Documente Academic
Documente Profesional
Documente Cultură
APPROVED
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(MR.KAMAL JOSHI)
CHECKED
BY:
..........................................
(MR.SACHIN SHUKLA)
Acknowledgement
This industrial training was a big eye opener for us prospective engineering professionals aiming to gain
knowledge about a mega production plant and this would not have been possible if we did not have support of
many individuals. Therefore we would like to extend our sincere gratitude to all of them.
The internship opportunity we had with HONDA CARS INDIA Ltd. was a great chance for learning and
professional development. Therefore, we consider ourselves very lucky individuals as we were provided with an
opportunity to be a part of it.
We are using this opportunity to express our deepest gratitude and special thanks to Mr. Kamal Joshi ( H.O.DUtility), Mr. Raj Kumar Paliwal (Manager-Utility), Mr. Sachin Shukla, Utility Dept. who took time out to hear,
guide us during our training.
We express our deepest thanks to Mr. Gaurav Mathur, Utility Dept. for giving necessary advices and guidance
and arranged all facilities to make our lives & access to different departments a lot easier.
We also express our deepest thanks to Mr. Chandan Bhatia & Mr. Anshul Aggarwal , Utility Dept. for entrusting
us with a project and providing any kinds of help or resources regarding the project.
Last but not the least we would like to thank every department, engineer and operator who let us in and took out
time from their busy schedules to provide valuable knowledge to us students.
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List of Contests
1. Abstract...................................................................................................04
2. HCIL-Brief Profile..................................................................................05
3. Utility Department..................................................................................05
Compressor House.........................................................................06
Diesel Generator House.................................................................08
132 KV Switch House & Substations...........................................10
Fire Pump House...........................................................................14
Water Treatment Plant..................................................................15
Waste Water Treatment Plant.......................................................17
Yards.............................................................................................19
4. Project Undertaken.................................................................................20
5. A/F Shop.................................................................................................22
6. PA System...............................................................................................24
7. PO Shop...................................................................................................25
8. POPA Shop..............................................................................................26
9. SPC Shop.................................................................................................27
10. Press Shop..............................................................................................28
11. Conclusion..............................................................................................30
12. Bibliography............................................................................................31
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Abstract
As we mentioned earlier that our main purpose for this internship/ industrial training was to gain knowledge and
get perspective regarding the operation of a mega production facility. Our wishes were more than answered
when HONDA CARS INDIA Ltd. provided us with an opportunity like this to intern at the Tapukara plant. This
internship has been really an eye opener for us all. We were placed in the Utility dept. and primarily toured all
the sub divisions coming under them. Utility dept. was responsible for mainly running and aiding the plant
behind the scenes. It provided and helped in maintenance of the 4 major industrial utilities i.e. electricity, water,
natural gas & air. Utility dept. does not manufacture any vehicle but without their aid & behind the scenes hard
work even manufacturing dept. can do nothing. We also had the great opportunity to observe different
departments other than the Utility. It was the first time that we had seen a mega factory up close & personal. One
thing which struck us was that how such a giant manufacturing plant operates, it is so huge that it has several
departments some of which functions individually as a small autonomous unit itself. Each dept. can have many
sections as well, in order to manage them there are section heads and above them there is a consolidated head
called the Head of Dept. (H.O.D) . A plant this big is like an enlarged machine which has individual intelligent
parts which function individually and together to create a final product i.e. a HONDA car.
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Utility Department
Utility dept. as we mentioned earlier is the dept. responsible for maintaining & supplying water, electricity,
natural gas & air to the plant where they are utilized in production. The 4 major utilities in industry are
electricity, water, natural gas & air. Without the utilities a plant cannot produce because it's the key component
on which all the machines and tools operate which are then used to convert raw material into finished goods. The
utility dept. has different kinds of treatment plants, substations, switch house, compressor houses, diesel
generator house etc. Basically it deals with energy and its different forms. It's like the fuel that is required to run
a machine, in this case utility dept. is the fuel & the whole plant is the machine.
