ACKNOWLEDGEMENT

First of all I wish to express my sincere thanks to the Rajasthan Technical University, which introduce the scheme of providing practical training for technical student during the 4-year course of B.TECH. With the drastic development of technology & speedy industrializations of the country I consider my self to fortunate to have undergone practical training in INSTRUMENTATION LTD. I am very thankful to Mr. Barwa(Head of Training Department, I.L) & other concerned person of IL, Kota for their guidance, constant encouragement, strong support & kind help of understand many technical aspects in my training period.

DIKSHA MALIK B.Tech. 4th year. Branch ECE College Poornima Institute Of Engineering & Technology

PREFACE
I took my practical training of 30 days from 25-05-2012 to 24-06-2012 at INSTRUMENTATION LIMITED which is a govt. of India enterprises. According to the rule of Rajasthan Technical University towards the fulfillment of 4 years degree course of B.TECH. We are supposed to go training of 30 days after 3rd year. The object of practical training in engineering filed is to co-relate the theory with practical knowledge & to make student familiar with industrial environment. I have been fortunate to get practical training in such a industry which has been continuous by climbing the ladder of development utilizing the latest technology, here I could gain knowledge of various equipment which are tested & calibrated in the enterprise. My report that follow is the summary of all the knowledge that I gained additional.

Diksha Malik

CONTENTS

S .No. 1. 2. 3. 4. 5. 6. 7. 8. 9.

PARTICULARS INTRODUCTION CARD ASSEMBLY RAILWAY SIGNALING RELAYS GAS ANALYZERS U.P.S. QUALITY ASSUARANCE TELECOM CENTRE CONCLUSION BIBLIOGRAPHY

INTRODUCTION

INSTRUMENTATION LIMITED, KOTA is a govt of India enterprises established in kota(raj) in 1966-67 with the prime objective of attaining self reliance in the field of contract and automation for the process industry. The major products that IL presently manufacturing is:1) Process control instruments 2) Control valves 3) Railway signalling system 4) Sets of telecommunication 5) Microprocessor based recorders 6) Digital switching system 7) Rural automation exchange 8) Main automation exchange 9) Panels 10) Defence products Today, IL is supplying these control equipments to various sectors of the industries wiz power, steel fertilizer, chemical, petrochemical, refineries, cement, paper textiles, space, oil, gas, the turn over target is more than 150 cores. It has its plant at Kota, peaked with over 25 years of experience and a dedicated work force. It has measured all complicities of control system requirements can lead you right through your project from system design detailed engineering, manufacturing, installation final commissioning to after sales services & customer training. Il after establishing itself as an undisputed leader has crossed the Indian border to supply equipment. On turnkey basis in international market. It has supplied instrumentation on tur key basis for 2 thermal power stations in Malaysia & established a service centre at kufa power complex in Iraq, supplied instrumentation for utopian petrol company, supplied instrumentation for steel plant Iran and also a major breakthrough has been made in capturing the market for hi-tech digital control system for refineries in the USSR.

All work centre of IL are well equipped and appropriately upgraded with manufacturing capability and capacity. The men power are well experienced and also given exposure to various new technologies. To meet the equipment in working environment, all work places are adequately dust controlling For assembly and testing of hi-tech electronic instrument, totally dust free air conditioner hall are used with static protection. I considered myself fortunate one to have undergone practical training in instrumentation limited. There are 9 departments or section in Kota unit 1) Assembly shop 2) Telecom division 3) Digital electronic units 4) Maintenance shop 5) Railway relay 6) Gas analyzer (production) 7) Defence project department 8) PCB centre 9) Ups centre

Chapter 1 CARD ASSEMBLY (PCB Centre)

Types of card assembly 1. Through hole (TH) 2. Surface mount technologies (SMT)

SMT is an electronic assembly technique where electronic component are mounted to the surface of printed circuit board without holes drilled through the board for insertion of component leads. The SMT devices must be precisely placed on the circuit board and held in the position by solder pays or glue until the soldering process, which is usually automated, can make connection. Benefits of SMT Reduction in package size results in greater functionality in the same board area. Reduction in weight, mobile and handhold electronic items such as video cameras and cell phones are examples which have low weight and high performance. Reduction in noise this is primarily due to small electronics path compare to leaded components. Higher operating speed due to shorter interconnections.

