PART-1

CHAPTER-1 :- INTRODUCTION
MSEDCL stands for Maharashtra State Electrical Distribution Corporation
Limited. It is founded in 6th June 2005. It is developed and created from MSEB. It is
serving 307,713 sq.km covering about 457 cities and 41095 villages of
Maharashtra. It is a company that is State Government registered under Companies
Act 1956. There main objectives is to develop, operate and maintain the distribution
system for supplying electricity in a particular area. Mahavitaran or Mahadiscom or
MSEDCL (Maharashtra State Electricity Distribution Company Limited) is a
wholly- owned subsidiary of the Maharashtra State Electricity Board.
It is the largest electricity distribution utility in India (2nd largest in the World
after SGCC). MSEDCL distributes electricity to the entire state of Maharashtra
except for some parts of Mumbai city where , Tata Power and Adani Electricity
Mumbai Limited are electricity distributors. The erstwhile Maharashtra State
Electricity Board (MSEB) was looking after Generation, Transmission &
Distribution of Electricity in the State of Maharashtra. But with the enactment of
the Electricity Act 2003 of the Government of India, MSEB was unbundled into 4
Companies on 6 June 2005 viz.
 Mahanirmiti or Mahagenco (Maharashtra State Power Generation Company
Limited (MSPGCL)
 Mahapareshan or Mahatransco (Maharashtra State Electricity Transmission
Company Limited (MSETCL)
 Mahavitaran or Mahadiscom (Maharashtra State Electricity Distribution
Company Limited (MSEDCL)
In this report we are studying about MSEDCL and its billing structure. In the
case of electricity bills, these are categorized into, domestic, industrial and commercial
bills.
 Domestic Bills:- The domestic bill comes from the electric circuits that are used
in different appliances at home.
 Industrial Bills:- The industrial bills come from factories, plants and
manufacturing processes. It also includes installing, maintaining and repairing
consumptions.

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  Commercial Bills:- The commercial electricity bill comes from industrial
electric load power requiements.
1.1 Industrial Bill:-
The Industrial Bill is divided into;
1.1.1 Consumer Details:-
The consumer details consists of Consumer Number, Consumer Name,
Address, Village Name and its pin-code. It also Consists of personal details of
consumer like Email ID, Mobile Number, Meter Number, and Load shed. The Load
shed maybe industrial or domestic. But, here in this case we are taking industrial load
shed into consideration. There are also some details about the payment.
 Last Receipt No./Date:- It shows at which date receipt was taken after paying
amount.
 Last Month Payment:- It shows how much payment was done in the last month.
 Scale/Sector:- It shows whether the industry is small scale or large scale and
whether it belongs to Private sector or Government Sector.
The bill amount changes according to due. If the consumer does not pay the bill at a
particular date, the amount of bill would get increased. These are considered on the
following conditions;
 Prompt Payment Discount:- A prompt payment discount of 1% of the monthly
bill (excluding Taxes and Duties) shall be provided to the consumers for
payment of electricity bills within 7 days from the date of their issue.
 Delayed Payment Charges:- In case the electricity bill is not paid within the due
date mentioned on the bill, delayed payment charge on the billed amount
including the taxes, duties , etc. shall be levied on the interest basis at the rate of
1.25% on the billed amount for the first month of delay.

Fig 1. Consumer details

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  Sanctioned Load:- The load which is mutually agreed between the Distribution
Licensee and the consumer is called as Sanctioned Load. It is expressed in terms
of Kilowatt(KW). In case the motor is installed on the LV/MV side, the
methodology to be followed for billing purpose is given by adding 2% of the
MV demand reading, to determine the KW or KVA billing demand, and X units
to the MVA reading to determine the total energy consumption to compensate
the transformer losses. It is calculated by the formula;

[X’= 730 * KVA rating of transformer/500 units per month]

This formula is used to find out iron losses. The Copper losses are calculated by
adding 1% at the LT side of the transformer.

 Contract Demand:- Contract Demand means the demand in KW or KVA that is

mutually agreed between the Distribution Licensee and consumer as entered
through agreement or agreed through written communication. It is expressed in
terms of KVA.

 Connected Load:- The amount of load that is connected to the system less than
or equal to the load mutually agreed between Distribution Licensee and the
consumer into written communication is referred to as connected load. It is
expressed in KW.

 70% of the contract demand:- The 70% required of the Contract demand is
taken into consideration.

Fig 2. Load Details

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  Feeder Voltage:- A feeder line is a peripheral route or branch in a network,
which connects smaller or more remote nodes with a route or branch carrying
heavier traffic.

 Security Deposit Held:- For consumers having monthly billing cycle, the
amount of the security deposit shall be twice the average billing of the billing
cycle of 12 months period. For consumers having quarterly billing cycle, the
amount of the security deposit shall be 1.5 times the average billing of the
billing cycle period. If the consumer not paid the bill, supply can be only after
serving him a notice and after giving him a period of days.
 Additional security deposit:- To avoid losses in such cases, security deposit
equivalent to electricity consumption of one month is collected from every
monthly billed domestic consumer. This period may vary as per the duration of
the billing.
 Date of Connection:- It defines the date at which the connections are given to
the consumer by the Distribution Licensee.

1.2 Billing History:-

The Billing history consists of bill month, units, bill demand in KVA, bill amount.
The amount that is highest and highest bill demand is printed on the blank spaces.

Fig 3. Biling History

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Electricity bill payment history will tell you about all your earlier payments off your
electricity bills.
1.3 Current Consumption Details:-
The current consumption details consists of various parameters that that are
showed to signify the active, reactive and apparent power of the consumption. It also
contains current power rating and last month power rating. The third column consists of
difference between the current consumption and previous consumption.

Fig 4. Current Consumption Details

In the above fig, it has shown current consumption details of a particular type of
bill. The various parameters are shown like KWH, KVAH, KVARH(Lag),
KVARH(Lead), KW(MD) and KVA(MD). The first row denotes current rating,
previous, difference, multiplying factor, consumption, Total consumption, etc.

 KWH Rating:- The KWH rating is displayed on the energy meter. KWH is
related to active power of the system. It is the output power of the system for a
particular period of time. KWH rating denotes mechanical energy of the device
for a particular period of time.
[KW=V*I*P.F*t]
Where,
V=voltage; I=current; P.F= power factor: t= time period

 KVAH Rating:- The KVAH rating needs to be calculated. It is not shown on

the energy meter. KVAH is related to reactive power of the system. KVAH is
input
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 power of the system given for a particular period of time. KVAH rating denotes
electrical energy of the system. It is given by the formula,

[KVAH=KWH/P.F]

 KVARH(LAG)(LEAD):- The reactive power (Q) is used to provide the

electromagnetic field in inductive equipment and drawn from grid. Also,
reactive power is supplied by consumer to grid in case of excessive capacitive
load. It is measured in kVAr (Lag / Lead) and is totalized by the energy meter as
KVARH (Lag / Lead). The lagging P.F is produced when inductive load is used
and leading
P.F is produced when capacitive load is introduced. But, in distribution system
mostly transformers are used which is why it has lagging P.F. The lagging P.F
lies between 0.99 to 0 and leading P.F lies between -1 to 0.

 KW(MD):- This is the maximum power value, usually the average of 15

minutes, reached during the billing period (this average time may vary
depending on the country). Once the value is higher than the contracted power,
the customer will pay a penalty on the electricity bill. Maximum demand (kW or
kVA) i.e the maximum power value during a specified time interval, usually the
average of 15 minutes (may vary) reached during the billing period.

Fig 5. Maximum demand (KW & KVA)

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  Multiplying Factor:- The multiplying factor is calculated by division of product
of external CT ratio and external PT ratio to meter CT ratio and meter PT ratio.

