PUSA INSTITUTE OF TECHNOLOGY

INDUSTRIAL TRAINING REPORT

TRAINING AT:

HINDUSTAN CONSTRUCTION COMPANY

SUBMITTED BY: SUBMITTED TO:

 NAME: MOHAMMAD AQIF MR.BHARAT KUMAR

 ROLL NUMBER:1508131057

 BRANCH:MECHANICAL(A) MORN.

SEM/YEAR:5th 3rd YEAR



ACKNOWLEDGEMENT
The success and final outcome of this project required a lot of guidance
and assistance from many people and I am extremely privileged to have
got this all along the completion of my project.All that I have done is
only due to such supervision and assistance and I would not forget to
thank them.
I respect and thank Mr.satbir Tyagi and MR.Ayush for providing me an
opportunity to do the training in HCC and giving us all support and
guidance which made me complete the project duly.I am extremely
thankful to them for such nice support and guidance although they had
busy schedule managing the corporate affairs.
I owe my deep gratitude to our project guide Mr.Anand,who took keen
interest on our project work and guided us all along,till the completion
of our project work by providing all the necessary information for
developing a good system.

I am thankful to and fortunate enough to get constant encouragement,

support and guidance from all teaching staffs of Mechanical department
which helped us in successfully completing our project work.Also I
would like extend our sincere esteems to all staffs at site for their timely
support.
MOHD AQIF

TABLE OF CONTENT
S.NO. TITLE PAGE NO.
1. Introduction
2. Layout details
3. Diesel generator
4. Study of transformer
5. Air compressor
6. Future plans of organization
 Chapter-1 INTRODUCTION TO
HINDUSATAN CONSTRUCTIOIN COMPANY

HCC is a business group of global scale developing and building responsible

infrastructure through next practices. With a group turnover of Rs. 8768 Cr (US $
1.32 billion), its businesses span the sectors of Engineering & Construction, Real
Estate, Infrastructure, Urban development & Management.
Founded by Industrialist Seth Walchand Hirachand in 1926, HCC Ltd has
constructed a majority of India’s landmark infrastructure projects, having
constructed 28% of India’s Hydel Power and over 65% of India’s Nuclear Power
generation capacities, over 3600 lane Km of Expressways and Highways, more
than 300 Km of complex Tunneling of which over 165 km are in the Himalayan
region and over 356 major bridges. Today, HCC Ltd. serves the infrastructure
sectors of Transportation, Power and Water.
Landmark projects executed by HCC include the Bandra Worli Sea Link − India’s
first and longest open sea cable-stayed bridge; the Farakka Barrage – world’s
longest barrage; the Kolkata Metro – India’s first Metro; the most challenging
sections of the Mumbai-Pune Expressway – India’s first six-lane concrete
expressway and the Kudankulam Nuclear Power Plant – with India’s first and
largest Light Water Reactors, having a capacity of 2X1000 MW.
Being the first construction company in India to implement ISO certified
Quality, Occupational Health & Safety and Environment Management systems and
robust Corporate Governance norms, HCC has also achieved the fastest
implementation of SAP- ERP across all its project locations, some even at record
breaking altitudes of 11,000 feet in the Himalayan ranges.
The Company has invested in the early adaption of advanced engineering
equipment, new and innovative technology and strategic international associations.
HCC’s order book as of March 31, 2016 was Rs 18,123 crore ($2.72 billion). The
company had clocked revenues of Rs. 4190.9 Cr ($ 629.08 million) and net profit
of Rs 84.97 crore ($12.75 million) during FY 2015-16.
HCC is developing Lavasa, India’s first planned hill city on the country’s
western front, comprising of five self-sustained towns with a permanent population
of over 2.4 lakh. Meticulously master planned by leading U.S based town planners;
HOK International Ltd. with an aim to strike a balance between urban living and
environment sustainability, the Lavasa city plan has won several international
awards. Lavasa currently hosts a multitude of global leaders in hospitality, tourism,
education, health care, business research and industry.
 In harmony with HCC’s long standing commitment to adopt practices that
deliver ‘Responsible Infrastructure’. HCC’s CSR Policy defines 5 heads of CSR
interventions namely Environment, Health, Education, disaster response, and Rural
Development. HCC’s Sustainability Reports have consistently been rated with an
Application Level Check A+ grade by the GRI (Global Reporting Initiative),
Netherlands.
HCC is the first Asian company to endorse the United Nations’ Global
Compact (UNGC)’s CEO Water Mandate and it executes a range of interventions
to recycle, reuse and recharge water.

Over the years, HCC has been at the forefront of rescue and relief operations
in a range of natural disaster scenarios. HCC is a member of the Disaster Resource
Partnership (DRP), an alliance initiated by the World Economic Forum and also
the founder member of Disaster Resource Network India. HCC is a member of the
executive committee of the TERI Business Council for Sustainable Development
(TERI-BCSD).
The HCC case study highlights its efforts towards water neutrality and showcases
its initiatives at its projects. More recently, HCC was awarded “Global
Sustainability Leadership Award for “Best Community Action’ – HCC’s
Community Development Project – ‘Ujjivana’

HCC Group of Companies

The HCC Group of companies now comprises of HCC Ltd, HCC Infrastructure
Co. Ltd, Lavasa Corporation Ltd and Steiner AG in Switzerland,Highbar,Hincon
holdings.Ltd.,Hincon Finance Ltd.

HCC Infrastructure Co. Ltd. is a leading infrastructure developer engaged in the

creation and management of premium assets in the areas of transportation, power
and water. HCC Infrastructure has a portfolio of over Rs.4900 Cr (US$ 736
million). Its current assets under management include four NHAI concessions.