Types of assembling Full SMT board with parts on 1 or both side of the board A combination of through holes and SMT components Only through hole components

Assembly procedure for SMT Surface mount assembly is basically a 4 step process Print the solder paste glue Place the component Reflow the paste to form the solder interconnection between the component and the land area of the board Clean up

Equipment used Screen printer- to print the solder paste on the board Pick and place machine- to place the component on the printed board Reflow oven to place the component on the printed board Waves soldering machines- for soldering of through hole component

Advantages of SMT

SMT allows production of more reliable assemblies, increase board density and reduced weight, volume and cost considerable, cause saving can also be realized through a reduction in material as well as the labour cost associated with automated assembly

Pick and mound machine This machine is very important and it is only one machine at IL kota in Rajasthan. This machine is very costly (6cores). It picks up small component with the help of programming we put in the computer and mount on the PCB. This machine mound small component on the PCB at 1 after this we solder the PCB. After this we solder the PCB components then we take out card and test it. When any component short Then we check it manually and remove difficulties and after we give to testing and after that we clean the card

Soldering machine We insert card. There is a sensor in this machine we pass the card on the heating plate. This plate is divided into 3 parts. 1st. Is low heated, 2nd is higher heated and 3rd one is very higher heated. After this card and heating plate distance is larger due to plunges. After this we pass the card on the melt liquid of Ag+Sn+SMT is an electronic assembly technique where electronic component are mounted to the surface of printed circuit board without holes drilled through the board for insertion of component leads. The SMT devices must be precisely placed on the circuit board and held in the position by solder pays or glue until the soldering process, which is usually automated, can make connection. This card is solder by liquid temp. 240.c and we soldered 10 cards at a time and card soldering is done one card per/sec.

Various assembly process 1. Issue of kits 2. Numbering 3. Baking 4. Mechanical assembling 5. Mounting 6. Pre solder inspection 7. Soldering 8. Re work and touch up 9. Post solder inspection 10. Final dispatch

flow chart:Kits from

Components forming

rectification

Pre-solder inspection

Soldering of PCB

cleaning

rework

Post solder

Testing and repairing

i.

Issue of kits : during the assembling of PCB several operations are required initially various component which are required for the purpose of assembling received from the stores in the form of kits Numbering: the purpose of numbering PCBs is to lay down the procedure for identification and traceability of the products. The PCBs are identified at the initially stages and higher stages by providing the serial number on them which is of 10 digit code.

ii.

iii.

Baking: before proceeding to the various operation the baking operation is done due to followings During soldering the card passes through temp. Range in pre heating and soldering chamber. During baking the card become dry and it can bear thermal shocks during soldering. The baking is done in a furnace at 120.c the baking erent cards It is one hour in use of single layer 4 hour in case of 2-4 layer 8 hours for above 4 layers

iv.

Mechanical Assembly:-Although we are using the electronic components in assembly. But some components are assembled fastened by mechanical tools fasters. Components which are mechanically assembled are connectors, injectors, switches etc. components, which are assembled on the later stages are:1. Those components, which may be spoiled during soldering. 2. Those components that may be provide obstacle during soldering

v.

Mounting:- After exception of kits mounting is done with the help of following steps:A. Forming:-after receipt of kit of required PCB, which is to be assembled, the forming operation is held with the help of component list in the following steps:-

a) Cutting: - several components bear long leads may create problem in soldering. Hence leads of such components cut into required length with the help of tools. b) Bending: - these are some components, which cant be used directly in their original shape. A particular pitch is their the leads of their length components are given the required shape with the help of required tool. The pitch distance is also maintain during the pending now its easier and perfect to maintain the pitch distance through tools. B. Binning: - with the help of components list, all the components are kept in different boxes called the BINS. Mounting of components on the card is done in the order of: Save product cost Save labour cost C. Mounting: - during forming operation, the components are kept in different bins. The cutting and bending operations is performed for the required components, now the components are ready for mounting purpose, the assembler starts mounting of components. vi. Pre-solder inspection: - as soon as the mounting is over these assembled cards are offered for inspection, which are known as pre-solder inspection. If any mistake there in mounting it is recovered by the assembler and if mounting is ok then these are send for soldering. vii. Soldering: - two types of techniques are used for the soldering of PCB. a. Through hole technology b. Surface mount technology a) Through hole technology:Wave soldering machine are used for soldering the components on PCB. The process of wave soldering machine is defined as: o Fluxing o Pre-heating o Wave soldering o Cleaning

Fluxing: - fluxing is done to remove the oxidation and other contaminants, no clean flux is used as solvent. Excess flux is removed by using the air knife arrangements. Pre-heating: - after fluxing and removal of excess flux, the PCB moves to preheating section, where the solder side of PCB receive radiations from solder & this the oxidation. The PCB is completely dry and it can bear thermal shocks. Here 6 heaters are there, their temp. Rises gradually gives 20 to 25c. Heater temp rises to 220 to 360c.