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Compressor House
Definition: By definition a compressor house is that area of the plant that supplies clean and dry compressed air
to different departments in the plant for further use. There are namely two compressor houses in the Honda plant,
they are compressor house-1 & compressor house-2.
Importance & Uses of Compressed Air: Compressed air, commonly called Industry's Fourth Utility, is air that is
condensed and contained at a pressure that is greater than the atmosphere. The process takes a given mass of air,
which occupies a given volume of space, and reduces it into a smaller space. In that space, greater air mass
produces greater pressure.
Industrial Plant Maintenance: Air tools, such as paving breakers, are used to fix cement floors, to open up brick
walls for assorted service lines, and other comparable work.
For other maintenance work, plants can use air-operated drills, screwdrivers, and wrenches, provided that the air
outlets are well placed throughout the plant. Painting can be done using paint-spraying systems.
On the Production Line: Pneumatic tools are convenient for industrial production because they have a low
weight-to-power ratio, and they may be used for long periods of time without overheating and with low
maintenance costs. Chipping and scaling hammers are used in railroads, oil refineries, chemical refineries,
shipyards, and many other industries for general application. They are also used in the foundry for cleaning large
castings, and to remove weld scale, rust, and paint in other industries.
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Pneumatic drills can be used for all classes of reaming, tapping, and drilling anytime that the work cannot easily
be carried to the drill press and for all classes of breast drill work. These air-powered drills are also often used
for operating special boring bars, and in emergencies, for independent drive of a machine tool where required
horsepower is within their capacity.
Different tools running on compressed air like impact wrench, air ratchet & pneumatic paint sprayer.
(source: www.indiamart.com)
List of Compressors: There are 6 compressors in compressor house-1 & general pressure requirement is around
6.5 bar. There are 3 compressors in compressor house-2 & general pressure requirement is around 5.5 bar.
Compressors from 2 companies are employed in the plant, they are Atlas Copco & Ingersoll Rand. All Atlas
Copco compressors are screw type & are needed where the pressure requirement is high. All Ingersoll Rand
compressors are Centrifugal type & are needed where higher amount of air is required. Following is the list of
compressors employed at the plant.
Compressor House-1
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Compressor Type
Atlas Copco
Screw
Atlas Copco
Screw
7.5 bar
8.6 bar
8.6 bar
Atlas Copco
Screw
8.6 bar
Atlas Copco
Screw
Atlas Copco
Screw
Ingersoll Rand
Centrifugal
8.6 bar
6.5 bar
Compressor House-2
Maximum Air Pressure
Manufacturer
Compressor Type
Atlas Copco
Screw
8.6 bar
6.5 bar
Ingersoll Rand
Centrifugal
6.5 bar
Ingersoll Rand
Centrifugal
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The last genset present is the genset from MAN. It's large genset that is capable of producing 2.5 MW. It's a
pneumatic or air starter generator. Compared to a gasoline ("petrol") engine, diesel engines have very
high compression ratios to improve engine efficiency. An electric starter powerful enough to turn a large diesel
engine would itself be so large as to be impractical, thus the need for an alternative system. When starting the
engine, compressed air is admitted to whichever cylinder has a piston just over top dead centre, forcing it
downward. As the engine starts to turn, the air-start valve on the next cylinder in line opens to continue the
rotation. As this goes on, fuel is injected into the cylinders, the engine is then under way and the air is cut off.
This genset can run on diesel as well as on furnace oil. It's a low speed engines with speed ranging around 750
rpm.
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Interior of a substation consisting distribution and controlling panels or altering various parameters (source:
www.blackburn-starling.co.uk)
Types of Substations in Plant:
Transformer sub-stations, sub-stations which change the voltage level of electric supply are called transformer
sub-stations. These sub-stations receive power at some voltage and deliver it at some other voltage. Obviously,
transformer will be the main component in such sub-stations. Most of the sub-stations in the power system are of
this type.