Hincon Holdings Limited was incorporated on September 24, 1996 as a private

limited company under the name of Hincon Holdings Private Limited. The
company was converted to a public limited company and the name of the company
became Hincon Holdings Limited with effect from July 23, 1999.
 Lavasa Corporation Ltd. is focused on developing a planned Hill City, Lavasa,
which is a 3-hour drive away from Mumbai near Pune, in Western India. It is 1/5th
the size of Greater Mumbai, and is spread across a picturesque landscape of over
10,000 hectares. Meticulously master planned by leading U.S based town planners;
HOK International Ltd. with an aim to strike a balance between urban living and
environment sustainability, the Lavasa city plan has won several international
awards. The integrated development at Lavasa will include five self-sustaining
towns with a permanent population of over 2.4 Lakh. Dasve, the first town of
Lavasa is almost complete. Envisioned as an inclusive city with a ‘365 day
economy’, Lavasa currently hosts a multitude of global leaders in hospitality,
tourism, education, health care, business research and industry. Lavasa is seen as
the blueprint for the many future cities India will need as it responds to massive
rural-to-urban migration.

Steiner AG is Switzerland’s second largest total services contractor. With a

heritage of nearly 100 years, the company specialises in turnkey development of
new buildings and refurbishments, and offers services in all facets of real estate
development and construction. The company has registered a revenue of CHF CHF
636.8 million (Rs 4,255 crore) in FY 2015-16 The order backlog was CHF 1.32
billion (Rs 9,075 crore) at the end of the year. The company has initiated
international operations with the formation of Steiner India Ltd in Mumbai.

Highbar Technologies is one of the most preferred IT solutions provider for the
infrastructure industry. Highbar's portfolio of ERP solutions, line of business IT
solutions and process consulting is aimed at increasing efficiencies for
organizations. Infrastructure domain knowledge backed by IT expertise and
strategic alliances are the key differentiators which enable us to provide end-to-
end, customized IT solutions to infrastructure organisations. 

Hincon Finance Ltd was incorporated on May 20, 1992 as a private limited
company under the name of Hindustan Finvest Private Limited. The company was
converted to a public limited company and thereafter the name of the company was
changed to Hincon Finance Limited with effect from September 5, 2006.

LAYOUT MAP:-
LAYOUT DETAILS:-
In the site,there were several departments which were divided for different
works,like batching plant for concrete mixing,workshop for maintenance and
assembly of various equipments.,store and power supply house .
Batching Plant:-it was the plant which was used for mixing of concrete as that was
a construction site.its maintence was done once in a month to get proper
product.

Workshop:-Workshop was the most used place there,all the tools and
equipments were assembled and mainrened there.There were different
machines like lathe,drilling machine,small tools like files ,etc

Power supply house:-It was the most important sector of plant because all the
equipments require electricity which was provided by it.The power was produced
by the help of an diesel generator which was a 520 kw generator. It also requires
more precautions because it can lead to some accidents.

Medical rooms:-As,that was a construction site therefore ,accidents can happen

anytime to provide proper medical treatment at the right time,medical rooms
were made.

TBM Launching shaft:-it was the launching shaft of TBM(Tunnel Boring Machine),
from where the TBM machine was launched to bore the tunnel .

Store:All the equipments and uniforms of labours were stored there and were
issued through there.

CORE BUSINESS :-
With nearly a century's heritage in construction, HCC has evolved into an
engineering and construction leader. We have established a vast presence and
gained recognition in the sectors of Hydro Power, Water Solutions, Transportation
and Nuclear Power. Through every project and at every step, we aim to set new
benchmarks and deliver world class infrastructure.
HYDEL POWER:- HCC has expanded its construction capabilities to serve the
entire Hydro Power segment. HCC's accomplishments in the sector include dams,
barrages, tunnels, underground power stations and surface power stations, along
with water conductor systems like surge shafts, pressure shafts and penstocks. We
undertake Hydro Power projects on EPC basis as well.

WATER SOLUTIONS:- HCC’s extensive experience and expertise has powered

the progress in the Water Solutions segment. Since our debut, we have successfully
executed a number ofchallenging projects. With a strong focus on standards and
quality, HCC has developed specialized systems for high value projects.

NUCLEAR POWER PLANTS:- HCC has been a construction partner from the
inception of India's nuclear power generation program and has built over 65% of
India's nuclear power generation capacity. All 8 phases of the Rajasthan Atomic
Power Project have been entrusted to HCC since the first Unit completed in 1972.
HCC specializes in pre-stressed containment structures for reactor buildings. The
company has executed India's largest nuclear power plant in Kudankulam (2 X
1000 MW), Tamil Nadu.

TRANSPORTATION:- HCC has built some of the most remarkable

transportation projects in India. Whether it was India's first sea link or the
redevelopment of the historic Mughal Road, our technical knowledge and project
management experience has guaranteed the successful execution of futuristic and
technologically advanced construction methodologies 

DIESEL GENERATOR:-
Introduction Of Diesel Generator:- An diesel generator is a device that
converts mechanical energy obtained from an diesel engine into electrical energy
as the output. A diesel generator is the combination of a diesel engine with an
electric generator (often an alternator) to generate electrical energy. This is a
specific case of engine-generator. A diesel compression-ignition engine often is
designed to run on fuel oil, but some types are adapted for other liquid fuels or
natural gas.

The diesel generator operation is similar to that of the diesel engine. There are
two types of diesel engines. The 2-stroke and the 4-stroke opeIntroductiontwo
types.