Wave soldering: - after pre heating we move to wave soldering. Different cards on which the components like transformer, high power resistance, capacitance to be mounted are placed on system and soldered by wave soldering machine. In this machine A card is placed on the card carrier having an arrangement of motion through bearings and magnets are mounted on it. Now PCB is placed over foam flux, the flux is isopropyl alcohol, which removes the metal oxide layers on the pins on the component. Here compressed air is mixed with flux to produce foam flux. The PCB is then passed through heater which pre-heat the PCB from 240*c to 340*c temp. The heating is provided in 6 stages becauseTo avoid explosion when cold flux directly comes in contact with hot solder at 240*c tamp. The flux reacts rapidly with metal oxide layer. The Bakelite melts on sudden increase in temp so, to avoid this slow heating is done on sudden cooling also, bending in PCB occurs which destroys the internal connections, so it also gradually cooled.

Cleaning: - after soldering the PCB are cleaned with isopropyl alcohol.

b) Surface mount technology (SMT): -SMT is an electronic assembly technique where electronic component are mounted to the surface of printed circuit board without holes drilled through the board for incretion of component leads. The SMT devices must be precisely placed on the circuit board and held in the position by solder pays or glue until the soldering process, which is usually automated, can make connection.

A machine known as pick and place machine carries out this method. It is a semi automated machine, which works in 2 planes X and Y. The capacity of this macine is 20,000 components per hour. it can be divided into 2 parts: a. Pick and place machine b. Reflow oven i. Pick and place machine: - this is fully automated programmable pick and place machine, the machine is most versatile, it can place not only chip components but also components in trays, tubes and tapes.

Important Features of an Automatic SMD Pick & Place System: Component size should be: 0402. Component placement speed 20,000 components per hour Feeder capacity: 198 feeder Ability to handle all type of components Vision correction to align leaded component Two head with 8 nozzeles The software is window NT based program can be used online as well as offline system.

ii.

Re-flow oven: - after placing the SMT component on PCB, the PCB is checked manually and then sent to re-flow oven. In this 6 stages of heating is provided from 240*C to 340*C, this temp range is changed with the help of programmed panel.

viii.

Rework and touch up: - after soldering and cleaning rework is done, its advantages are: Solder defects are rectified. A proper touch up is given.

ix.

Post solder inspection: - it is also called final inspection, when PCB is complete in all aspects, final inspection is done, after inspection these are ready for dispatch.

x.

Final dispatch: - after final inspections, ejectors are mounted on components, which are assembled after soldering, are fastened. Then these cards are sent for testing and repair center.

xi.

Process Capabilities Fully automatic SMD Double sided SMD & PTH Fine pitch placement 12 mil BGA Placement 0.04 mm. Passive Placement 0204 BGA & fine pitch rework No clean / water soluble solder Paste & flux conformal coating Electro-mechanical system assembly Complete turnkey final assembly Of your product Functional card / system testing Inward Good inspection

Chapter 2 RAILWAY SIGNALING RELAYS (RSR)

1. Introduction 2. What is a relay and where it is used 3. Related terms and their meanings 4. Components 5. Working 6. Calibration 7. Specification of various relays manufactured at instrumentation Ltd. Kota

1. Introduction
Railway Signalling Systems are basically intended for dispatch and control of Trains in the fail-safe manner. These are most vital systems involving human safety I.L has executed large turnkey Railway signalling jobs for Western Railway, Southern-Central Railway, RITES, IRCON, and NTPC etc.

2. What is a relay?
A relay is a multi switch device with multiple mating contact pairs. The contact Configuration consists of two types of contact pairs-font and back. The back Contact pairs are normally closed and the front contact pairs are normally open. When a relay is energized the status of front and back contact pairs reverses. Relay manufactured at instrumentation limited (Kota) are electromechanical type Neutral line and track relays. They work on the following two main operating principles:a. ELECTROMAGNETIC ATTARACTION b. ELECTROMAGNETIC INDUCTION The load current flowing through the magnetic coil generates magnetic flux in The core and this flux is responsible for functioning of relays.