Multiplying factor = (External CT ratio*External PT ratio)/(Internal CT ratio*Internal

PT ratio)

 Billed Demand (KVA):- Maximum demand register (kW or kVA). This is the
maximum power value, usually the average of 15 minutes, reached during the
billing period which may vary depending on the country . It is the actual
maximum demand record in a month between 6p.m to 12p.m . 75% of the
highest demand is recorded Once the value is higher than the contracted power,
the customer will pay a penalty on the electricity bill. This is categorized into:-
a) Fixed Window (Block window):- This is the maximum demand
calculation during a defined interval (usually every 15 minutes). Once
the data is obtained, the value is stored and it makes a reset to start a new
calculation for the next 15 minutes. These four registers will be
measured every hour.

b) Sliding Window:- In sliding window method determination of the MD is

based on 30 min DIP (Demand Integration Period). Here the 30 min
period is not fixed as in case of the block window.
In block window method the demand recorded by the system was
split into two blocks of time interval and hence the demand recorded by
the system is much less than the actual peak loads on the system i.e.
transformers, transmission lines & generation capacity. Hence sliding
window method was incorporated in new meters to determine demand
more accurately. Once the data is obtained, the value is stored and it
makes a reset to start a new calculation for the next 15 minutes. The 30
min demand integral period is sliding consecutively with 10 min sub-
interval as explained below:

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 0 min 10 20 30 40 50 60 70 80 90 100
W1
W2
W3
W4
W5
W6
W7
B1 W1 toW7 -:
B2 Slidingwindows B1 & B2:-
Blcok winodws

Fig 6. Sliding window method

In sliding window method there will be four complete DIP and four overlapping partial
‘DIP’.
Hence for consumer with 1000 KVA load for 30min duration.
We can observe that B1=W1 & B2=W4
Example:
Consider a 30 min consecutive consumption with constant 1000 kVA load from period
10:15 to 10:45 Hrs.

 Assessed Consumption:- The consumption so assessed shall be charged at twice

the rate per unit of the tariff applicable to the consumer category after adjusting
the amount paid by the consumer / person for the energy consumption assessed
for the assessment period if any. The amount billed at this rate shall not be taken
into consideration for the purpose of computing consumer’s liability to pay
monthly / annually minimum charges, wherever applicable.
[ Units Assessed = L* F * D * H ]

 Total Consumption:- This is the total monthly consumption by all the appliances
that are connected to the meter. This is the value that needs to come down in
order to reduce the electricity bill.

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1.4 Billing Details:-
The billing details consists of the following parameters;
 Assessed P.F:-Power factor is an expression of energy efficiency. It is usually
expressed as a percentage—and the lower the percentage, the less efficient
power usage is. Power factor (PF) is the ratio of working power, measured in
kilowatts (kW), to apparent power, measured in kilovolt amperes (kVA).
 Average P.F:- Average Power Factor means the ratio of kilowatt hours
consumed in the month to root of sum of squares of kilowatt hours consumed in
the month & reactive kilo-volt ampere hours consumed in the month or the ratio
of kilowatt hours consumed in the month to kilo-volt ampere hours consumed in
the month.

[ KWH consumed in a month/ ( KWH)+(KVAH)reactive2]

Penalty in % according to power factor level

 Power Factor:- Power factor is an expression of energy efficiency. It is usually
expressed as a percentage—and the lower the percentage, the less efficient
power usage is there
Power factor (PF) is the ratio of working power, measured in kilowatts (kW),
to apparent power, measured in kilovolt amperes (kVA). Apparent power, also
known as demand, is the measure of the amount of power used to run machinery
and equipment during a certain period. It is found by multiplying (kVA = V x
A). The result is expressed as kVA units. PF expresses the ratio of true power
used in a circuit to the apparent power delivered to the circuit. A 96% power
factor demonstrates more efficiency than a 75% power factor. PF below 95% is
considered inefficient in many regions.

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 If a circuit were 100% efficient, demand would be equal to the power available. When
demand is greater than the power available, a strain is placed on the utility system. For
most utilities, demand is calculated based on the average load placed within 15 to 30
minutes. If demand requirements are irregular, the utility must have more reserve
capacity available than if load requirements remain constant. Peak demand is when
demand is at its highest. The challenge for utilities is delivering power to handle every
customer’s peaks. Using power at the very moment it is in highest demand can disrupt
overall supply unless there are enough reserves. Therefore, utilities bill for peak
demand. For some larger customers, utilities might even take the largest peak and apply
it across the full billing period.

The power factor is differentiated into;

a) Unity power factor:- When power factor is at unity, the voltage and current
waves are aligned or in phase with one another. This is expressed as a PF of 1.0.
b) Lagging power factor:- In a circuit, when the current lags behind the voltage,
then the power factor of the circuit is known as a lagging power factor. The
power factor lags when the circuit is inductive.
c) Leading power factor:- When the current in the circuit leads the voltage, then
the power factor of the circuit is said to be leading. A capacitive circuit has a
leading power factor.

Lagging and Leading power factor

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 Tariff:- The rate at which electrical energy is supplied to a consumer is known
as tariff. Cost of Producing Electricity depends upon the magnitude of
Electricity consumed by load. Tariff fixation has to be given to different types of
consumers (e.g., industrial, domestic and commercial). In industrial bills, the
maximum demand tariff is used.
Tariff fixing for different consumers is more complicated. Proper returns
should be provided by tariff. The tariff should be fair so that all the consumers
should be satisfied by the electricity charge. It should be simple to understand
for the consumer. The tariff should provide a reasonable profit. Tariff should be
attractive that large amount of consumers gets encouraged for using the bill.
a) Maximum Demand Tariff:- Maximum Demand Tariff consists of
two parts, i.e. demand charge and energy charge. The demand charge
is based on the maximum demand in kVA, while the energy charge
depends on the energy consumption in Unit (kWh) of the month.
Tariff charges are subject to a minimum of 100 kVA of the
chargeable demand. Maximum Demand Tariff is only beneficial to
electrical installations with a high load factor. This applies to
accounts of considerably high electricity consumption over a long
period of time with a steady load.

 Consumption type:- The type of consumption depends on the industrial,

residential and commercial areas. All the different areas have their different
rates. Sometimes the rate remains same for industrial and commercial areas.
 E.D ( Electricity Duty):- Ed stand for electricity duty is basically tax which is
charged by Central Government or state government to everyone having
electricity connection are you can say it is a service tax for all consumer having
electricity connection. It is the 5% of the sum of electricity charges and fixed
charges It is calculated by the formula;
E.D = (EC+FC)*5%

 EC (Electricity Charge):- It is defined as the total electricity unit that is

showed in a month.
[EC = Units consumed in a month * Tariff rate]

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  FC (Fixed Charge):- If no electricity is used in a particular month then a
fixed amount bill need to be paid by the consumer. This is called as fixed
charge.
 Load Factor (L.F):- The load factor is the ratio of total consumption to
the product of contract demand, billed P.F per month.
[L.F = Total Consumption/ ( Contract demand * Billed P.F * 24hrs. * days in a month)]

 TOD (Time Of Day):- In the Time of Day (TOD) Tariff system, rather than
being charged for electricity at the same rate at all times of the day, the price
you pay for electricity will vary according to the time of day. Usually, the
electricity demand is highest during the time 6pm to 10pm. The electricity
demand is lowest at the 12pm to
6pm period.

Billing details
 TOD Tariff EC:- It is the sum of amount of charge that is taken of all the
TOD zones.