The 4-stroke operation is the one that is typically used in diesel generators. This
process as the name implies uses four strokes The typical diesel generator is run at
1800RPM and is water cooled. This makes them great work horses as they are able
to run for longer periods of time when compared to the gasoline generator and
without much maintenance work required. They are also cheaper to operate due to
the low fuels costs as compared to the other types of fuels such as gasoline and
propane as well as the lowered maintenance costs due to there being no spark plugs
and carburetors. The packaged combination of a diesel engine, a generator and
various ancillary devices (such as base, canopy, sound attenuation, control
systems, circuit breakers, jacket water heaters and starting system) is referred to as
a "generating set"

Application Of Diesel Generator :- Diesel generators are widely used

in industrial applications because of their supreme reliability and low use of fuel.
This also makes them environmentally friendly. They are safer to operate than
gasoline-powered generators because diesel fuel is less flammable. Diesel
generators seldom require more than routine maintenance because of the simple
design. They will provide years of dependable service.
 Diesel generators are primarily used for backup in case of a power outage.
If the business has to suspend operations, this can be extremely costly in terms of
both lost production and pay for idled employees. Diesel generators can enable the
manufacturer to continue production. They provide power and cooling for large
data equipment. They ensure safe, reliable emergency power for hospitals and
other critical services like Hospitals, datacentres, and other critical public service
operations must have reliable, instantly available backup power in case of a
blackout or a natural disaster such as a hurricane. Life-support equipment and basic
operation of a hospital must continue to operate. Human lives are on the line in an
emergency. While some uses of power such as lighting may be reduced, most of
the power demands of a hospital continue to be required. In a disaster, they will
actually increase due to the influx of new patient.

Classification Of Diesel Generator:- Diesel Generator are classified

on the basis of it’s output power in terms of electrical energy as kva(kilo volt
ampere) & kw(kilowatt).Diesel Generator are available form 20kw to 5000kw.
We can choose a genset as per our requirements.Diesel Generators are also
classified in the following way

 working cycle of diesel engine

1. Two stroke
2. Four stroke
 Start-up arrangement
1. Manual starting for generators with no specified start-up time.
2. Automatic start-up - Long-break; Generator started from stationary on
grid failure.
 According to cooling way
1. Water cooling
2. Air cooling
 According to air admission way.
1. Naturally aspirated ( non-supercharging )
2. Supercharging
 According to number of cylinder.
1. Single cylinder
2. Multi cylinder
 Classification according to cylinder arrangement.
1. Inline type
2. Horizontal type
3. V- type
4. Opposite type
 According to rotation speed of crankshaft.
1. Low speed ( 150 to 450 rpm for large size machines)
2. Medium speed (600to 1200 rpm for medium size machines)
3. High speed (1500 to 1800 rpm for small size machines)
 Working Of Diesel Generator:- It is important to understand that a
generator does not actually ‘create’ electrical energy. Instead, it uses the
mechanical energy supplied to it to force the movement of electric charges
present in the wire of its windings through an external electric circuit. This flow
of electric charges constitutes the output electric current supplied by the
generator. This mechanism can be understood by considering the generator to
be analogous to a water pump, which causes the flow of water but does not
actually ‘create’ the water flowing through it.
The modern-day generator works on the principle of electromagnetic
induction discovered by Michael Faraday in 1831-32. Faraday discovered that the
above flow of electric charges could be induced by moving an electrical conductor,
such as a wire that contains electric charges, in a magnetic field. This movement
creates a voltage difference between the two ends of the wire or electrical
conductor, which in turn causes the electric charges to flow, thus generating
electric current.
 Main components of a Diesel Generator :- The Diesel generator is an
assembly of several essential and complex parts with some very small parts
too .The main components of an electric generator can be broadly classified as
follows.
(1) Engine
(2) Generator
(3) control Panel
(4) Main Assembly / Frame

1. Engine :- Engine is most important or main part of a diesel

generator.Engine is the source of the input mechanical energy to
the generator. The size of the engine is directly proportional to the
maximum power output the generator can supply. There are
several factors that you need to keep in mind while assessing the
engine of your generator.These are internal combustion engine
which runs on a 2 stroke cycle or a 4 stroke cycle.They are further
classified which will be discussed below

Engine assembly
2. Control panel :- is the user interface of the generator and contains
provisions for electrical outlets and controls. The following article provides
further details regarding the generator control panel. Different
manufacturers have varied features to offer in the control panels of their
units. Some of these are mentioned below.
a) Electric start and shut-down:- Auto start control panels
automatically start your generator during a power outage, monitor the
generator while in operation, and automatically shut down the unit
when no longer required.
b) Engine gauges:- Different gauges indicate important parameters
such as oil pressure, temperature of coolant, battery voltage, engine
rotation speed, and duration of operation. Constant measurement and
monitoring of these parameters enables built-in shut down of the
generator when any of these cross their respective threshold levels.
c) Generator gauges:- The control panel also has meters for the
measurement of output current and voltage, and operating frequency.
d) Other controls:- Phase selector switch, frequency switch, and
control switch (manual mode, auto mode) among others.