TYPES OF RELAYS:I.L manufactures three types of signalling relays. They are: a. LINE RELAY b. TRACK RELAY

C. KEYLOCK RELAY a) LINE RELAY: This type of relay is used for classification of line. It gives signal to lines for up and Down. There are two signals Red and Green. Here, red signal indicates that the line is busy whereas the green signal indicates that line is clear. b) TRACK RELAY: This type of relay is used for changing track at railway station. As we know only two lines up and down are present & number of lines are present at railway station. c) KEYLOCK RELAY: These are automatic relay & are used for the protection of accidents when train arrives &gate is automatically closed. These all types of relays are controlled at control room

3. Related terms and their meanings:Pick up voltage/current: Minimum voltage/current at which relay operates i.e. normally closed contact pairs change to normally open. Drop away volt /current: Maximum voltage/current at which relay releases fully. i.e. The contacts acquire their normal positions. Contact gap: The voltage/current variation between the first back break and the last front make, when the voltage/current applied gradually increasing step by step. Ultimate pick up: Minimum voltage/current at which the armature touches the core of the coil. Ultimate pick up is achieved after all the front contact achieves close status. Operating time: The time that is taken by the relay from application of voltage to change of state of contacts. This is taken on each contact. Release time:The time taken by the relay from removal of rated voltage to change of state of contacts.

4. COMPONENTS:Relay broadly consists of: a. Contact block assembly b. Magnetic assembly c. Armature assembly d. Relay base Contact block assembly: Contact block assembly mounted on the relay base consists of ten contact blocks. The first two from the coil end are for coil termination and the rest are used in pairs as mating contacts. The two contacts in each pair consist of one silver and one sig (silver impregnated graphite) contact. Each contact block consists of maximum four contacts that can be either silver or sig contact depending on the configuration. Each contact has a corresponding mating contact of other type in the adjacent contact block hence the two forming a switch. The operating card supported by adjust spring at one and inserted in the slots provided in the operating arm at the other, is interwoven in slots provided in the contact springs so as to move only the silver contacts. The sig contacts are kept in position by the slots provided in adjustment card, which in turn are supported at one end by suppurated at one end by support spring and by adjustment card bracket at the other. Magnetic assembly: Also mounted on relay base, the magnetic assembly consists of coil, yoke, pivot plate; adjustment card bracket and armature return spring. Armature assembly: The armature riveted with the operating arm is pivoted on the pivot plate such that it can rotate a small angle in the plane perpendicular to the line of the armature and the pivot plate. WORKING:As the relay is plugged in the plug board it becomes operational. The contact pairs are connected with the circuit receiving 3v.. The coil on the other hand receives supply in two modes-no supply (off) and full supply (on). Full supply given to the relay is enough for the relay to pick up (energize) and their values (either in current or in

voltage as in case of track relay and line relay respectively) depend on the specification of the relay. When the coil supply is in off condition the back contact pairs are in Open status. As the supply is given to the coil, it develops a magnetic field that attracts the armature towards itself, since the armature is a magnetic material. The magnetic field provides the torque for the armature to rotate about the pivot. The magnetic field developed by the coil depends on the current within. This current will however increase to its peak value from zero (initially) following exponential curve because of the reverse magnetic field developed due to induction effect. When the torque on the armature due to magnetic field increase enough to overcome the opposing the torque of armature return spring and operating cards, the relay energize and the armature rotates about the pivot. The operating arm rotates with it. However the rotation if operating arm can be visualized as linear movement in the direction parallel to the relay since the angle of rotation is small. This linear movement is transferred to operating card and in turn to the silver. CALIBRATION: Calibration involves adjustment of various electrical and mechanical parameters for proper functioning of Relay. Calibration is done on a special stand and with tools made for this purpose. The parameters that are adjusted are: Pickup / Drop away voltage: The relay should energize and energize at specific voltage / current. These parameters are function of various torque acting on armature assembly viz. magnetic force, armature return spring force and the operating card force. For adjustment the last two forces are varied to obtain the desired effects. Contact Pressure: The SIG contact springs should press against the adjustment card slots with a pressure not less that 40 grams, this pressure is introduced in the springs by bending machines at the manufacturing stage. However little adjustment if required, is done at calibration stage. Tension gauges of suitable range measure the pressure. The pressure is required to ensure proper contact between silver and SIG contacts. Contact gap: Ideally all back contacts should break simultaneously and all the front contacts should make simultaneously as the relay energizes. But this is not achieved in practice.

So, out of all the back contacts, usually there is one contact to break first and one to break last Likewise there is one front contact to make first and one to make last. The voltage / current variation between first back break and last front make should be less than 0.6V. None overlapping: The distance traversed by the contact assembly between the last back contact break and the front contact make should be not less than 0.3 mm. This is ensuring that any font and back contacts do not achieve close status simultaneously. Test conducted to achieve this at inspection stage is non-bridging test. Thrust: Whenever the silver and SIG contacts mate, the silver contact pushes the SIG contacts to ensure firm contact. The SIG contacts that are supported by the edge of adjustment card at its free end moves away from the edge by a distance that should be not less than 0.4mm. The calibrator with the help of feeler gauge ensures this distance.