Switching sub-stations, sub-stations that do not change the voltage level i.e. incoming and outgoing lines have
the same voltage. However, they simply perform the switching operations of power lines.
Different Components of Substation
a) Lightening Arrestors: Lightening arrestors are the instruments that are used in the incoming feeders so that to
prevent the high voltage entering the main station. This high voltage is very dangerous to the instruments used in
the substation. Even the instruments are very costly, so to prevent any damage lightening arrestors are used. The
lightening arrestors do not let the lightening to fall on the station. If some lightening occurs the arrestors pull the
lightening and ground it to the earth. In any substation the main important is of protection which is firstly done
by these lightening arrestors.
The lightening arrestors are grounded to the earth so that it can pull the lightening to the ground.
c) Capacitor Voltage Transformer (CVT): A capacitor voltage transformer (CVT) is a transformer used in power
systems to step-down extra high voltage signals and provide low voltage signals either for measurement or to
operate a protective relay.
d) Isolators with Earth Switches (ES):Isolators are the no load switches and used to isolate the equipment.
(Either line equipment, power transformer equipment or power transformer). With the isolators, we are able to
see the isolation of the equipment with our naked eye. The line isolators are used to isolate the high voltage from
flow through the line into the bus. This isolator prevents the instruments to get damaged. It also allows the only
needed voltage and rest is earthed by itself.
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g) Circuit Breaker: The circuit breakers are used to break the circuit if any fault occurs in any of the instrument.
These circuit breaker breaks for a fault which can damage other instrument in the station. For any unwanted fault
over the station we need to break the line current.
This is only done automatically by the circuit breaker. These are load switches. It is able to make or break the
normal load current as well as the fault currents.
Types of Circuit Breakers used in Plant
1)Natural air (called air circuit breakers-ACB) (415v)
2)Vacuum (called vacuum circuit breaker-VCB)
3)SF6 gas (called Sulphur Hexafluoride-SF6 gas CB)
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Pump Name
Jockey 1
17.1 m^3/hr
Jockey 2
16.3 m^3/hr
Main Pump 1
273 m^3/hr
Main Pump 2
273m^3/hr
Main Pump 3
410 m^3/hr
D.G Pump 1
273 m^3/hr
D.G Pump 2
410 m^3/hr
GROUND WATER
FIRE TANK
D.M.F
(OVERFLOW
TANK)
(DUAL MEDIA
FILTER)
TREATED
WATER
FLOURIDE
FILTER
TANK
b) Water softening: It's a process which decreases the hardness of the treated water to a value that is permit able
for use in the plant.
TREATED
WATER TANK
WATER
SOFTENER TANK
SOFT WATER
HARDNESS: 2PPM
BRINE
SOLUTION
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c) U.V treatment: It's a process in which treated water is passed through U.V (ultra violet) filters so that harmful
bacteria present in water are eliminated and the water becomes fit for drinking.
TREATED
WATER TANK
U.V (ULTRA
VIOLET)/
CANDLE FILTERS
d) R.O(Reverse Osmosis) treatment: It's a water purification technology that uses a semi-permeable membrane
to remove large particles from water. In the plant it's used to alter conductivity of water according to the
requirement.
TREATED
RO TREATED WATER
RO-1
CONDUCTIVTY<10
WATER
TANK
ANTISCALANT, PH
BOOSTER, HCl
RO TREATED WATER
RO-2
CONDUCTIVTY>40
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MANUAL
BAR
SCREENING
E.D.
CATCH PIT
E.D
EQUALISATION
TANK
D.A.F (DISSOLVED
AIR FLOATATION)
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EMULSION
BREAK TANK
b) Biological Process: a mechanical biological treatment system is a type of waste processing facility that uses
micro/ biological organisms to treat water for harmful bacteria, foul smell etc. which can't be done using
traditional chemical processes.