Fig:- control panel

3. Generator:- Generator also known as the ‘genhead’, is produces the
electrical output from the mechanical input supplied by the engine. It
contains an assembly of stationary and moving parts encased in a housing.
The components work together to cause relative movement between the
magnetic and electric fields, which in turn generates electricity.

a) Stator – This is the stationary component. It contains a set of electrical

conductors wound in coils over an iron core
b) Rotor / Armature – This is the moving component that produces a
rotating magnetic field.
Fig:- Generator

Main assembly/ frame :- All generators, portable or stationary, have

customized housings that provide a structural base support. The frame also
allows for the generated to be earthed for safety.
 DIESEL ENGINE:-

The diesel engine (also known as a compression-ignition or CI engine) and named

after Rudolf Diesel, is an internal combustion engine in which ignition of
the fuel which is injected into the combustion chamber is caused by the elevated
temperature of the air in the cylinder due to mechanical compression (adiabatic
compression). Diesel engines work by compressing only the air. This increases the
air temperature inside the cylinder to such a high degree that atomised diesel fuel
that is injected into the combustion chamber ignites spontaneously . This contrasts
with spark-ignition engines such as a petrol engine (gasoline engine) or gas
engine (using a gaseous fuel as opposed to petrol), which use a spark plug to ignite
an air-fuel mixture. In diesel engines, glow plugs (combustion chamber pre-
warmers) may be used to aid starting in cold weather, or when the engine uses a
lower compression-ratio, or both. The original diesel engine operates on the
"constant pressure" cycle of gradual combustion and produces no audible knock.

The diesel engine has the highest  thermal efficiency  (engine efficiency) of any
practical internal or external combustion engine due to its very high expansion
ratio  and inherent  lean  burn which enables heat dissipation by the excess air.
A small efficiency loss is also avoided compared to two-stroke non-direct-
injection gasoline engines since unburned fuel is not present at valve overlap
and therefore no fuel goes directly from the intake/injection to the exhaust. Low-
speed diesel engines (as used in ships and other applications where overall
engine weight is relatively unimportant) can have a thermal efficiency that
exceeds 50%.
.
 WORKING
The diesel internal combustion engine differs from the gasoline powered Otto
cycle by using highly compressed hot air to ignite the fuel rather than using a spark
plug (compression ignition rather than spark ignition).
In the true diesel engine, only air is initially introduced into the combustion
chamber. The air is then compressed with a compression ratio typically between
15:1 and 23:1. This high compression causes the temperature of the air to rise. At
about the top of the compression stroke, fuel is injected directly into the
compressed air in the combustion chamber. This may be into a (typically toroidal)
void in the top of the piston or a pre-chamber depending upon the design of the
engine. The fuel injector ensures that the fuel is broken down into small droplets,
and that the fuel is distributed evenly. The heat of the compressed air vaporizes
fuel from the surface of the droplets. The vapour is then ignited by the heat from
the compressed air in the combustion chamber, the droplets continue to vaporise
from their surfaces and burn, getting smaller, until all the fuel in the droplets has
been burnt. Combustion occurs at a substantially constant pressure during the
initial part of the power stroke. The start of vaporisation causes a delay before
ignition and the characteristic diesel knocking sound as the vapour reaches ignition
temperature and causes an abrupt increase in pressure above the piston (not shown
on the P-V indicator diagram). When combustion is complete the combustion
gases expand as the piston descends further; the high pressure in the cylinder
drives the piston downward, supplying power to the crankshaft.
Major advantages
Diesel engines have several advantages over other internal combustion engines:

 Diesel fuel has higher energy density and a smaller volume of fuel is
required to perform a specific amount of work.
 Diesel engines inject the fuel directly into the combustion chamber, have no
intake air restrictions apart from air filters and intake plumbing and have no
intake manifold vacuum to add parasitic load and pumping losses resulting
from the pistons being pulled downward against intake system vacuum.
Cylinder filling with atmospheric air is aided and volumetric efficiency is
increased for the same reason.
 Heavier fuels like diesel fuel have higher cetane ratings and lower octane
ratings, resulting in increased tendency to ignite spontaneously and burn
completely in the cylinders when injected. Increased compression ratios create
higher combustion chamber temperatures to ignite the injected fuel. Higher
compression ratios increase pumping losses as more work is required to
compress intake air to a smaller volume, but pumping loss increases are offset
by increased power and efficiency. Increasing compression ratios in spark-
ignition engines requires higher octane fuels that are harder to ignite and burn
completely and/or advanced spark timing to avoid pre-ignition, knocking and
resulting performance losses and engine damage. Power gains from increased
compression ratios are reduced in spark-ignition engines while the pumping
losses remain comparable to similar compression ratio increases in diesel
engines.
 Because of the above differences in diesel fuels vs. gasoline and other spark-
ignition fuels, diesel engines have higher thermodynamic efficiency, with heat
efficiency of 45% being possible compared to approximately 30% for spark-
ignition engines. Gasoline engines are typically 30% efficient while diesel
engines can convert over 45% of the fuel energy into mechanical energy
(see Carnot cycle for further explanation).
 They have no high voltage electrical ignition system, resulting in high
reliability and easy adaptation to damp environments. The absence of coils,
spark plug wires, etc., also eliminates a source of radio frequency
emissions which can interfere with navigation and communication equipment,
which is especially important in marine and aircraft applications, and for
preventing interference with radio telescopes.
 TRANSFORMER
Transformer is a device which:

 Transfer Electrical power from one electrical circuit to another Electrical

circuit.
 It’s working without changing the frequency.
 Work through on electric induction.
 When, both circuits take effect of mutual induction.
 Can’t step up or step down the level of DC voltage or DC Current.
 Can step up or step down the level of AC voltage or AC Current.

Without transformers the electrical energy generated at generating stations won’t

probably be sufficient enough to power up a city. Just imagine that there are no
transformers.How many power plants do you think have to be set up in order to
power up a city? It’s not easy to set up a power plant. It is expensive.Numerous
power plant have to be set up in order to have sufficient power. Transformers help
by amplifying the Transformer output (stepping up or down the level of voltage or
current).When the number of turns of the secondary coil is greater than that of
primary coil, such a transformer is known as step up transformer.