For example, from the above fig. [ -43357.50+8496+16148= -18713]

 FAC ( Fuel Adjustment Charge):- FAC is the Z-factor charge that will be
determined in accordance with the formula specified in multiyear tariff
regulations and any directions that may be given from time to time. In case of
any variation in the fuel prices and power purchase prices, the distribution
Licensee shall pass on the adjustments through the FAC component.
 Bulk Consumption Rebate:- Rebate for bulk consumers for eligible consumers
within HT industrial category shall be governed.
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 PART-2
CHAPTER 1:- INTRODUCTION

1.1 History of Anshul Speciality Molecules Pvt.Ltd:

Anshul Specialty Molecules Pvt. Ltd., established on October 5, 1971, is a

prominent manufacturer in the specialty chemicals sector. Headquartered in Jogeshwari,
Mumbai, the company has additional facilities in Roha, Maharashtra, and Vadodara,
Gujarat. It is a part of the prestigious Excel group, founded by the Shroff family, and
boasts a rich legacy spanning five decades.
The company specializes in producing intermediates for APIs (Active
Pharmaceutical Ingredients), ingredients for flavours and fragrances, and offers custom
synthesis solutions. Anshul's state-of-the-art manufacturing facilities and a strong focus
on quality and sustainability have positioned it as a leader in its field. The company is
committed to sustainable manufacturing practices, including zero liquid discharge
(ZLD) systems, rainwater harvesting, and renewable energy initiatives.
Anshul Specialty Molecules Pvt. Ltd. established its manufacturing facility in
Roha, Maharashtra, as part of its expansion to enhance production capabilities and cater
to a broader market. Situated in the well-developed MIDC (Maharashtra Industrial
Development Corporation) area of Roha, this facility benefits from excellent
infrastructure, including robust roads, ample water supply, uninterrupted electricity, and
proximity to the Nhava-Sheva port, about 70 km away. This strategic location facilitates
efficient logistics and supply chain management.

Fig.7 Anshul Speciality Molecules Symbol.

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1.2 Industry Details:

1. Research and Development (R&D):

Discovery: Anshul Specialty Molecules focuses on discovering novel chemical
entities (NCEs) with specific therapeutic effects, employing advanced research
methodologies.
 Preclinical Studies: They conduct rigorous preclinical testing to evaluate safety,
efficacy, and pharmacokinetics of potential APIs using state-of-the-art in vitro
and in vivo models.
2. Process Development:
 Route Selection: Anshul Specialty Molecules selects synthesis routes based on
criteria such as efficiency, cost-effectiveness, and environmental impact,
emphasizing sustainable practices.
 Optimization: They optimize chemical synthesis processes for scalability and
cost-efficiency, leveraging innovative reaction conditions and purification
methods.
3. Manufacturing:
 Good Manufacturing Practices (GMP): Anshul Specialty Molecules strictly
adheres to GMP regulations, ensuring high-quality production standards.
 Synthesis and Purification: They employ advanced synthesis techniques and
purification methods like crystallization, chromatography, and filtration to
achieve high purity APIs.
4. Quality Control and Assurance:
 Analytical Testing: Rigorous testing using techniques such as HPLC, MS, and
NMR ensures APIs meet stringent purity, potency, and stability requirements.
 Stability Testing: Comprehensive stability studies validate API shelf life and
storage conditions.
5. Regulatory Considerations:
 Regulatory Submissions: Detailed documentation and validation data are
meticulously prepared for regulatory authorities like FDA and EMA.
 Compliance: Anshul Specialty Molecules complies with ICH guidelines and
local regulations, ensuring global market readiness.

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 CHAPTER 2

ELECTRICAL COMPONENTS

2.1 Transformer:
 Rating of Transformer:
 Capacity: 2000 KVA
 Voltage Ratio: 22/0.433 KV
 H.T Current: 52.48 A
 L.T Current: 2667 A
 H.T Voltage: 22 KV
 L.T Voltage: 433 V
 Cooling Type: ONAN (Oil Natural Air Natural)
 Ambient Temperature: 40 Degree Celius
A transformer is an electrical device that transfers electrical energy between two or
more circuits through electromagnetic induction. Transformers work on the principle of
Faraday's law of electromagnetic induction. The changing current in the primary coil
(winding) induces a voltage in the secondary coil, which allows the transfer of electrical
power from one circuit to another. Usually made of laminated iron or other magnetic
materials, the core provides a path for the magnetic flux, enhancing the transformer's
efficiency. The coil connected to the input voltage source.The coil connected to the
output load.
Transformers can step up (increase) or step down (decrease) voltage levels
depending on the turns ratio of the primary and secondary coils. Used in power
distribution systems to step down high voltage from power lines to lower voltage levels
for residential and commercial use. Found in power generation plants and substations,
they are used to step up voltage for long-distance power transmission and step-down
voltage for distribution. Provide electrical isolation between the primary and secondary
circuits, often used for safety reasons.
Transformers are designed to be as efficient as possible to minimize energy losses
during the transfer of power. Transformers generate heat during operation, and various
cooling methods (air, oil, or liquid cooling) are employed to maintain optimal operating
temperatures.

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 Transformers are fundamental to electrical power systems, enabling the efficient
generation, transmission, and distribution of electrical energy. They are also used in
various electronic devices. Transformers are typically housed in enclosures to protect
against environmental factors and to ensure the safety of personnel. Regular
maintenance is essential to ensure the proper functioning and longevity of transformers,
including checking for insulation integrity and monitoring oil levels in oil-filled
transformers.The construction of a transformer involves several key components that
work together to facilitate the transfer of electrical energy. the constructional
information of a typical power transformer is as follows;
 Core: The core is usually made of laminated steel sheets. This laminated
construction reduces eddy current losses and improves the efficiency of the
transformer. The core provides a low-reluctance path for the magnetic flux
generated by the primary winding.
 Windings (Coils): The coil connected to the input voltage source. The windings
are insulated to prevent short circuits and to ensure electrical safety. The turns
ratio between the primary and secondary windings determines the voltage
transformation capability of the transformer.
 Insulation: Various insulating materials are used to separate the windings and
ensure electrical insulation. Common materials include paper, oil-impregnated
paper, and synthetic materials. Proper insulation is critical for the transformer's
reliability and safety.
 Tank (Enclosure): The tank is typically made of steel and serves as a protective
enclosure for the core and windings. Some transformers are equipped with
cooling fins or radiators on the tank surface to dissipate heat generated during
operation.
 Oil (In Oil-Filled Transformers): Oil-filled transformers use transformer oil as
a coolant and insulating medium. The oil helps dissipate heat and provides
insulation. Transformers may have natural convection cooling or forced oil
circulation systems.
 Tap Changer: Some transformers have tap changers that allow adjustments to
the turns ratio, enabling voltage regulation. On-load tap changers (OLTC) and
off- circuit tap changers (OCTC) are common types.

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  Buchholz Relay: Installed in oil-filled transformers, the Buchholz relay detects
and responds to internal faults, such as the presence of gas due to overheating or
arcing.
 Breather: A breather is often attached to the transformer tank to control the
moisture level inside. It contains a desiccant to absorb moisture from the air.
 Conservator (For Oil-Filled Transformers): In larger transformers, a
conservator is used to compensate for oil volume changes due to temperature
variations. It helps maintain a constant oil level.
 Bushings: Bushings are insulating devices through which the conductors
(wires) pass into or out of the transformer. Porcelain or other insulating
materials are used to construct bushings.

The specific design and construction details can vary based on the transformer's
application, voltage rating, and manufacturer specifications. Transformers are crucial
components in electrical power systems, facilitating the efficient transmission and
distribution of electrical energy.

Fig. 8 2000 KVA Transformer.