FLOCULATION
REACTION
TANK
TANK
FROM BREAK
AERATION
CLARIFIER
FILTER
TANK
TANK
TANK
FEED TANK
TO
GARDENING
&
DISCHARGE
FLUSHING
TANK
COAT
FORMING
C.F
REACTION
TANK
TANK
SAND
FILTER
FLOCULATION
TANK
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BREAK TANK
A.C.F (ACTIVATED
CARBON FILTER)
TUBE
SETTLER
Yards
Definition: Yards are the storage areas which contain different gases, fuels etc. that are required for general
operation of the plant.
Name
Propane Yard
Ammonia Yard
H.S.O (High speed
diesel)
Furnace Oil
Nitrogen & Argon
Yard
Number of
Bullets/Tanks
2
Capacity
Application
2
2
10 MT X 2
50 Kl X 2
1
2
200 Kl
19.41 CUM
5.45 CUM
50 MT X 2
b) Remote operated valve or R.O.V is a valve which can be operated pneumatically and electrically.
c) Vaporisers are present to create vapours artificially inside the bullets when they are not present naturally.
d) Pressure transmitter is a device that transmits a signal when the pressure drops below a certain working range.
e) Safety relief valve is a valve which opens when the pressure increases beyond a certain value.
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SPECIAL HAZARD
ALKALINE
ACIDIC
CORROSIVE
OXIDISING
RADIOACTIVE
REACTS
VIOLENTLY WITH
WATER
REACTS
VIOLENTLY WITH
WATER & OXIDISES
MSDS LABEL
CHEMICAL NAME:
C
A
RATING NUMBER
4
HEALTH HAZARD
(B)
CAN BE LETHAL
FLAMMABILITY
HAZARD (C)
WILL VAPORIZE
AND BURN AT
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INSTABILITY
HAZARD (D)
MAY EXPLODE AT
NORMAL
CAN CAUSE
SERIOUS OR
PERMANENT
INJURY
CAN CAUSE
TEMPORARY
INJURY
CAN CAUSE
SIGNIFICANT
IRRITATION
NO HAZARD
NORMAL
TEMPERATURES
CAN BE IGNITED
UNDER ALMOST
ALLAMBIENT
TEMPERATURE
MUST BE HEATED
OR HIGH AMBIENT
TEMPERATURE TO
BURN
MUST BE
PREHEATED
BEFORE IGNITION
CAN OCCUR
WILL NOT BURN
TEMPERATURE OR
PRESSURE
MAY EXPLODE AT
HIGH
TEMPERATURE OR
SHOCK
VIOLENT
CHEMICAL
CHANGE AT HIGH
TEMPERATURE OR
PRESSURE
NORMALLY
STABLE. HIGH
TEMPERATURE
MAKES UNSTABLE
STABLE
PERSONAL
PROTECTIV
E
EQUIPMENT
WIRING
INTERIOR
CHASSIS
EXTERIOR
VEHICLE
ZONE
ZONE
LINE
ZONE
QUALITY
a)Wiring zone: The complete vehicle wiring is done in wiring zone. The wiring for tail amps, headlamps
and dashboard circuiting is done in this zone.
b)Interior zone: The floor and ceiling matting, instrument panel is installed in the interior
zone.
c)Chassis line: It is a critical line and conveyors are fast moving in this line or this line engine docking,
suspension mounting, breaks installation is done.
d)Exterior zone: wheels from the wheel subassembly come through conveyors and are installed on the
vehicle. A final inspection of the vehicle is being done and electrical corrections checked. After this the
vehicle is sent to vehicle quality.
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The base coat is applied after the primer coat. This coat contains the visual properties of colour and effects, and
is usually the one referred to as the paint. Usually sprayed on top of a coloured basecoat, clear coat is a glossy
and transparent coating that forms the final interface with the environment. For this reason, clear coat must be
durable enough to resist abrasion and chemically stable enough to withstand UV light. When the painting
process is completed the bumper goes through a polishing zone and it's also cured under the ultra violet lights
also called the zebra checking point. The completely finished bumpers are then sent to operators for attaching the
font grills and headlights( tail lights in case of rear bumper ). The finished part i.e. the front end or rear end is
then sent to the assembly frame shop.