Likewise when the number of turns of coil of primary coil is greater than that of
secondary transformer, such a transformer is known as step down transformer.
 CONSTRUCTION OF TRANSFORMER/PARTS OF
TRANSFORMER

PARTS OF

TRANSFORMER
1 oil filter valve 9 bct terminal 17 oil drain valve

2 conservator 10 tank 18 jacking boss

3 buchholz relay 11 de-energized tap changer 19 stopper

level gauge

4 oil filter valve 12 tap changer handle 20 foundation bolt

5 pressure relief vent 13 fastener for core and coil 21 grounding terminal

7 low- voltage bushing 13 fastener for core and coil 22 skid base

8 suspension lug 14 lifting hook for core and coil 15 end frame

16 coil pressure bolt 23 coil 24 coil pressure plate

25 core 26 terminal box for 27 rating plate

28 dial thermometer 29 radiator 30 manhole

 TYPES OF TRANSFORMER
There are many different types of transformers. These are of are classified on the
basis of following factors:-

With respect to core:-

1.Core type transformer

2.Shell type transformer

3.Berry type transformer

With respect to uses:-

1.Large power transformer 2. distribution transformer 3. small power
transformer

4.Sign lightening transformer 5. bell ringing transformer 6. control

&signaling transformer

7.Instrument transformer 8. constant current transformer

9. series transformer for street lightening 10.gaseous discharge lamp

transformer

Types of instrument transformer :-

1.current transformer

2.potential transformer

3.auto transformer

4.constant current transformer

5.rotating core or induction regular transformer

 OPERATING &WORKING PRINCIPAL OF
TRANSFORMER

Transformer is static device (and doesn`t contain on rotating parts,hence no friction

losses), which convert electrical power from one circuit to another without
changing its frequency.It step up(or step down)the level of AC voltage and
current.Transformer works on the principle of mutual induction of two coil or
Faraday`s laws of electromagnetic induction.when current in the primary coil is
changed the flux link to the secondary coil also changes.Consequently and EMF is
induced in the secondary coil due to Faraday`s law of electromagnetic induction.

The transformer is based on two principles:

1.first, that an electric current can produce a magnetic field (electromagnetism).

2. second that a changing magnetic field within a coil of wire inducees voltage
across the ends of the coil (electromagnetic induction).

Changing the current in the primary coil changes the magnetic flux that is
developed. The changing magnetic flux induces a voltage in the secondary coil.
A simple transformer has a soft iron or silicon steel core and windings placed on
it(iron core). Both the core and the windings are insulated from each other. The
winding connected to the main supply is called the primary and the winding
connected to the load circuit is called the secondary.

Winding (coil) connected to higher voltage is known as high voltage winding

while the winding connected to low voltage is known as low voltage winding. In
case of a step up transformer, the primary coil (winding) is the low voltage
winding, the number of turns of the windings of the secondary is more than that of
the primary. Vice versa for step down transformer.

EMF is induced only by variation of the magnitude of the flux.When the primary
winding is connected to ac mains supply, a current flows through it. Since the
winding links with the core, current flowing through the winding will produce an
alternating flux in the core. EMF is induced in the secondary coil since the
alternating flux links the two windings. The frequency of the induced EMF is the
same as that of the flux or the supplied voltage.

By so doing (variation of flux) energy is transferred from the primary coil to the
secondary coil by means of electromagnetic induction without the change in the
frequency of the voltage supplied to the transformer. During the process, a self
induced EMF is produced in the primary coil which opposes the applied voltage.
The self induced EMF is known as back EMF.
 Limitation of the Transformer:-
A transformer is an AC machine that steps up or steps down an alternating voltage
or current. A transformer being an AC machine however cannot step up or down a
DC voltage or DC current. It sounds a bit weird though. You might be thinking “so
are there not DC transformers?”To answer the two questions whether there are or
there are not DC transformers and know “why transformer cannot step up or step
down a DC voltage” it’s necessary we know how electric current and magnetic
field interact with each other in transformer operation.

Electromagnetism
The interaction between magnetic field and electric current is termed
electromagnetism. Current carrying conductors produces magnetic field when
current passes through it. Movement of electrons in a conductor will result to
electric current (drifted electrons) which occurs as a result of the EMF set up
across the conductor.

The EMF set up across the conductor can be in form of that stored in chemical
energy or magnetic field. Current carrying conductor placed in a magnetic fields
will experience mechanical force while a conductor placed in a magnetic field will
have its electrons drifted which will results to Electric current

Field Flux
Two magnets of unlike poles will attract each other while magnets of like poles
will repel each other (so it is with electric charges). Every magnet is surrounded by
a force field and is represented by imaginary lines emanating from the north pole
of a magnet going into the south pole of the same magnet.

ELECTROMAGNETIC INDUCTION :-Electromagnetic induction is a

phenomenon that explains how EMF and current is or can be induced in a coil
when a coil and a magnetic field interact. This phenomenon”electromagnetic
induction”is explained by Faraday’s laws of  electromagnetic induction. The
direction of induced EMF in a coil is explained by Lenz’s law.
Faraday’s Laws Of Electromagnetic Induction
After Ampere and others investigated the magnetic effect of current, Michael
Faraday tried the opposite. In the course of his work he discovered that when there
was change in a magnetic field in which a coil was placed, EMF was induced in
the coil.

This happened only whenever he moved either the coil or the magnet he used in
the experiment. EMF was induced in the coil only when there was change in the
field flux (if the coil is fixed, moving the magnet towards or away from the coil
causes EMF to be induced). Thus Faraday’s laws of electromagnetic induction
states as follows;

Faraday’s First Law

Faraday’s first law of electromagnetic induction states that “EMF is induced in a
coil when there is a change in the flux linking the coil”.

