ESS ESS KAY CO. LTD.

Post Box no-8, Factory area, Kapurthala (ISO 9001:2000)

Submitted by: SAVYASACHI 90210718927 B.Tech, EEE 2009 - 2013

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Six Months Industrial Training Report

Dec. -- May

INTRODUCTION TO COMPANY

MAIN DEPARTMENTS
Sheet metal shop Paint shop Electroplating shop Moulding shop Switchgear assembly Shop Panel shop Quality assurance department/Test Labs

SHEET METAL SHOP/DEPARTMENT

C.R.C.A sheet (ESSAR STEEL INDIA LTD.) (60 sheets, Wt. 2.8MT,(2/1.5*1250*2500mm) Shearing Machine(Mechanical cutter) (HH, 415V, 6200kg,6mm,3,working area 3100mm) Bending machine (HH,415V,8700kg,6mm,w.a.3100mm,10 ton, DELEM) (AMADA,5100kg,w.a.2505mm,80 ton) Punching machine (VIPROS 225,9800kg,50-60hz,196KN,27kva) (HH, 3,9000kg,2000KN,415V,3.8A,DELEM)

 Welding machine
(Sunrise , Spot/Projection,pf-0.4,415V,50hz,3,1.5litre) (MIG welding, copper electrode) (Gas welding, O2,Acetylene)

Drilling machine (Sunrise,pf-0.6,415V,50-60hz,3)

Power press (Sunrise,415V,50-60hz,pf-0.4,3,14.gauge2100Kg)

(18.gauge,2300Kg)(20 gauge,2500Kg)

PAINT SHOP/DEPARTMENT
Power Coating Gun (Based on electrostatic charging,0.5-1A,230V) Paint Process Phosphating (Degreasing Tank- Caustic soda & Soda ash,10 PH,75-850C,10min)
(Derusting Tank-Acid,1 PH,50-600C,5min) (Phosphating Tank- Zinc Phosphate,1 PH,30-350C,3min)

(Water rinsing Tank- Water,7 PH,270C,1min)

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 Painting(Coating)
(2 pipes,-vely charged powder, +vely charged body) (Thermoplastic/Thermoses polymer )

(NUT WHITE SEMI GLOSSY) Baking

(182-2200C, 4-5A, 350V, 55ns layer, 15min)

Sealing
(Sodium dichromate,4 PH ,70-800 C, 5min)

Test Applied After Coating the Body

o Scratch Test:(with cello tape) o Bend Test:(bend it up to 900)
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ELECTROPLATING SHOP
Types Of Electroplating Acid Zinc Electroplating (for Iron)
(24-270C, 9-12V,15ns, Anode:- Zinc, Cathode:- Iron)

Acid Tin Electroplating(for Brass) (24-270C, 5-8V,12ns, Anode:-Tin, Cathode:- Brass ) Silver Electroplating(for Brass & Cu) (24-270C, 1.5V,4ns, Anode:- Silver, Cathode:-Brass or Cu) Copper Electroplating (for mild steel) (500C, 7-8V,6ns,Anode:-Cupper, Cathode:-Steel) Inspection
Coating Thickness Surface Finish
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MOULDING SHOP
Raw Materials (Polycarbonate resin/granules, Heated at 400C in preheater then fed to barrel of Molding machine) PBT:- used in high rating switch & socket. (high tensile strength due to glass fibre) Moulding Machine (L & T, 5000*1400*2000mm,
locking force-440KN, Ejection force-28KN, Oil tank-180L, Injection pressure -50bar, 415V, 3, 0.45pf, 50-60hz)

 Molds/Dye (Mainly frames, Two plates, injection

mold, ejector mold, silicon spray for cooling)

All types of frames of household electrical accessories are prepared by this type of machine by changing Dye. e.g. Batten holder, Ceiling rose, Sockets, Switches, Regulators, Bell push,switch socket combined, Plugs, Indicator, Telephone jack, Angle lamp holder, TV socket, Computer jack, foot light, cage frame. e.t.c