2.2 Diesel Generator:

 Rating of Diesel Generator:-

 Capacity: 1010 KVA
 Total Power: 808 KW
 Voltage: 415 V
 Current: 1405.12 A
 Speed: 1500 RPM

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  Frequency: 50 Hz
 Duty: S
 Insulation Class: H
 Power Factor: 0.8
 Ambient Temperature: 40 Degree Celius
 Three-Phase Star Connected
 Manufacture: Cummins
A diesel generator is a type of electrical generator that uses a diesel engine to
convert mechanical energy into electrical energy. The primary component responsible
for converting fuel into mechanical energy. Diesel engines are known for their
durability and fuel efficiency. It Converts the mechanical energy from the diesel engine
into electrical energy.
The generator produces alternating current (AC) electricity. Stores diesel fuel to
supply the diesel engine. Delivers the right amount of fuel to the combustion chamber
for efficient combustion. Diesel generators have a cooling system to regulate the
temperature of the engine and prevent overheating. Expels the combustion gases
produced during the operation of the diesel engine. Controls the speed of the diesel
engine to maintain a steady frequency of the generated electrical output.

Fig.9 Diesel Generator.

Control Panel Houses controls and indicators for starting, stopping, and monitoring
the generator's operation. Includes protection mechanisms such as overload protection,
low oil pressure shutdown, and high-temperature shutdown.Voltage Regulator Maintains
a stable output voltage within specified limits, ensuring the quality of the generated
electricity. In standby power applications, an ATS automatically switches between the
main power source and the generator when a power outage occurs. The generator set is

18
mounted on a base frame or skid for stability and ease of transportation. Commonly used
as backup power sources for critical facilities such as hospitals, data centres, and
industrial plants during power outages. Prime Power is Used as the primary source of
power in locations without access to a stable grid, such as remote construction sites or
off-grid installations. Standby Power Provides power during peak demand periods or
when the primary power source is temporarily unavailable. Regular maintenance,
including oil changes, fuel system checks, and periodic inspections, is crucial to ensure
the reliable operation of a diesel generator.
Diesel generators are valued for their reliability, fuel efficiency, and ability to
provide a quick and efficient source of power, especially in situations where a stable
electrical grid may be unavailable or unreliable. They are widely used in various
industries and applications worldwide.

2.3 Automatic Power Factor Correction Panel:

An Automatic Power Factor Correction (APFC) panel is an electrical control

system designed to automatically improve the power factor of an electrical system by
adjusting or correcting the reactive power. Power factor is a measure of how efficiently
electrical power is converted into useful work output. It is the ratio of real power
(working power) to apparent power (total power). Reactive power is the non-working
power that flows back and forth in the power system without performing any useful
work. It is necessary for the operation of inductive loads like motors and transformers
but does not contribute to useful work output.
Power factor correction involves reducing or offsetting the reactive power,
improving the power factor and increasing the efficiency of the electrical system.
Monitors the power factor of the system and determines the required correction.
Typically, these are capacitors that can be switched on or off to provide the necessary
reactive power compensation. Sensors and meters to measure power factor and other
relevant electrical parameters.
The APFC panel operates automatically based on the real-time power factor
readings. When the power factor falls below a set threshold, the controller activates the
capacitors to compensate for the reactive power, thereby improving the power factor.
Automatic Power Factor Correction is an essential element in managing electrical

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systems efficiently, reducing energy costs, and complying with utility regulations related
to power factor.

Fig.10 APFC Panel.

An Automatic Power Factor Correction (APFC) panel is an electrical device

used to improve the power factor of electrical systems. Power factor is a measure of
how effectively electrical power is being used. A low power factor indicates poor
utilization of electrical power, which can result in higher electricity bills and increased
load on the electrical infrastructure.

2.4 Ring Main Unit:

A Ring Main Unit (RMU) is a compact, sealed and metal-enclosed switchgear used
in medium voltage (MV) electrical distribution networks. It plays a crucial role in
controlling and protecting the power distribution within urban and industrial areas. The
primary purpose of a Ring Main Unit is to control and distribute electrical power in a
ring-shaped network, providing a reliable and efficient means of supplying electricity to
multiple users. RMUs typically include vacuum circuit breakers or SF6 gas-insulated
circuit breakers to interrupt the current flow in case of faults or for maintenance
purposes.

These are used for manual or automatic control of the distribution system. Load and
fault switches are common components. RMUs have busbars that connect various
incoming and outgoing circuits, facilitating the flow of electrical current within the unit.
RMUs may include relays, meters, and other devices for monitoring and protection
purposes. RMUs are housed in metal enclosures that are typically compact,
weatherproof, and designed to withstand environmental conditions, ensuring the safety
and reliability of the unit. RMUs are known for their space-saving design, making them
suitable for installations in urban areas where space is often limited.
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 The compactness is achieved by incorporating the necessary components within a
single enclosure. RMUs can be easily expanded or modified to accommodate changes
in the distribution network. This scalability is important for adapting to the evolving
power requirements of a given area. RMUs are designed for ease of installation and
maintenance. The sealed and compact design minimizes the need for extensive
maintenance, and the components are often easily accessible for inspection or
replacement when necessary.

These are commonly used in medium voltage distribution networks within urban
and industrial areas. Suitable for applications where a ring-type network topology is
preferred for enhanced reliability. Some modern RMUs may be equipped with
automation capabilities and the ability to be monitored remotely, providing enhanced
control and visibility of the distribution network. RMUs are enclosed in robust and
weatherproof metal housings, commonly made of stainless steel or aluminium, to
protect the internal components from environmental factors. Busbars are conductive
bars or strips within the RMU that carry electrical current. They connect various
incoming and outgoing circuits and ensure the flow of electricity within the unit.

Fig.11 Ring Main Unit.

RMUs incorporate circuit breakers to interrupt the electrical current in the event of a
fault or for maintenance purposes. Common types include vacuum circuit breakers or
SF6 gas-insulated circuit breakers. Load and fault switches are used for manual or
automatic control of the distribution system. Insulating materials are used to separate
conductive parts and prevent electrical arcing. SF6 gas is often used as insulation in
gas- insulated RMUs.

21
2.5 Gang Operated Device:

A Gang Operated Device (GOD), also known as a Gang Operated Switch

(GOS), is a type of electrical switchgear used in power distribution networks. These
devices are designed to simultaneously open or close multiple electrical circuits, often
used in medium and high-voltage power systems. They play a crucial role in isolating
sections of the network for maintenance, controlling power flow, and protecting the
system from faults. The core feature of these devices is their ability to operate multiple
switch contacts simultaneously, ensuring that all phases of the circuit are opened or
closed together. High- quality insulators are used to support and separate the electrical
contacts, ensuring safety and reliability in high-voltage environments.
Manual or motorized operating mechanisms are used to control the switch.
Motorized systems can be remote-controlled for convenience and safety. Devices
equipped with arcing horns help to safely manage and extinguish arcs that occur during
the opening and closing of the circuit. High-conductivity materials are used for the
contacts to ensure efficient and reliable operation. Use air as the insulating medium.
When the switch operates, the arc formed is extinguished in the air. Use a vacuum as
the insulating medium.
The arc is extinguished in a vacuum, which is very effective in medium voltage
applications. Use sulphur hexafluoride gas to extinguish the arc. These are commonly
used in high-voltage applications due to their superior arc-quenching capabilities. Used
to isolate sections of the substation for maintenance and control the flow of power
through the network. Installed on poles to control sections of overhead lines, allowing
for maintenance and fault isolation without affecting the entire network. Used to
manage the distribution of power within large industrial facilities, ensuring reliable and
safe operation of electrical equipment.
It is Used in solar and wind power installations to control and isolate different
sections of the power generation and distribution network. Provides a means to safely
isolate sections of the network, protecting maintenance personnel and preventing
accidental re-energization. Allows for better control over the power distribution
network, improving reliability and efficiency. Facilitates quick isolation of faulty
sections, reducing downtime and improving overall system availability. Motorized and
remote- control options allow for operation from a safe distance, enhancing safety and
convenience.