Faraday’s Second Law

Faraday’s second law of electromagnetic induction states that “the magnitude of
induced EMF in a coil is directly proportional to the rate of change of flux linking
the coil”.

e = N dϕ/dt

Where

e = Induced EMF , N = the number of turns

dϕ = Change in flux

dt = Change in time

Lenz’s Law
Lenz’s law entails how the direction of an induced EMF in a coil can be
determined. “It thus states that the direction of induced EMF is such that it opposes
the change causing it.
In other words, When an E.M.F is induced in a circuit, the current setup always
opposes the motion, or change in current, which produces it. OR

An induced EMF will cause a current to flow in a close circuit in such a direction
what its magnetic effect will oppose the change that produced it.

According to this law (which introduced by Lens in 1835), the direction of current
can be found. when the current through a coil changes magnetic field, the voltage
is created as a result of changing magnetic field, the direction of the induced
voltage is such that it always opposes the change in current.

In very simple words, lenz’s law stating that the induced effect is always such as to
oppose the cause that produced it.

Fleming’s Right Hand Rule

It states that “if the thumb, the forefinger and the middle finger are held in such a
way that they are mutually perpendicular to each other (makes 90° of Angles), then
the forefinger points the direction of the field, the thumb points the direction of
motion of the conductor and the middle finger points the direction of the induced
current(from EMF).
 Why Transformers Can’t step Up Or Step Down A DC
Voltage or Current?
A transformer cannot step up or step down a DC voltage. It is not recommendable
to connect a DC supply to a transformer because if a DC rated voltage is applied to
the coil (primary) of a transformer, the flux produced in the transformer will not
change in its magnitude but rather remain the same and as a result EMF will not be
induced in the secondary coil except at the moment of switching on, So the
transformer may start to smock and burn because;

In case of DC supply, Frequency is zero. When you apply voltage across a pure
inductive circuit, then according to :Xl= 2 π f L

if we put frequency = 0, then the overall Xl (inductive reactance) would be zero as

well.

Now come to the current, I = V / R (and in case of inductive circuit, I = V / Xl)

…. basic Ohm’s Law

If we put Inductive reactance as 0, then the current would be infinite (Short circuit)
…

So, If we apply DC voltage to a pure inductive circuit, The circuit may start to
smoke and burn.

Thus transformers are not capable of stepping up or stepping down a DC voltage.

Also there will be no self induced EMF in such cases in the primary coil which is
only possible with a varying flux linkage to oppose the applied voltage. The
resistance of the primary coil is low and as such a heavy current flowing through it
will result to the primary coil burning out due to excessive heat produced by the
current.
 AIR COMPRESSOR

Compressors are used to increase the pressure of a gas. Like pumps, compressors
can be classified as either kinetic machines, which includes centrifugal and axial
compressors, or positive-displacement machines, which include reciprocating and
rotary compressors. The compressing medium or ‘gas’ depends on the application,
such as, if air is used it is termed as an air compressor.

TYPES OF COMPRESSOR
1.Reciprocating Compressor
In a reciprocating compressor, gas is compressed by mechanical variation of the
volume of space inside the cylinder, by reciprocating motion of the piston.

For a cycle of operation, there are two strokes such as,

1.) Suction stroke, and

2.) Compression stroke

As the piston moves down, air is sucked from atmosphere to the cylinder through
suction valve (a non-return valve). As piston moves up, air is compressed and at
the end of compression stroke, air is delivered through delivery valve (which is
also a non-return valve). Topmost portion the piston can travel inside the cylinder
is called Top Dead Center (TDC), and bottom most portion the piston can reach
inside the cylinder is called as Bottom Dead Center (BDC).
2.screw compressor

Screw compressors (also called as helical lobe compressors) are positive

displacement machines in which gas is being compressed is forced through the
casing by two screws. Unlike the reciprocating compressors which are also
positive displacement machines, screw compressors does not typically require
internal suction or discharge valves. In addition the flow from screw compressor is
generally more uniform and has fewer pulsations than the flow from a
reciprocating compressor.

A twin screw compressor consist of two meshing helical rotors mounted on

counter rotating parallel shafts that are enclosed within close-clearance casing. One
screw is called driving screw which is coupled with a drive, say an electric motor,
while the other screw is called as the driven screw, since it is driven by the driving
screw. Gears used for driving the screws are called timing gears, since they are
properly timed to maintain the close-clearance between the screws.

For screw compressors oil is injected into the screws while operation. There are
mainly 3 functions for the oil, they are,

1) Sealing of the screws to prevent leakage of the gas

2) Lubrication of the parts, especially the screws, and

3) Cooling of the gas compressed, which results in increased efficiency of the

system
 MATERIAL USED FOR CONSTRUCTION
1.Reciprocating compressor

Crank case and body-----Cast iron

Crankshaft -spheroidal graphite cast iron or stainless steel

Connecting rod – Forged Steel

Piston – Aluminium Alloy or Cast / Ductile Iron

Piston Rings – Cast Iron

2.screw compressor
Casing – Cast or Ductile Iron

Screw – Steel or Stainless Steel or Nickel Alloy

APPLICATION OF COMPRESSOR
Reciprocating Compressor
Reciprocating compressors are characterized with higher pressures and reduced
mass flow rate. They are mainly used in high pressure applications since it can
deliver air at about 30 – 40 bar.

1) For diesel engine starting, where electric motor starting becomes costly and
impractical.

2) Refrigeration compressors are normally reciprocating type (Single Stage) with a

discharge pressure around 10 bar.