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 Waste Grinder Machine

Dharma engg. works, Size of grinder :- 9 Size of blade :- 6*4 Connecting load :- 5HP Max o/p :- 50-70 kg Voltage 415V Current rating;- 1.5-2A Frequency:- 50-60hz phase:- 3 Wt of machine:- 2400kg

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SWITCHGEAR ASSEMBLY SHOP

Rewirable Fuse & HBC fuse
Base:- Porcelain, Bakelite Contacts:-Electrolytic copper Silver plated Screw:-Brass Screw insulating material:- Wet ceramic

Cubicle Fuse Switch Fuses are placed in enclosure. Range :16-100A No of poles :SPN,DP,TPN Rated voltage :240,415V Insulation Voltage: 660V
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Metal clad plugs & sockets

Molded Polyester compound, Deep recessed socket contact tubes & surrounded plug pins to avoid accidental contacts. Range 1.5A,3A,6A/230V

Cubical Isolator Switch

Range 16A to 200A,220v-415V Poles:- SP, DP, TP, TPN Double Break Switch Fuse Incoming supply can either be connected Top & Bottom Range : 63 400A Poles : TP,TPN,FP
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 Change over switch

63 A, 415 V Asbestos sheet

Metal clad change over switch range:- 32A- 200A 220V-415V TPN Insulated Iron rod Bakelite case
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Element names of change over

Silver cupper bimetal rivets

Wooden block

Holding spring

Brass clamp

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TESTING LIST
Heating Oven Test for switches & holders
kept on 800C for 8hrs.

Mechanical Strength test for lamp holders

1 kg wt. hanged for hrs.

Tumbling barrel test checks mech. Strength of plug socket. wire tightened to socket & whole combination is put in tumbling barrel, it revolves & mechanical strength is checked
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 Endurance test for switches

general operation 4000 times in test lab 3 times more i.e. 12000 operations

Ampere test
tested for 6A when rating is 2A 30 sec

Conditional Wire test

cu wire, placed at 150C. 1 min. twisted & checked for cracks

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 Short circuit test for change over

done at 3KV-4KV. contacts are touched for 5 sec. 0KV shows short circuit.

Milli volt drop test

done for checking gap b/w contacts while closed

Making & Breaking Capacity tested at 130% of rated current & 110% at rated voltage. 500 operations, interval 30 sec.
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SSK COOL PACK AC SYSTEM

Capacity-1 ton
Temp range:- 100C to 450C Refrigerant :- R22,400 gm Voltage 230VA, 50HZ, 3.5 FLA

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PANEL SHOP
Assembling of Panel for AC coach of Indian railways.
Enclosure or Cabinet a/c to design.
Wire needed near about 6Km in one panel 70 sq mm, 2.5 sq mm for dc, 1.5 sq mm for ac Clipping tool(multi cutter) clipping of wire is done range 1.5mm-6mm Wire Ducts (Halogen free pvc material)

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AEL(Alternator earth leakage) operating voltage:- 110V UVR(under voltage relay) 25VA@750V/AC/50Hz Contactor (ABB Company) 415 V, 2 NO/NC

Residual Current transformers 690V- 12KV

shell type(3 phase, p-750V,s-415-110V,0.3kva)

core type(1 phase, p-750V,s-24V, 200va)

ACB(ABB company) 4 pole, 7 NO/NC, for relay operation, 800A, 415V, 50/60 hz Outer Left side of panel
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Pilot lights (indicators) operates at 24V Selector switch (4 way selector switch) Buzzer 24 V dc, 96-104Db range:- 50m Push buttons kit Kat fuse (L & T, 32A,220V)

Ammeter(0-800A)
Voltmeter(0-800V) Frequency meter 45-55Hz Socomec kilowatt meter Front view of panel
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Wago terminals OVR (over voltage relay)

DC Time Delay Relay

OSR(over speed relay) LOP(low oil pressure) AFR(alternator fault relay) Generator protection relay current range(4.0-10.3A) max gen. voltage 1000V ac aux voltage 24 V dc ATS(auto transfer switch) Ground wire 70 sq mm, 100A Bus bar (woehner) Inner view of panel
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FINAL PRODUCT

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Any Queries

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