22
Regular inspection and maintenance are crucial for the reliable operation of gang-
operated devices. This includes checking the integrity of insulators, ensuring the proper
functioning of the operating mechanism, and verifying that contacts are clean and free
from corrosion.

Fig.12 Gang Operated Device.

23
 CHAPTER 3 :-IN-PLANT SECTION
3.1 Coal Fired IBR Boiler:

Output Steam/Hr: 5 Tons

A coal-fired IBR (Indian Boiler Regulations) boiler is a type of steam boiler that
uses coal as its fuel source and complies with the Indian Boiler Regulations, which
govern the design, construction, operation, and maintenance of boilers in India. These
boilers are commonly used in industries such as power generation, manufacturing, and
processing plants where steam is required for various processes.
The chamber where coal combustion occurs. It is designed to maximize combustion
efficiency and ensure complete burning of the coal. The surface on which coal is
burned. It can be a fixed grate, moving grate, or vibrating grate, depending on the
design and application. Devices that introduce coal and air into the furnace and ensure
proper mixing and ignition. Tubes that carry water through the furnace, where it is
heated by the combustion gases to produce steam. A cylindrical vessel where water and
steam are separated.
The steam drum collects saturated steam generated in the water tubes. A set of tubes
where saturated steam is further heated to produce superheated steam, which has a
higher temperature and energy content. A heat exchanger that preheats the feedwater
using residual heat from the flue gases, improving overall efficiency. A device that
heats the incoming air using residual heat from the flue gases, further improving
combustion efficiency. A tall structure that releases flue gases into the atmosphere,
ensuring proper draft and dispersion of exhaust gases.

Fig.13 Coal Fire IBR Boiler.

24
Working Principle:
Coal is fed into the furnace and burned on the grate. The combustion process
generates heat, which is transferred to the water tubes. Water circulated through the
tubes absorbs heat from the combustion gases, converting it into steam. The mixture of
steam and water is separated in the steam drum. The saturated steam is collected in the
drum while the water is recirculated. Saturated steam passes through the superheater
tubes, where it is heated further to produce superheated steam.
The superheated steam is used to drive turbines or for various industrial processes
requiring high-temperature steam. Flue gases pass through the economizer and air
preheater, transferring residual heat to the feedwater and combustion air, respectively.
Cooled flue gases are released through the chimney or stack into the atmosphere. Coal-
fired IBR boilers are designed to maximize fuel efficiency and steam generation. Coal
is relatively inexpensive compared to other fuels, making these boilers cost-effective for
large-scale steam production.
It is designed to handle high pressures and temperatures, ensuring reliable and
continuous operation. Adherence to Indian Boiler Regulations ensures safety,
reliability, and compliance with national standards. Coal combustion generates
significant emissions, including CO2, SO2, NOx, and particulate matter, contributing to
air pollution and climate change. Requires regular maintenance to ensure efficient and
safe operation. Components like grates, burners, and tubes need periodic inspection and
cleaning. Coal handling and storage require significant infrastructure and safety
measures to prevent hazards such as fires and explosions. Must comply with stringent
environmental regulations and emissions standards to minimize the impact on the
environment.

3.2 Effluent Treatment Plant:

An Effluent Treatment Plant (ETP) is designed to treat industrial wastewater to

ensure that it meets environmental standards before being discharged into the
environment or reused. These plants are crucial for managing the effluents generated by
industries such as pharmaceuticals, textiles, chemicals, and food processing, which can
contain harmful contaminants. Removes large solids and debris from the wastewater.
Removes sand, gravel, and other heavy particles. Balances the flow and load of
wastewater, ensuring consistent treatment.
It allows suspended solids to settle, reducing the load on subsequent treatment

25
processes. It uses microorganisms to degrade organic matter. Common methods include

26
Aerobic bacteria break down organic matter in aeration tanks. Wastewater is sprayed
over a bed of media where biofilm degrades the contaminants.
It Treats wastewater in batches, combining aeration and sedimentation in a
single tank. Removes remaining suspended solids using sand filters, membrane filters,
or other filtration methods. Kills pathogens using chlorine, ultraviolet (UV) light, or
ozone. It May include processes like activated carbon adsorption, ion exchange, or
advanced oxidation to remove specific contaminants.
Working Principle:
Wastewater is collected from the industrial facility and transported to the ETP.
Initial screening and grit removal to eliminate large particles and debris. Equalization
tank evens out fluctuations in flow and load. Sedimentation tank allows heavier solids
to settle out. Biological treatment processes degrade organic pollutants. Clarifiers
separate treated water from biological sludge. Advanced filtration and disinfection to
ensure effluent quality meets regulatory standards. Treated water is discharged to a
receiving body of water or reused within the facility.

Fig.14 Block Diagram of ETP.

Environmental Protection reduces pollution and protects aquatic ecosystems by

ensuring that discharged water meets regulatory standards. Regulatory Compliance
Helps industries comply with local, national, and international wastewater discharge
regulations. Treated water can be reused in industrial processes, reducing freshwater
consumption. Treated sludge can be used as fertilizer or energy source. Reduces the risk
of waterborne diseases by eliminating pathogens from wastewater. Reduces potential
fines and penalties associated with non-compliance. May provide cost savings through
water reuse and resource recovery.

27
3.3 Glass Lined Rector:
A Glass-Lined Reactor is a type of chemical reactor vessel used in the manufacturing of
chemicals, pharmaceuticals, and other products. It is constructed with a steel shell that
is lined with a layer of glass. The glass lining serves as a protective barrier between the
corrosive contents inside the reactor and the steel shell, offering resistance to corrosion
and ensuring product purity.
The glass lining is typically applied to both the interior surfaces of the reactor and its
accessories, such as agitators and baffles. This design is advantageous because it
combines the strength of steel with the corrosion resistance of glass. The glass lining
also provides a smooth and inert surface, reducing the risk of contamination and
facilitating easy cleaning.

Fig.15 Glass Lined Reactor.

The basic structure of a glass-lined reactor consists of a carbon steel shell with a
high-quality enamel or glass lining applied to the interior surfaces. The glass lining is
typically fused to the steel at high temperatures to ensure a strong and durable bond.
One of the primary advantages of glass-lined reactors is their excellent resistance to
corrosion from aggressive chemicals. This makes them suitable for handling corrosive
substances, acids, and other reactive materials without compromising the integrity of
the reactor.
They are used in processes that involve both high and low temperatures, making
them versatile for various chemical reactions. Glass-lined reactors often incorporate
agitators or stirrers to ensure proper mixing of the reaction components. These agitators
may have a glass-lined design as well, providing uniform mixing while maintaining
corrosion resistance.
28
3.4 Stainless-Steel Reactor:

A stainless-steel reactor is a type of chemical reactor vessel constructed primarily from

stainless steel, a corrosion-resistant alloy composed of iron, chromium, nickel, and
other elements. These reactors are utilized in a variety of industries for the processing of
chemicals, pharmaceuticals, food products, and other materials. Stainless steel reactors
are made from high-quality stainless-steel alloys, commonly grades such as 304, 316, or
316L. These alloys offer excellent corrosion resistance, mechanical strength, and
durability. The primary advantage of stainless-steel reactors is their exceptional
corrosion resistance, making them suitable for handling corrosive substances and
chemicals. This resistance is attributed to the protective oxide layer that forms on the
stainless-steel surface.