3) Air conditioning systems also uses reciprocating compressors (Nowadays trend

is changed to screw compressors).
 Screw Compressors
Screw type compressors provide air at increased mass flow rate but with reduced
discharge pressure around 8 bar. Hence applications are also in low pressure
systems, such as,

1) Service air compressors used in industry (For cleaning air, etc.)

2) Air conditioning systems nowadays employ screw compressors. (which have

low power consumption and increased mass flow rate as advantages)

3) For low pressure air required for running pneumatic tools, pneumatic-hydraulic
equipment, etc.

CYCLE OF OPERATION

The process that occurs in a cycle 1-2-3-4-1 are explained below

The process that occurs in a cycle 1-2-3-4-1 are explained below

(3) – (4) – As piston travels from BDC to TDC air trapped inside the cylinder is
compressed.

(4) – (1) – As piston approaches TDC discharge valve opens and compressed air is
delivered.

(1) – (2) – Undelivered air trapped in the clearance space is expanded as piston
moves down.
(2) – (3) – When trapped air in the clearance space is expanded to atmospheric
pressure, further downward movement of the piston creates a vacuum inside the
cylinder and thereby atmospheric air enters through suction valve.

Again cycle repeats

In fig. ‘Va’ indicates the volume corresponding to actual stroke of the piston from
TDC to BDC (also called stroke volume). Similarly ‘Ve’ indicates the volume
corresponding to the effective stroke of piston, when atmospheric air enters the
cylinder.

The ratio of effective stroke volume to the swept volume is known as the
volumetric efficiency of the compressor,

Voleff = [ ( Ve / Va ) * 100 ] %

CLEARANCE SPACE
volumetric efficiency is 100% when

Effective stroke = Actual stroke

In other words, no clearance volume exists. This is practically impossible, because

some clearance space is required otherwise piston hits on the cylinder head as it
travels. Also expansion of piston occurs as it travels and very little clearance may
cause the same problem. Also increased clearance space reduces compressor
efficiency and increase its running hours. So clearance volume must be kept
around a reasonable value as instructed by the manufacturer.

HOW TO MEASURE CLEARANCE VOLUME

The clearance between piston and cylinder head while piston at TDC is called
bumping clearance. This can be measured in different ways. One common method
is, remove the valves from the top of the piston. Put a lead ball of sufficient

diameter into the cylinder. Slowly turn the flywheel one revolution by hand. Take
out the lead piece and measure its thickness, which gives the bumping clearance.
 WHY COOLING IS REQUIRED

Reciprocating compressors are generally cooled with air or water. The cylinders in
air cooled compressors often include large external fins that increase the surface
area available for heat transfer.

In water cooled compressors, freshwater is circulated through jackets that are built
into the walls of the cylinders and cylinder heads.

The compression cycle is illustrated graphically down below.

Single stage compression Double stage compression

Above cycle compresses gas from atmospheric pressure to 8 bar in a single stage.
The area enclosed by the points 12341 represents the work of compression in a
single stage compressor. Also see the cycle or Pressure-Volume diagram (P-V)
below which compresses gas from atmospheric pressure to 8 bar in two stages.

DOUBLE STAGE COMPRESSION:

Here first stage compresses gas from atmospheric pressure to 3 bar and then
gas is cooled isobarically (at constant pressure, refer diagram above). Now gas is
again compressed to 8 bar. Now we can see that the work of compression
corresponding to the shaded area in the diagram is saved by incorporating an inter
cooling between two stages. Hence when comparing with a single stage
compressor work can be reduced by inter cooling in a multistage compressor.

.
ISOTHERMAL COMPRESSION

During the process of compression, whatever heat produced is taken away by a

cooling medium. In other words, it is the compression , keeping temperature of the
gas constant. For a process to be isothermal, the process must be very slow, which
is impractical. From the indicator card, it is clear that, work of compression is
minimum in isothermal compression.

ADIABATIC COMPRESSION:-Whatever heat produced during compression is

kept inside the gas only, or heat transfer is zero in an adiabatic compression. For a
perfect adiabatic process, process must be very fast. All the thermodynamic
process resembles adiabatic process. It can be seen from the indicator card that,
work of compression is maximum in adiabatic compression. Specific heat is
defined as the heat energy required to raise the temperature of unit mass of
substance by unit degree.

POLYTROPIC COMPRESSION

Work of compression can be minimized by isothermal compression. But

compression is practically a fast process. So it better resembles an adiabatic
process. Jacket cooling of compressor makes the compression polytropic.Now the
only way to make the compression more isothermal is, by dividing the process to a
number of stages. Between every stage inter cooling of gas is done. Hence the
work can be saved substantially.
 AIR COMPRESSOR SAFETY TIPS
Hoses:- Ensure that all hose fittings are tight. Loose fittings can not only damper
you compressors performance, but also cause personal and equipment damage.

Keep all hoses clean of dirt and debris. This will not only lengthen the life of your
hose, but your air compressor as well.

Voltage:-Ensure that the machine is plugged into a properly grounded outlet. If

your machine is plugged into an outlet without the properly grounded electrical
circuits,there may be damage to the electrical panel of the compressor as well as
the possibility of a fire.Consult the owners manual for the recommended extension
cord use. Using a longer extension cord than recommended can result in a loss of
power, and can cause damage to the compressors electrical panel and/or moto

Tools:-Ensure that the machine is plugged into a properly grounded outlet. If your
machine is plugged into an outlet without the properly grounded electrical circuits,
there may be damage to the electrical panel of the compressor as well as the
possibility of a fire.Consult the owners manual for the recommended extension
cord use. Using a longer extension cord than recommended can result in a loss of
power, and can cause damage to the compressors electrical panel and/or motor.

