% of total quantity. If found defects more than tolerance ,
then declared as reject.
GENERAL STORE PROCEDURE

Product Inspection of Given

Inventory respective
Received product
department

Working of store