OA ASSEMBLY:
For the production of railway signalling Relay. We required following test stand.

1. IR / IS TEST IR Test at 500v.dc IS Test at 1 kV, AC (1 to 2 sees) Both the test conducted in b / w (a) Body to terminal (BT) (b) Terminal to Terminal (TT) 2. NON BRIDGING TEST 1. Test of physical gap b/w Back and Front Contact at 500v DC

3. ACIMMUNITY TESTING (1) 300 V, ac (Gradually) Back contact should not break. (2) 300V, ac (Abruptly) Back contact should not break. (3) 1000V, ac (Abruptly) Front contact should not make.

Chapter 3 GAS ANALYZERS

Gas Analyzers are the instruments used for continuous measurement of percentage of a particular gas in a gas mixture. It plays an important role in process engineering where it provides information on composition of a gas mixture in the process leading to Straight forward quality control and cost saving. On the basis of values obtained from the gas Analysis, there is a possibility of correcting the process and altering it in such a manner that it is optimized. Based on the principle of measurement there are broadly following types of Gas Analyzers that have been manufactured / supplied by IL Kota:S.NO. 1. 2. 3. 4. TYPE OF ANALYSER GAS MEASURED Paramagnetic O2 Thermal Conductivity H2, SO2, CO2, Ar Infrared CO, CO2, SO2, NH3 Zirconias Probe type Analyzer O2

All the above Analyzers are continuous measuring type Analyzers i.e. the gas available in the process which is to be analyzed is continuously fed to the Analyzers, it gets measured and then goes to exhaust. However the process gas is normally not suitable for directly feeding to Analyzers. A gas sampling system is used to make the process gas suitable for feeding to the Analyzer. The sampling system consists of following accessories:1. Gas sampling probe 2. Heating device 3. Condensate removal and filtration device 4. Sample gas cooler 5. Diaphragm pump 6. Pressure Reducer 7. Flow meter

Working Principle:1. Paramagnetic Analyzer: - it works on the principle that out of all the gases oxygen is a gas which is highly paramagnetic in nature i.e. the molecules of oxygen gas have got the property to get attracted by magnetic field. Based on

this analyzer is used for measurement of oxygen. 2. Thermal Conductivity Analyzer: - this Analyzer works on the principal of different thermal conductivities of different gases. Hydrogen is a gas, which has very conductivity as compared to other gases like nitrogen, argon etc. this analyzer is used in thermal power plants for monitoring of H2 in Turbo generator cooling. 3. Infra Red Analyzer: -This analyzer works on the principle that all Polly atomic, non-elemental gases absorb the infrared radiation selectively in a particular bandwidth or frequency spectrum. Based on this specific absorpt ion of infrared radiation, the IR analyzer is used for measurement of co, co2, ch4, nh3, and hydrocarbon etc. 4. Zirconias Probe Oxygen Analyzer:-This analyzer work on the principle that a disc of zirconium oxide material acts as a solid electrolyte, when it is subjected to different partial pressure of oxygen on its two sides. The mV generated across the 2 sides of the Zr O2 disc is governed by Nernst equation:Emf= KT log 10 (P1/P2) P2= partial pr. Of O2 in measured gas on one side. P1=partial pr. Of O2 in reference gas on other side. T= Absolute temperature. K= an arithmetic constant C= cell constant In the above equation since all other are constant, the Emf generated is a function of P2 I e % of O2 in measured gas.

Chapter 4 UPS (UNINTERRUPTED POWER SUPPLY)

WHAT IS UPS: The basic UPS consist of rectifier/charger, inverter, external source of stored power (usually a battery), associated circuitry, protective devices and accessories for proper operation. The basic function of UPS is to continue power supply to critical load within its specified tolerances during a failure or deterioration of the normal power supply. Continuity of electric power to critical load shall be maintained for emergency period with the UPS supplied externally stored power up to the specified time or until the restoration of normal power source.