Maintenance check :-
Air compressor owners often forget that an ounce of prevention is worth a pound
of cure. Maintaining your air compressor can save you both time and money down
the road. By performing the following checks each time you operate your air
compressor, you are saving yourself a world of pain in the future.

Checking compressor pump oil level:-.

1. Ensure unit is off and disconnect from the power source

2. Ensure compressor is on a flat and level surface

3. Remove fill cap / plug

4. Inspect the oil in the crankcase assembly and look for dirt or debris

5. Oil should not exceed the halfway point of the sight glass
Changing compressor pump oil:-
1. Ensure unit is off and disconnect from the power source

2. Ensure compressor is on a flat and level surface

3. Remove fill cap / plug

4. Place collection container underneath the oil drain cap.

5. Remove the oil drain cap, and let the oil drain out.

6. Replace the oil cap and be sure to tighten this nut securely. White plumbers
tape (PTFE) is generally a good idea to help create a tighter seal. Fill crankcase
with appropriate oil, be sure it does not exceed the halfway point.

Checking air filler element:-

1. Ensure unit is off and disconnect from the power source

2. Allow compressor pump to cool off.

3. Unscrew the filter top from the filter base by turning (generally) counter-
clockwise.

4. Separate the filter top cover from the base.

5. Remove the element from the filter base

6. Blow out dust and debris from the filter element.

7. Replace element if needed.

8. Reconnect filter top to the base and secure filter.

 FUTURE PLANS OF ORGANISATION

1.IRCON CONTRACT IRCON CONTRACT

HCC has been awarded a contract by IRCON International Ltd to construct two
tunnels and a bridge on Katra-Banihal Section of Udhampur – Srinagar- Baramulla
New BG Railway line Project. The project will be completed in 30 days.

Client: IRCON International Ltd

Project location Jammu & Kashmir

Value Rs. 1750 crore

Scope of work Construction of two main tunnels (T13 & part of T14) totaling
12.8 km along with parallel safety tunnels, a 200 m bridge adjoining these two
tunnels and a station yard at Basindadhar.

2.HYDROELECTRIC POWER PROJECT IN JAMMU AND

KASHMIR
HCC has been awarded a contract by JKSPDC to construct a 1500 m long double
lane tunnel which shall be the access road to 1856 MW Sawalkote Hydroelectric
Power Project in Jammu & Kashmir. The project is to be completed in 30 months.

Client: Jammu & Kashmir State Power Development Corporation (JKSPDC)

Project location Jammu & Kashmir

Value Rs. 167 crore

Scope of work EPC contract involving investigation, design & construction of

a double lane tunnel in accordance with IRC Codes as per the approved design.
3.RAILWAY TUNNEL BETWEEN TUPUL AND IMPHAL
9.5 km tunnel between Tupul and Imphal. It is a pleasure to inform you that HCC
in joint venture with Coastal Projects Ltd, has been awarded a contract by
Northeast Frontier Railway to develop a 9.5 km tunnel between Tupul and Imphal.
This is the fourth order received by HCC from Northeast Frontier Railway on the
new railway line between Jiribam and Tupul in Manipur. The project will be
completed in 40 months.

Client: Northeast Frontier Railway

Project location:-Assam

Value:- Rs. 785 Crore (HCC share 60% which is Rs. 471 Crore)

Scope of work : The scope of work will broadly include construction of 9.5 km
of Main Tunnel and 1.45 km of Adit-1 and 420 m of Adit-2 for new single line BG
Tunnel.

4.RAMBAN BANIHAL (NH44)

Hindustan Construction Company (HCC) has been awarded a prestigious NHAI
contract worth Rs 1783.42 crore for constructing a 36 km highway which includes
3 kms of tunnels between Ramban and Banihal in Jammu & Kashmir. The project
is a part of NHDP Phase-II program of NHAI on NH1A (now NH44) and is known
for its difficult terrain and low temperatures especially in winter seasons. The
NH1A is major road connectivity to Srinagar from rest of the country and this
project will decongest the existing narrow road between Ramban and Banihal and
will cut short travel time considerably due to provision of tunnels. Commenting on
new order win, Mr. Arun Karambelkar, President & CEO- E&C, HCC Ltd. said
“We are pleased to win this important contract from NHAI. This project not only
allows us to further expand our presence in road related business segments but also
gives us immense pride as this highway will contribute to the infrastructure growth
of our nation.” In the transportation segment HCC has a strong track record in
construction of Roads, Highways, Bridges, Railways and MRTS (Mass Rapid
Transport System). HCC has already constructed 3600 lane km of Expressways /
Highways across the country. In the MRTS space, the company has executed the
Kolkata and sections of Delhi Metro Rail project. It has built nearly 356 bridges
and 300 km of complex tunneling.

Quick Statistics

Client:NHAI

Project Value:-Rs. 1783.42 crore

Scope of workConstruction of

a) Four laning of 36 Kms from Ramban to Banihal Section of NH-1A

Completion42 months

5.BRIDGE ON SONE RIVER

Bihar Rajya Pul Nirman Nigam Ltd has awarded a contract to HCC to construct
2.9km long four lane bridge between Daudnagar and Nasriganj including approach
roads over river Sone in the district of Aurangabad and Rohtas in the state of
Bihar.

Quick Statistics

ClientBihar Rajya Pul Nigam Limited

Project ValueRs. 432.69 crore

Scope of workConstruction of

a) Construction of Main Bridge, 2.9 km in length - Precast segmental Box

Construction, including earthworks for main structure and Approach roads

b) Construction of Road works including embankments.

c) Construction of Foundation works using pile /well foundation.

d) Drainage works along the roads and bridge structure.

e) Road furniture, Lighting and traffic signs.

f) Painting and Miscellaneous works