A Project ReportOn Industrial Training In Sudhir Power Ltd. ( Genset Manufacturing Plant ), IMT Manesar, Gurgaon Submitted by- Ayush Saraswat 13BME0399 VIT University, Vellore DECLARATION BY THE CANDIDATE I hereby declare that the given industrial internship project report is a record of bonafide project work carried out by me under the supervision of Sudhir Power Ltd., Manesar (Gurgaon). I further declare that the work reported in this project has not been submitted and will not be submitted, either in part or in full, for the award of any other degree or diploma in this institute or any other institute or university. Signature of the Candidate Name of the Candidate: Ayush Saraswat . Also to fellows completing their projects alongside with me with their generous questions. Name of the Candidate: Ayush Saraswat . My sincere thanks to Sudhir Power Ltd. My thanks also goes to internal faculty who made us aware of all the processes happening. I would convey my regards to Mr. ACKNOWLEDGEMENT I would like to thank all those who provided me with the possibility to complete my industrial training. Rohit Beniwal (HR) who allowed me to complete the training. (Manesar plant) for this wonderful opportunity. 17 9.18 10.. Using CNC machine……………………………………….9 5... General Notes…………………………………………. Bloksets………………………………………………………. CONTENTS 1.11 6. Important Notations and Codes…………………….. Designing of Bloksets…………………………………….7 3. Conclusion………………………………………………22 12. Process………………………………………………………….5 2. Some Important Terminologies……………………. References………………………………………………23 . – An Overview…………………. Sudhir Power Ltd.8 4. Manufacturing of blokset………………………………14 8.…. After Machining………………………………………19 11.13 7. The client base of the company includes companies like Reliance ADAG. Sudhir Power Projects Limited. Sudhir group has three wholly owned subsidiaries. which is into EPC business. East India Hotels Ltd etc. – AN OVERVIEW Sudhir Gensets Limited (SGL) is part of the Sudhir group of companies. . The company is controlled & managed by the Seth family with a dominant presence in the northern & north-western states of India. Unitech Limited.50 KVA to 3000 KVA and associate equipment such as control panels and acoustics. and Sudhir Intravidyut Limited. GE Power. It is one of the leading manufacturers of DG sets in the range of 7. The company is an OEM of Cummins (India) Ltd & is primarily engaged in the business of manufacturing of DG sets based on the technology of Cummins India Limited. SUDHIR POWER LTD. which is into the manufacture of transformers of up to 20 MVA MVA and Sudhir Sales and Services Limited which is into servicing of DG sets. namely. BHEL. Sudhir Seth in 1973. promoted by Mr. DLF Limited. IOCL. LT Panels 2. Gensets 4. Cummins 2. Transformers 5. HT Panels 3.Strategic Alliances 1. DU-PONT 4. Schneider Electric 3. Tesar Products 1. PV Solar Modules 6. Bloksets . BLOKSETS Blokset is a modular offer for the production of LV switchboards for electrical distribution up to 6 300A and for motor control up to 250 kW. Applications Modular Structure-Global Design. Local Implementation. High Performance. Reliability & High-End Needs. Up gradation or Modification . Cost Effective Installation. Intelligent System. Focus on Safety. Flexibility in Project Management. Only few parameters and design features were edited to meet the demand of the organization which demanded the blokset designs to be like that. DESIGNING OF BLOKSETS The above is the 2D drawing of a new blokset that Sudhir Power Ltd. It is an assembly in which many parts are to be assembled and they are highlighted with their product code to cross-check the product parameters. Mechanical division has to design and fabricate to give the desired new design to it’s one of the client. . Scale of the drawing should be accordingly. 3. . GENERAL NOTES 1. All dimensions are in mm. Degree of protection is very important factor which varies from IP52 to maximum upto IP68. 4. Temperature compatibility for interior parts are to be kept in mind. Proper gaps between the interior parts are necessary to avoid any damage to the blokset. 