NECESSITY OF UPS: Main AC is not clean power. It has inherent defects & poses to danger to sophisticate & sensitive electronic instruments. The sensitive load is frequently subjected to voltage variation, transients, interruption and frequency variation. According to IBM the UPS Systems are capable to overcome 99.9% of power line disturbances. The most common kind of main disturbances are as follows: DISTURBANCES Voltage Variation Electrical Noise Frequency Variation Large Harmonics Power Failure EQUIPMENTS USED Voltage Stabilizers Insulated Transformer UPS UPS UPS

The disastrous consequences of such disturbances are now well known to users of Computers. They cause: Lost data Scrambled data Component failures Down time of complete equipment

BASIC TYPES OF UPS: OFF LINE UPS ON LINE UPS OFF LINE UPS: - It includes: BATTERY CHARGER INVERTR

BATTERY In OFF LINE UPS input is directly connected to output. Inverter is not used in this type of UPS. Output will be in square form. Because input is directly connect to output so to reduced disturbances a BuckBoost converter is use. Frequency may vary according to input applied. ON LINE UPS: - It includes: BY PASS Static Switch BATTERY CHARGER INVERT INPUT

In ON LINE UPS Input is connected to load through inverter. Output is in sine form. Frequency of output is constant. In case of inverter failure there is an emergency system called BY PASS to directly connect input to output load. WORKING of UPS: The UPS System basically consists of Rectifier, Inverter, Transfer Switch and Battery. Under normal condition, the battery charger supplies the entire power necessary to the inverter for supplying the load, and simultaneously charges the battery in float charging condition. The battery charger affects charging the battery automatically. If power failure occurs, the inverter is supplied the DC power from battery and

supplies continuously the stable AC power to the load. After restoration of power the UPS come back to normal operation. The transfer switch or static switch is used to transfer load from inverter mode to bypass mode. In case inverter becomes faulty the load is transferred from inverter to Bypass automatically. The battery used in home segment is generally Lb-Acid tubular (wet type) batteries and require maintenance periodically. The most critical part of maintenance of battery is to keep level of acid to required level by adding distilled water. Also the life of battery is of 2-3 years. In UPS it is general to use Scaled Maintenance FREE Batteries that do not require any topping of distilled water. These batteries also have limited life of 2-3 years. However SMF batteries are very sensitive to temperature and their life reduces drastically if temperature goes above 25 deg C. So it is batter to keep UPS in cooler places.

PARALLEL CONFIGURATION OF UPS: To increase the reliability, UPS should be used in parallel redundant configuration. In this load is equally shared by both UPS, in case of failure at any one, full load is taken by other UPS . If both UPS fail, then the load is transferred to by pass.

Battery: Battery plays an important role in UPS. The higher the back up time, more batteries are required . This adds cost to the battery and stronger chargers required to charge the battery. Further batteries have definite 3 to 5 years of life. Also, the life of batteries gets further detiorated due to high environmental temperature. Therefore, batteries suitable only for optimum battery back up time must be taken and UPS must be backed up with a generator to take care of large duration of power outage.

APPLICATION: In critical and higher end application such as power plants, refinery or industries using computer-controlled equipments, all the instrumentation & critical loads are on UPS supply. Failure of controls and tripping of plants causing tremendous loss. As such reliability of UPS power supply are very important parameter. This is achieved by using higher configuration of UPS. In one such configuration called parallel redundant configuration, two UPS are used with their output paralleled. During normal operation both the UPS supplies 50% load. In case of failure of one UPS or taken out for maintenance, the other UPS automatically start supplying 100% load. In the worst case when both UPS fail load is transferred to Automatic Voltage Stabilizer without break in load through static transfer switch.

Chapter 5 QUALITY ASSURANCE The Eight Quality Management Principles

Each major clause of ISO 9001-2000 has been based upon the following eight Quality Management principles:CUSTOMER FOCUS: Organizations depend on their customer and therefore should understand current and future customer needs, should meet customer requirements and strive to exceed customer expectations.

LEADERSHIP: Leaders establish unity of purpose, direction and the internal environment of the organization. They create the environment in which people can become fully involved in achieving the organizations objectives.

INVOLVEMENT OF PEOPLE: People at all levels are the essence of an organization and their full involvement enables their abilities to be used for the organizations benefits.

PROCESS APPROACH: A desired result is achieved more efficiently when related resources and activities are managed as a process.

SYSTEM APPROACH TO MANAGEMENT: Identifying, understanding and managing a system of inter related processes for a given objectives contributes to the effectiveness and efficiency of the organizations.

CONTINUAL IMPROVEMENT: A permanent objective of the organization is continual improvement.

FACTUAL APPROACH TO DECISION MAKING: Effective decisions are based on the logical or intuitive analysis of data and information.

MUTUALLY BENEFICIAL SUPPLIER RELATIONSHIPS: the ability of the organization and its suppliers to create value enhanced by mutually beneficial relationships.