Stainless steel reactors are designed to withstand a wide range of operating

temperatures and pressures. This versatility allows them to be employed in various
processes, including those involving high-temperature reactions or high-pressure
conditions. Stainless steel reactors find applications in diverse industries such as
chemical processing, pharmaceuticals, petrochemicals, and food production. They are
utilized for both batch and continuous processes. Similar to glass-lined reactors,
stainless steel reactors often include agitators or mixing systems to ensure thorough
blending of reactants.

These agitators can vary in design based on the specific requirements of the process.
Some stainless-steel reactors feature a jacketed design, allowing for temperature control
by circulating heating or cooling fluids around the vessel. This is particularly useful for
processes that require precise temperature regulation. In industries like pharmaceuticals
and food production, stainless steel reactors are favoured for their hygienic properties.

Fig.16 Stainless Steel Reactor.

29
3.5 Sifter:
An industrial sifter is a device or machine used in various industries to separate,
classify, and sift materials based on particle size. The primary purpose of an industrial
sifter is to screen and sort granular or powdered materials, ensuring that they meet
specific size or quality requirements.
These devices are commonly employed in industries such as food processing,
pharmaceuticals, chemicals, agriculture, and manufacturing. Screening Mechanism of
Industrial sifters typically consist of a mesh or screen through which materials pass. The
mesh has openings of specific sizes, allowing particles smaller than the openings to pass
through while retaining larger particles. Sifters may employ vibratory or rotating
mechanisms to enhance the sifting process. Vibratory sifters use vibrations to move
materials through the mesh, while rotating sifters use spinning motion to achieve
separation. Some industrial sifters have multiple decks or layers of screens.
This allows for multiple stages of sifting, helping to achieve finer separation and
ensuring that the final product meets precise size specifications. Many industrial sifters
come with adjustable settings, allowing operators to customize the size of the screened
particles based on specific requirements. This flexibility is crucial for industries that
demand precise control over particle size distribution. Industrial sifters may include
features to minimize dust generation during the sifting process.
Dust containment systems are important, especially in industries like
pharmaceuticals or food processing, where cleanliness and product integrity are critical.
Good industrial sifters are designed for easy maintenance, including quick access to
screens and components for cleaning or replacement.

Fig.17 Sifter.
21
0
3.6 Centrifuge:
A centrifuge is a mechanical device that utilizes the principles of centrifugal
force to separate components of a mixture based on their density or mass. It is
widely used in various industries, including biology, chemistry, medicine, and
environmental science, for tasks such as separating particles from liquids, isolating
specific components, and analysing samples. A centrifuge typically consists of a
rotor, which can spin at high speeds, and a chamber where samples are placed. The
rotor, driven by an electric motor, rotates rapidly, creating a strong centrifugal force
that acts radially outward from the centre of rotation. Samples to be processed are
placed in specialized containers, such as tubes or buckets, which are then loaded
into the rotor. The centrifuge can accommodate multiple samples simultaneously.
When the rotor spins, centrifugal force is generated, causing the denser components
of the sample to move outward and settle at the bottom of the sample container.
The centrifuge separates components based on their density, with heavier
particles or components moving to the bottom of the container during centrifugation.
Centrifuges are used for a wide range of applications, including the separation of
blood components in medical settings, clarification of liquid suspensions, isolation
of cellular or molecular components in biological research, and various industrial
processes. Different types of centrifuges include ultracentrifuges, microcentrifuges,
refrigerated centrifuges, and high-speed centrifuges, each designed for specific
applications and sample sizes.
Centrifuges operate at various speeds depending on the type and model.
Ultracentrifuges, for example, can achieve extremely high speeds, often measured in
revolutions per minute (RPM) or relative centrifugal force (RCF). Rotors come in
different configurations, such as fixed-angle rotors and swinging-bucket rotors, each
suited for specific types of separations. Modern centrifuges often include programmable
controls for setting speed, time, and acceleration/deceleration rates.
Safety features such as lid-locking mechanisms and imbalance detection ensure safe
operation. Regular maintenance, including rotor balancing and inspection, is essential
for optimal performance and user safety. The construction of an industrial centrifuge can
vary depending on its type, application, and intended use. However, here are the general
construction details and components commonly found in industrial centrifuges:
The centrifuge is typically mounted on a sturdy frame that provides support and
stability. The housing encloses the rotor and other critical components, ensuring safety

30
and containment. The rotor is a key component that spins at high speeds, generating
centrifugal force to separate materials. Rotors come in various designs, such as fixed-
angle rotors or swinging-bucket rotors, each suitable for different applications. An
electric motor provides the driving force to rotate the rotor. The drive system may
include a variable frequency drive (VFD) to control the speed of the centrifuge.
Industrial centrifuges accommodate sample containers, which can be tubes, buckets, or
other specialized containers. These containers hold the materials to be separated during
centrifugation.
A control panel allows users to set and adjust parameters such as speed, time, and
acceleration/deceleration rates. Some centrifuges have programmable controls for
specific protocols. Centrifuges often feature controls to set the rotational speed in
revolutions per minute (RPM) or relative centrifugal force (RCF). Acceleration and
deceleration rates can be adjusted to prevent sample disruption during start-up and stop.
In some industrial centrifuges, especially those used for temperature-sensitive
applications, a cooling system may be included to maintain a low temperature during
operation.
Many centrifuges have a lid-locking mechanism to ensure that the lid remains
securely closed during operation, enhancing user safety. Modern industrial centrifuges
incorporate safety features such as imbalance detection, emergency lid-lock release, and
automatic rotor recognition systems. Centrifuge components, including the rotor,
housing, and sample containers, are often made from materials such as stainless steel or
other corrosion-resistant alloys.

Fig.18 Centrifuge

31
3.7 Blender:
An industrial blender, also known as an industrial mixer or food processor, is a
heavy-duty machine designed for large-scale blending, mixing, and processing of
ingredients in industrial and commercial settings. These robust appliances are capable
of handling significant quantities of materials, making them suitable for industries such
as food processing, pharmaceuticals, chemicals, and manufacturing. Here's a brief
description of an industrial blender.
Industrial blenders are constructed with durable materials, often stainless steel,
to withstand the rigors of continuous use in industrial environments. This ensures
resistance to corrosion and easy cleaning. Equipped with a powerful motor, industrial
blenders have high horsepower to handle large volumes and process dense or
challenging materials. The motor is designed for extended and continuous operation.
The blending chamber, typically larger than that of a domestic blender, can range from
several litres to hundreds of litres in capacity. It accommodates substantial quantities of
raw materials for processing.
Industrial blenders feature robust blade assemblies designed for efficient mixing
and blending of various materials. Blades may come in different shapes and
configurations depending on the intended application. The control panel of an industrial
blender often includes advanced features for precise control of speed, time, and
blending parameters. Some models may have programmable settings and automation
for consistent results. Industrial blenders are equipped with safety features, including
emergency stops, overload protection, and interlocking systems to prevent accidents
during operation. Industrial blenders are versatile and can handle a wide range of
materials, including dry powders, granules, liquids, and pastes. They are used for tasks
such as blending, mixing, emulsifying, and homogenizing.