5. 2. Frame parts 2. HR – Hot Rolled Properties a) Thickness – 3mm b) Usage – Base Structures. 5mm b) Usage – Gland Plates .Aluminium Properties a) Thickness – 3mm.5mm. 3mm b) Usage – Structures. Transformer 3. Al . CRCA – Cold Rolled Cold Annealed Properties a) Thickness – 1. SS – Stainless Steel Properties a) Thickness – less than 2mm b) Usage – Tanks 4. MATERIALS USED 1. 2mm. GI – Galvanized Properties a) Thickness – 2mm b) Usage – Outer Enclosure SOME IMPORTANT TERMINOLOGIES 1. 5. ST0030027 ISMC 200X75 @130kg/6mm 2. MS Angle . ISMC – Indian Standard Medium Channel Material Dimension @ weight/ length For eg. MS Flat Specific weight for rectangular and square bar = Length X Breadth X Thickness X 7.49 % as an average. 3. % Scrap-Ratio The % scrap ratio which was observed in the organization that was around 10.85 = 74800 – 8000 (kg/m3) Above range is for regular and ordinary steel 4. . . Degree Of Protection IP52 a) 5 – For dust b) 2 – For water In industry mechanical engineers used varying fromIP23 upto IP53. IMPORTANT NOTATIONS AND CODES 1. Important notation of the designs SGX – E / 12 – 21 / M + CCT2 a) SGX – RMU Model b) E – Extensible type c) 12 – Rated Voltage d) 21 – Short circuit current e) M – Metering Panel f) C – Load break switch – 1 g) C – Load break switch – 2 h) T2 – Breaker 2. MANUFACTURING OF BLOCKSET 1. the industry used 2 CNC machines – a) AMADA 2510NT – For Punching Size of metal sheet = 2500 X 1250 mm AE2510NT X-axis: –10 mm to 2510 mm Y-axis: +30 mm to 1340 mm (inner track) –10 mm to 1300 mm (center track) –50 mm to 1260 mm (outer track) . OUTER BODY PARTS For this. Punching Range G92: ESTABLISHING COORDINATE SYSTEM 2. AMADA AIII 1253 – For Bending . For bending of 600 and 900 And upto 4mm bending Force Force upto the 80 ton for was applied using these CNC machines. All these CNC machines were FANUC based CNC Machines. . . PROCESS The sheet metal was loaded on the CNC machine using the automatic sheet changer machine which was used. There was a detector which was there in the machine. 2. USING CNC MACHINE 1. . Then the drawing was transferred to AMADA AP100 software which deal with CAD/CAM processes which had 7 stages of it’s working like follows – a) Unfold drawing b) Parts processing c) Sheet pressing d) Simulation e) Data manager f) Parameter Manager g) Maintenance The afterward process was done itself as AMADA AP100 creates the GM CODE programming using drawing parameters and the sheet metal operation was successfully done with these processes. The drawing prepared was called GA drawing and then the nesting was prepared (DWG file format) with the help of AUTOCAD 2013. AFTER MACHINING 1. . Assembly Then the finally assembly took place and the blokset was ready to transfer in the Electrical department.8mm wire coiled. Properties CO2 gas used in MIG welding with 0. 2. Smoothening of surface After all these again grinding was done with grinding sheet of 80 grain size. Welding MIG welding used to be carried out to join the folded edges which were previously bended using AMADA 1253NT CNC machine. Grinding Grinding was done using different grinders to remove the extra deposition of splatter. 4. 3. . For joining the parts. workers used lock nuts to ensure better grip with more stability and rigidity. . Finally. Designing and fabrication of blockset require skills which can be developed by working with such skilled mechanical engineers in industry. it was observed that Sudhir Power is working efficiently to deliver the promises to it’s client and have been successfully manufacturing around 5 crores of gensets making it a large competition in today’s world. . The learning procedure of CNC machine and it’s working was really useful and it improved my technical knowledge along with practical use. CONCLUSION The whole training at Sudhir Power Ltd. (Manesar plant) improved my understanding to use sheet metal feature in SolidWorks and what other stages are required for the sheet metal to be finally worked upon. Google Images 3. Scribd. sudhirpower. REFERENCES 1. Internet .com 4.com 2.