Spin Casting
Definition: Casting is a manufacturing process by which a liquid material is usually poured into a mould, which
contains a hollow cavity of the desired shape, and then allowed to solidify. The solidified part is also known as a
casting, which is ejected or broken out of the mould to complete the process.
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Spin casting: Spin casting is a special casting technique which uses centrifugal force to produce hollow casting.
Due to the centrifugal force involved no core is required in this process which makes it very convenient and
advantageous.
Process: Metal (or alloy) to be casted is melted in a furnace by heating it to the required temperature (12001500C) and this molten metal is the passed to the holding furnace. A permanent mould is rotated continuously
about its axis at high speeds (1000-1500 rpm) as the molten metal is poured. The molten metal is centrifugally
thrown towards the inside mould wall, where it solidifies after cooling. The casting is usually a fine-grained
casting with a very fine-grained outer diameter, owing to chilling against the mould surface. After the process is
complete, we obtain 1 long tube which is passed through shot blast in which the surface impurities are removed
by small steel shots bombarded on the surface of the tube. This tube is then passed through a CNC cutting
machine which is programmed for cutting is into the desired no. Of cylinder liners (14 in case of petrol and 12 in
case of diesel engine).
After the desired length is obtained these liners are finish machined which involves boring and chamfering. The
process is concluded with quality inspection which involves inspection for any deformity, defects and
dimensional accuracy. The manufactured cylinder liners are then sent to engine assembly for installation.
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Press Shop
Definition: A forming press, commonly shortened to press, is a machine tool that changes the shape of a work
piece by the application of pressure. Presses can be classified on various parameters for example, according to
their mechanism: hydraulic, mechanical, pneumatic etc.
Operation: There are 2 types of press machines are being used in plant. One is mechanically operated and other
is servo motor operated. The output is measured in strokes per minute or SPM. the mechanical press has 9 SPM
& servo operated press has 11 SPM. The production of a vehicle begins in the press shop, where sheet metal is
integrated into the manufacturing process and the first shapes of the later vehicle are created.
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a)Mechanical Press: As the name suggests, a mechanical press's ram is run by reciprocating pistons which
controlled via clutches.
SHEET
METAL
DRAWING
CUTTING
PRESSURE:1500 TONNE
FINISHED
DOOR
PANEL
PIERCING
BENDING
b)Servo Operated Press: As the name suggests, a servo operated press's ram is controlled and run by servo motor
which is nothing but an electric motor with reduction gears. It uses a feedback mechanism in order to control
precisely timed repetitive automatic tasks.
SHEET
METAL
DRAWING
CUTTING
PRESSURE: 1000
TONNE
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Conclusion
This internship was a great opportunity for us engineering students & we again would like to thank HONDA for
providing this to us. As we have mentioned earlier our main purpose coming here was to gain experience, get a
feel how a large manufacturing plant operates, what is the code of conduct etc. It's safe to say that our
expectations were blown away, coming here we realized how much hard work and their precise management is
required to run the plant round the clock. For a layman it must be difficult to comprehend how this plant works
but being here we realized it's possible because every employee from each department does his/her designated
task efficiently in shortest possible without compromising on quality. We were placed in the Utility department,
in simple terms we can say that Utility department is the fuel if this plant is a machine & a HONDA vehicle is
finished product. Utility department doesn't aid in production of vehicles directly but supplies the other
department that are directly involved in production with the resources that are critically needed for the
completion of their task. Our time at HONDA was a great learning experience for us & we hope we can apply
some knowledge in our future workplaces.
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Bibliography
www.google.com
www.wikipedia.com
www.academia.edu
www.electrical4u.com
www.jameco.com
www.daifukuna.com
www.asme.org
www.a4mods.com
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