Fig.19 Industrial Blender

32
 The construction details of an industrial blender can vary based on the specific
design, purpose, and manufacturer. However, here are general components and features
commonly found in the construction of industrial blenders. The frame provides
structural support for the entire blender, and the housing encloses the internal
components. Both are typically made of durable materials such as stainless steel to
ensure stability and longevity. Industrial blenders are equipped with powerful electric
motors, often with high horsepower, capable of handling heavy loads and continuous
operation. Motors are designed for durability and efficiency. The mixing chamber is the
container where ingredients are blended. It can vary in size and shape based on the
blender's design and intended application.
Chambers are commonly made of stainless steel for hygiene and corrosion
resistance. The blender's lid covers the mixing chamber during operation, preventing
splashing and ensuring safety. It may have a secure locking mechanism to prevent
accidental opening. Industrial blenders feature a robust blade assembly designed for
efficient mixing. Blades can have different shapes and configurations depending on the
type of blending required, such as ribbon blades, paddle blades, or auger blades. High-
quality seals and bearings are crucial for preventing leaks and ensuring smooth
operation. These components are often designed to withstand the challenging conditions
of industrial use. It's important to note that the specific construction details of industrial
blenders can vary widely based on the manufacturer and the intended application. Users
should refer to the equipment's manual and specifications for detailed information and
guidelines on usage and maintenance.

Fig.20 Construction of Industrial Blender

33
3.8 Roto-Cone Vacuum Dryer:

A Roto-Cone Vacuum Dryer is a specialized drying equipment used in various

industries for the drying of heat-sensitive materials, pharmaceuticals, chemicals, and
other products that require gentle and efficient drying under vacuum conditions. The
Roto-Cone Vacuum Dryer is designed as a conical-shaped vessel that rotates on its axis,
resembling the shape of a cone. This design facilitates efficient mixing and drying of
materials. The vessel is typically constructed from stainless steel or other materials that
offer corrosion resistance and durability, meeting the stringent requirements of
industries like pharmaceuticals.
The conical vessel rotates on its axis, allowing for effective mixing and tumbling of
the material being dried. This rotation exposes a large surface area of the product to the
heated walls, promoting uniform drying. The Roto-Cone Vacuum Dryer is equipped
with a vacuum system that enables drying under reduced pressure. This helps in
lowering the boiling point of moisture, facilitating gentle and faster drying at lower
temperatures. The vessel is heated either through the walls of the cone or by using an
external jacket, depending on the design. Heating mediums such as steam or hot water
are circulated to provide the necessary heat for drying. To remove evaporated moisture
from the vacuum, a condenser is employed.
The condenser converts the vapor back into liquid form, allowing it to be collected
and removed from the system. The Roto-Cone Vacuum Dryer operates on the principle
of indirect heating. The material is loaded into the cone, and as it rotates, the heated
surface of the vessel comes into contact with the material, evaporating the moisture.

Fig.21 Roto-Cone Vacuum Dryer

34
 CHAPTER 4:- INDUSTRIAL AUTOMATION

4.1 Supervisory Control and Data Acquisition System:

The SCADA system, also known as the Supervisory Control and Data
Acquisition system, is a crucial technology in industrial automation and control.
Provides a graphical interface for operators to monitor and interact with the system.
Displays real-time data, alerts, and system status. Central system that gathers and
processes data from remote units. Typically includes servers and software for data
analysis and decision-making. Devices located at remote sites to collect data and
execute control commands. Interface with sensors and actuators to gather data and
control processes. Industrial digital computers used for automation of electromechanical
processes. Can be programmed to perform specific tasks and are highly reliable.
Network of communication channels, including wired and wireless methods, to
connect RTUs, PLCs, and the supervisory system. Ensures data is transmitted
accurately and reliably across the system. It Collects data from sensors and instruments
at remote sites. Includes parameters like temperature, pressure, flow rates, etc. Transfers
collected data from remote sites to the central supervisory system. Utilizes various
communication protocols and networks.
It analyses and processes the acquired data to generate meaningful information.
Includes trend analysis, anomaly detection, and performance monitoring. Sends control
commands to remote units to manage industrial processes. Includes starting/stopping
machinery, adjusting settings, and managing operations. Provides real-time
visualization of process data through the HMI.

Fig.22 Interface of SCADA System.

35
4.2 Programmable Logic Controllers:

Programmable Logic Controllers (PLCs) are digital computers used for

automation of industrial processes, such as control of machinery on factory assembly
lines, amusement rides, or light fixtures. The brain of the PLC, executing control
instructions contained in the PLC’s program. Manages communication with other parts
of the PLC and external devices. Stores the PLC’s program, operational data, and
system parameters.
It Includes non-volatile memory for program retention and volatile memory for
operational data. Interfaces with external devices, such as sensors and actuators. Input
modules receive signals from field devices and convert them into a form the CPU can
process. Output modules send control signals from the CPU to field devices. Provides
the necessary power for the CPU, memory, and I/O modules.
It Ensures stable and reliable operation of the PLC. Enable the PLC to
communicate with other PLCs, supervisory systems, and external devices. Supports
various communication protocols such as Ethernet, Modbus, Profibus, etc.

Fig.23 Block Diagram of PLC

It executes programmed logic sequences to control industrial processes. Includes

functions such as AND, OR, NOT, timers, and counters. Manages operations that must
occur in a specific sequence. Common in batch processing, assembly lines, and
packaging operations. Implements Proportional-Integral-Derivative (PID) control
algorithms. Used for precise control of process variables like temperature, pressure, and
flow rate.
36
 It performs data manipulation tasks such as math operations, data comparison, and
data conversion. Facilitates complex control strategies and data analysis. Exchanges
data with other systems and devices. Enables integration with SCADA systems, HMIs,
and other automation components. Designed to operate in harsh industrial
environments. High tolerance for electrical noise, temperature variations, and
mechanical vibrations. Easily reprogrammed to accommodate changes in the control
process. Modular design allows for expansion and customization of I/O modules.
Provides diagnostic tools and status indicators for easy fault detection.
It Simplifies maintenance with modular components and standardized
programming languages. Reduces wiring and installation costs compared to traditional
relay-based control systems. Lower operational and maintenance costs due to enhanced
reliability and ease of use. Controls machinery, production lines, and robotic systems.
Ensures efficient and precise manufacturing processes. Manages continuous processes
in industries such as chemical, oil and gas, and pharmaceuticals.
It ensures consistent product quality and process efficiency. Automates building
management systems, water treatment plants, and electrical grids. Enhances operational
efficiency and reliability of infrastructure systems. Controls assembly lines, painting
processes, and quality inspection systems. Improves production speed and product
quality in automotive manufacturing. Automates processing, packaging, and quality
control in food and beverage production.
It ensures compliance with hygiene and safety standards. Resembles electrical relay
logic diagrams. Widely used due to its simplicity and ease of understanding. Uses
blocks to represent functions and data flow. Suitable for complex control algorithms
and process control applications. High-level programming language similar to Pascal.
Suitable for complex mathematical calculations and data handling. Graphical
programming language for sequential control. Suitable for batch processing and
sequential operations.