QA-UPS For the purpose of quality of UPS following test are taken:1. Temperature testing (At 19deg C and at 40 deg C). 2. After exhausting the battery of UPS again temperature testing. 3. Output should be fixed given by manufacturer. 4. Testing of rectifier output, inverter output and battery output. 5. Ripple testing between battery and rectifier.

QA-PCB Two types of inspection are there for the purpose of quality assurance 1. Pre solder inspection 2. Post solder inspection 1. Pre solder inspection: -Following inspection are there in pre solder inspection: Card should not have any component having wrong value at any particular position. Card should not have defective component. Card should not have any missing component. Card should not have any lifted component. 2. Post solder inspection: - Following inspection are there in pre solder inspection: Card should not have any component having wrong value at any particular position. Card should not have defective component. Card should not have any missing component. Card should not have any lifted component. Card should not have any solder defects. Card should not have any unsoldered component. No shorting should be there.

Chapter 6 TELECOM TECHNOLOGY

This field of telecommunication has evolved from a stage when signs, drum beats and semaphores were used for long distance communication to a stage when electrical; radio & electro-optical signals are used. Telecommunication networks carry information signals among entities, which are geographically apart. Long distance voice communication is Telephony. Early switching systems were manual and operator oriented. Limitations of operator switching systems were quickly recognized and automatic exchanges came into existence. Automatic switching can be classified as electromechanical and electronic. Electromechanical switching systems and are batter known as strowger switching systems. With the introduction of automatic switching system various disadvantages of the manual exchanges were overcome; some of them are: In a manual exchange the subscriber needs to communicate with the operator and a common language becomes an important factor. In multilingual areas this aspect may pose problem. On the other hand, the operation of an automatic exchange is language independent. A greater degree of privacy is obtained in automatic exchanges, as no operator is normally involved in setting up and monitoring a call. Establishment and release of calls are faster in automatic exchanges. It is not unusual in manual exchange, for an operator to take quite a few minutes to notice the end of a conversation and release the circuits. This could be very annoying particularly to the business subscribers who may like to make a number of calls in quick succession. In an automatic exchange, the time required to establish and release a call remains more or less of the same order irrespective of the load on the system or the time of the day. In a manual switching system, this may not be true. However the major disadvantages of this stronger system is its dependence as moving parts and contacts that are subjected to wear and tear. Also the control functions in the stronger systems are performed by circuits associated with the switching element in the system. However in the cross bar system the call switching equipment and the call control equipment are separate. So these

stronger systems were replaced by the Cross Bar Switching Systems, which were designed using the common control concept.

INTRODUCTION TO TELECOM DIVISION: Telecom division comprises of: a) Manufacturing / production b) Quality Control c) Production Planning & System d) Evaluation & Revalidation e) PCB Assembly Shop I.L has been pioneer in manufacturing, supplying & servicing of Electronic Telephones Exchanges based on C-DOT (Centre for Development of Telematics). CDOT provides economical means for serving metropolitan, web on & rural environment. C-DOT has high traffic / load handling capacity up to 8,000,000 BHCA with termination capacity of 40,000 lines as local exchanges. Thus C-DOT is easy to maintain & highly reliable.

C-DOT DSS BUILDING MODULES C-DOT DSS consists of following basic modules: a) BASE MODULE b) CENTRAL MODULE c) ADMINISTRATIVE MODULE d) INPUT OUTPUT MODULE A) BASE MODULE (BM): BASE MODULE (BM) is the basic growth unit of the system. It interfaces the external world to the switch. The interface may be subscriber lines, analog & digital trunks. Each base module has Interface up to 2024 (2K) terminals. The number of base modules directly corresponds to exchange size. It carries out majority of calls processing functions & operation maintenance function with the help of Input Output Module

FUNCTIONS: a) Analog to Digital conversion of all signals on analog lines & trunks. b) Interface to digital trunks & digital subscriber. c) Switching the calls between terminal connected to same base module d) Communication with the administrative module via the control module for administrative functions BASE MODULE hardware is spread over four units: -

a) Analog Terminal Unit (ATU): For interfacing analog lines & trunks & provides special circuits.

b) Digital Terminal Unit (DTU): For interfacing trunks i.e.; MBPS PCM lines.Each digital trunk synchronization (DTS) card along with the digital trunk channel associated signaling (DTC) card interfacing 30 digital trunks.

c) Time Switching Unit (TSU): It has a time switch for time switching with in the BM, a control switch for control message communication within the BM & between BM and a service unit for providing call processing support services

B) CENTRAL MODULE (CM): CENTRAL MODULE (CM) is responsible for inter base module calls, communication between BM & AM and providing local clock and network synchronization. For this function, CM has a space switch controller and a control message switch. CM provides connectivity up to 16 BM. Each BM interfaces with CM via two 512 channel parallel buses each operating at 4 Mbps. These buses are called bus 0 & bus 1 and each bus carries information of 512 subscribers transmitted by the BM in the reverse direction after space switch controller (SSC) two parallel buses carry the switched voice information of 512 subscribers each at 4 Mbps towards the BM.