37
 CHAPTER 5:- SAFETY

5.1 Types of Fire Extinguishers:

The types of fire extinguishers are as follows;
1. Dry Powder Extinguishers:
Powder fire extinguishers are used for fighting burning solids, liquids
and gases (Class A, B and C fires). Specialist powder extinguishers are designed
to tackle type D fires involving combustible metals such as lithium, magnesium,
or aluminium. They work by the powder forming a crust which smothers the fire
and stops it from spreading. Disadvantages is that the powder does not soak into
materials and does not have an effective cooling effect on the fire, which can
result in the fire reigniting.
The powder is hazardous if inhaled, so they should be used in well-
ventilated areas and are not suitable for offices and domestic premises. The
powder damages soft furnishings, machinery, etc, and needs a lot of cleaning up
after use. They cannot be used on chip pan fires (Class F).
2. CO2 Extinguishers:
These contain only pressurised carbon dioxide gas and therefore leave no
residue. Carbon Dioxide (CO2) extinguishers are used on fires involving
burning liquids (Class B), and electrical fires, such as of large computer
equipment, so are practical in offices. CO2 works by suffocating the fire and
does not cause damage to the electrical items or cause the system to short
circuit.
However, CO2 extinguishers get very cold during discharge, and those
that are not fitted with double-lined, frost-free swivel horns may cause fingers to
freeze to the horn during deployment. the strong jet from the extinguisher can
carry the burning fat out of the fryer. Fires can quickly re-ignite once the CO2
has dissipated into the atmosphere, so they do not offer post-fire security.
3. Wet Chemical Extinguishers:
These are the only extinguishers apart from water mist suitable for Class
F oil fires (fats and cooking oils) and are mainly used in kitchens with deep fat
fryers. They can also be used on Class A and some can be used on Class B fires.
They consist of a pressurised solution of alkali salts in water, which, when
operated, creates a fine mist, cooling the flames and preventing splashing.

38
4. Water fire Extinguishers:
Water extinguishers are only used for Class A fires. Therefore, red coded
extinguishers can be used to tackle fires caused by ignited paper, wood, straw,
coal, rubber, solid plastics and soft furnishings. Water fire extinguishers work
by spraying water from the spray nozzle, which helps to cover larger surface
area. Water extinguishers are the easiest to maintain variety and the least
hazardous, since they only contain water. They cool the fire by soaking it and
the materials with water. This extinguishes the flames, absorbing heat from
burning objects.
5. Foam Extinguishers:
The foam smothers the fire in solids and liquids (Class A and B), but not in
burning fats or cooking oils (Class F), so foam fire extinguishers are used on
burning liquids such as petrol, paint or turpentine. A foam extinguisher can
also be used on some electrical fires if they have been tested and if fired from
1 metre away. However, they leave a residue that has to be cleaned up, and they
are more expensive than water extinguishers.

Fig.24 Classes of Extinguishers.

39
5.2 How to use Fire Extinguishers?
Fire extinguishers should ideally only be used by someone who has been trained
to do so and the following text does not count as training. Moreover, a fire extinguisher
should only be activated once the fire alarm has been triggered and you have identified
a safe evacuation route. Evacuate the building immediately if you still feel unsure about
using a fire extinguisher or if doing so is clearly the safest option.
The following order needs to be memorised while using an extinguisher;
1. Pull: Pull the pin to break the tamper seal.
2. Aim: Aim low, pointing the nozzle or hose at the base of the fire. (Do not touch
the horn on a CO2 extinguisher since it becomes very cold and can damage skin.
3. Squeeze: Squeeze the handle to release the extinguishing agent.
4. Sweep: Sweep from side to side at the base of the fire – the fuel source – until
the fire is extinguished.
Fire Blankets, Hoses and Buckets:
These methods of fire extinction are useful additions to extinguishers.
Fire buckets can be used filled with water on Class A fires, or with sand to use as an
absorbing agent for Class B fires, which are spilled flammable liquids. They must not
be used with water on burning fat or oil or on electrical appliances. However, they’re
sometimes left empty or misused and have a limited effect as they can’t use on large
fires. Fire hoses let out water at high pressure. They can be effective on Class A fires,
but are very heavy.

Fig.25 Operation of Fire Extinguisher.

40
5.3 Other safety equipment:
1. Safety Helmet:
Safety helmets are an essential piece of personal protective equipment
(PPE) that is designed to protect the wearer from head injuries caused by falling
objects, impact with stationary objects, or electrical hazards. However, not all
safety helmets are created equal. To ensure proper protection, safety helmets
must meet specific standards and regulations that govern their design, materials,
and performance.
The inner lining of the helmet also plays a crucial role in protecting the
wearer's head from impacts. The liner absorbs the energy generated by an
impact and distributes it across the helmet's surface area, reducing the force
experienced by the wearer's head.

Fig.26 Safety Helmet.

2. Safety Goggles:
Safety goggles are tight-fitting eye protection that completely cover the
eyes, eye sockets and the facial area around the eyes and provide protection
from impact, dust, mists, and splashes. Safety goggles can be worn over
prescription lenses.
Safety goggles are available with perforated, port-vented, or non-vented
frames. Safety goggles should be worn when working with liquids that may
splash or if vapor or airborne particulate protection is required.

Fig.27 Safety Goggles.

41
3. Rubber Gloves:
Safety Gloves are worn in thousands of work environments across the
world, in diverse settings such as bakeries, hospitals and building sites. Put
simply, safety gloves are protective garments that offer protection to your hands,
fingers, thumbs and wrists against particular external forces, chemicals,
elements and hazards in the workplace.

Fig.28 Safety Gloves.

4. Safety Shoes:
Safety shoes are a type of footwear that is designed to protect your feet from
potential hazards. They typically have a steel toe cap, which helps to protect your
toes from being crushed or injured. Safety shoes can also provide foot protection
from other dangers such as sharp objects or chemicals.

5. S.C.B.A:
A self-contained breathing apparatus (SCBA) is a device worn to provide
breathable air in environments with oxygen deficiency, smoke, dangerous gases,
and other airborne contaminants that may be otherwise dangerous to breathe.
Workers handling hazardous materials or operating in contaminated zones are
typically required to wear a self-contained breathing apparatus.
Only positive-pressure SCBAs are recommended for entry into atmospheres that
are immediately dangerous to life and health (IDLH). An SCBA typically consists
of a facemask with a hose that connects to an air source worn by the user. The air
source can be a tank of compressed air, compressed oxygen, or an oxygen-
generating chemical.

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 Fig.29 S.C.B. A Kit.

6. Hydrant Pump:
Fire Hydrant Pump systems (also known as fire pumps, hydrant boosters, or fire
water pumps) are used to increase a building's firefighting capacity by increasing
the pressure in the hydrant service when the mains pressure is insufficient or the
hydrant is tank fed. Pumps like this can also be used for irrigation and water
transmission. A fire sprinkler system's fire pump allows high-pressure water to enter
the system, allowing the water flow rate to be raised. When there is insufficient
water supply, a fire pump is required to meet the flow and pressure needs of fire
suppression systems. A fire pump is necessary if the supply cannot keep up with the
demand. On the other hand, a fire pump isn't necessary if the water supply meets the
required pressure and flow.
It consists of a diesel pump, main pump and jockey pump. The diesel pump is
used as a backup system during the time when there is no electricity supply present.
The main pump is mainly used.

Fig.30 Fire Hydrant System

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 CONCLUSION
In conclusion, my 15-day training at MSEDCL and remaining 15-day industrial
training at Anshul Speciality Molecules Pvt. Ltd. has been a transformative and
enlightening experience. Throughout this period, I have had the privilege of immersing
myself in the daily operations of a dynamic and forward-thinking organization, gaining
practical insights that complement my academic knowledge.
The training provided me with a comprehensive understanding of the Electrical
Engineering sector, allowing me to witness firsthand the application of theoretical
concepts in a real-world context. Engaging with experienced professionals and mentors
has been instrumental in broadening my perspective and enhancing my skill set.
Anshul Speciality Molecules Pvt. Ltd. stands out for its commitment to excellence,
innovation, and a collaborative work culture. The team's dedication to their respective
roles and the seamless coordination across departments have been inspiring. I am
grateful for the opportunities to contribute to meaningful projects and learn from
seasoned experts who willingly shared their knowledge.
The exposure to electrical wiring, motor and starter operation and many more has
not only deepened my understanding but has also sparked a keen interest in further
exploration and specialization within this field. The practical experience gained during
this training will undoubtedly serve as a solid foundation for my academic pursuits and
future career aspirations.

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