C) ADMINISTRATIVE MODULE (AM): ADMINISTRATIVE MODULE (AM) performs system level resource allocation & processing on a centralized basis. It performs all the memory and the time processing support functions and also administrative functions.

D) INPUT OUTPUT MODULE (I/O M): INPUT OUTPUT MODULE (I/O M) is a duplex computer that interfaces various secondary devices like disk drives and up to 8 serial ports for video display units, which are used for man-machine interface communication

ELECTRONIC EXCHANGES
C-DOT was established with a view to develop a telephone switch to be the standard equipment in the telephone exchange in the country. The telephone switch is the heart of the telephone exchange & performs all operation required to connect subscribers as and when they are desire. The purpose of telephone exchange as switch is to connect any subscriber to the other. The two subscribers may be connected to the same exchange or they may be in the entirely different parts of world.

REMOTE SWITCH UNIT (RSU) RSU is an integral part of C-DOT architecture. In order to realize a RSU, the normal BM can be modified for remoting with host exchange via 2Mbps digital links. The number of 2 Mbps links between the main exchange & RSU is primarily determined by the traffic. A maximum 16 PCM links can be provided between RSU main exchanges. Analog & digital trunk interfaces are also implemented in RSU to support direct parenting of small exchanges from RSU into itself instead of parenting it to main exchange, which will ultimately save the media required from main exchange. As far as call processing is concerned, RSU is an autonomus exchange capable of local call completion operation & maintenance function is handled by the host exchange. In case of failure of PCM links, RSU goes into stand-alone mode of operation. In this case, it is not possible to process a call request due to unavailability of links to the heart & the subscriber is connected to the appropriate tone or announcement.

During stand-alone mode of operation, the local and incoming termination calls in RSU are switched and the metering information of the entire RSU subscriber is stored in the RSU. From there, it is sent to the host whenever the PCM links are available again.

RURAL AUTOMATIC EXCHANGE (RAX)

C-DOT 128 RAX is a stored program controlled switching system with a capacity of 128 termination. These termination includes subscriber lines, trunk to other exchanges, tones etc. 128 RAX has been designed to work as a terminal exchange to the requirements of rural areas. It can be interfaced with all type of switching equipment working at present in Indian Telecom Network. FEATURES: a) Non blocking transmission & switching networks b) Real Time Clock. c) On Line maintenance. d) Redundancy e) Field programming. f) Automatic System Alarm. g) Automatic and Manual diagnostics

MAIN AUTOMATIC EXCHANGE (MAX)

The manufacturing of MAX has been stored from early 1991. MAX is mainly used for local, tandem & transit application for rural, urban & metropolitan areas. MAX is expandable, large capacity of the order of 2,000 lines or beyond. The C-DOT DSS of different capacities can be put to use at various switching modes in the telecommunication network. FEATURES: a) Architecture is flexible to work as a remote module b) 512 ports RAX is completely non-blocking. c) It supplies concentration of up to 1:4 on lines.

INTERACTIVE VOICE RESPONSE SYSTEM (IVRS)

C-DOT IVRS is a computer telephony application where in subscriber calls are answered automatically and the required information is conveyed to subscriber depending upon service chosen and subscriber input in the form of announcements. The C-DOT IVRS can also dial subscribers and convey suitable messages depending on service chosen.

FEATURES: a) Low cost hardware and software. b) Support global dyadic pulse and DTMF detection. c) Implemented using DSP technology. d) Multiple applications supported in single system. e) Supports software packages used in Indian Telecom Network. f) Applications are configurable.

CONCLUSION

Hence, in last I can say that taking training in such an organization provided to very beneficial for me. I learn write a lot about UPS unit, PCB unit etc. I also got first hand knowledge of how an industry practically works. These all are necessary to know for an Engineering Graduate. Now we can think a better in the field of an engineering industry by learning such things in the systematic way. At the end I would like to thank my co- workers and teachers who helped me in preparing this meaningful report. I hope this report will be successful to make others understand about the various technology and process used to prepare various equipments.

BIBLIOGRAPHY

1) MANUAL PROVIDED BY I.L. 2) I.L website www.ilkota.in