TITLE:INPLANT TRAINING REPORT

PREPARED BY : SHIJIN SHA SHAHUL

4TH YEAR MECHANICAL 2014
ADMISSION NUMBER :11246
REGISTER NUMBER :11012003

AT:ALIND,SWITCHGEAR DIVISION
MANNAR,KERALA
PERIOD; 13 TH JUNE TO 23RD JUNE

ALIND
.

ALUMINIUM INDUSTRIES LIMITED

ALIND-THE POWER MOVERS

The Aluminium Industries Limited came into existence, on 2nd January 1946, promoted by
then Seshasayee Group with its Conductor Division set up in Kundra, Kerala under technical
collaboration from the world renowned ALCAN, Canada, The Aluminium Development
Laboratories U.K. & ALCAN S.A., Zurich, Switzerland. Since then, ALIND has produced more
than a million kilometers of AAC, ACSR and AAAC conductors building the lifelines of
power in India and Aboard, and hence ALIND Could rightly call itself THE POWER
MOVERS.
As the years rolled by, ALIND diversified Its activities by uniting various streams of power
transmission technology and emerged as multi-divisional composite corporate entity. ALIND
has kept abreast of the latest technology by collaborating with world leaders in their
chosen fields.

Presently ALIND with its Corporate Office in Mumbai has manufacturing units located in
the Three states of Kerala, Orrisa and Andhra Pradesh manufacturing cables and
conductors, steel wires, wire-working machinery, High voltage Switchgears and Static
relays, Export Division, Consultancy and Engineering Services Division

ALIND THE FIRST AND THE FOREMOST

To propagate the use and supply of Aluminium Conductors.

To Bring the revolutionary Properzi Process of Continuous casting and rolling of

Aluminium wire

To Manufacture ACSR core wire and High Tensile steel wire

To Export Conductors

To be awarded the ISI mark

To Manufacture Fibre glass reinforced resin bonded components

To Propagate SF6 Gas Circuit breaker Technology and obtain licence for manutacture.

To manufacture and supply Static and Numerical relays, Static & Numerical C&R
panels,alarm annunciators, Vacuum Interruptors ad Vacuum Circuit Breakers for the
Traction Installation of Indian Railways and the Only Indian supplier approved by
RDSO for vacuum interrupters and vacuum circuit breakers so far.

ALIND THE WEALTH OF TECHNOLOGY

Division

Products

1 Cables and
Conductors

AAC, ACSR, AAAC, ACAR underground cables,

polyethylene insulated cables etc

2 Steel Wire
Products
3 Switchgear

ACSR Core Wire, Ground / Shield wire for wire ropes

etc.
Switchgear from 3.6 kV to 245 kV, Current
transformers from 3.6 kV to 145 kV etc.

4 Relays

Static relays, controls and relay panels, alarm

annunciators etc

5 Machinery

Wire processing machinery

6 Material Handling

Material Handling equipments for Thermal Power

Plants, Mines etc.

SWITCHGEAR DIVISION

The Switchgear Division of Alind went into operation in1969 at Mannar in Kerala with
technical and financial participation of the then Delle-Alsthom, France
The initial product range being outdoor MOCBs of 36kV & 72.5 kV and oil filled outdoor
current transformers upto 72.5 kV. Indoor metal clad switchgear panels with MOCBs and 145
kV oil filled outdoor current transformers were added into the product range in year 1974 75 and 1978-79 respectively.
Having obtained licence for manufacture of the new technology Sulphur Hexa Fluoride (SF6)
gas circuit breakers for the first time in India, Alind entered into technical collaboration with
the same world leaders M/s Alsthom Atlantique, France for manufacture of these breakers of
145 kV & 245 kV ranges, propagated this technology in India through nation wide appraisal
programmes for all utilities and consultants and commenced manufacture towards early
eighties.

Another breakt hrough was made in 1984 by venturing in to Vacuum technology by going for
another collaboration with M/s Meidensha Electric Manufacturing Company Ltd, Japan for
manufacture of 12kV indoor metal clad switchgear panels with Vacuum Circuit breakers and
25kV Single pole Vacuum Interruptors and 25kV single pole Vacuum circuit breaker for Indian
Railways approved by RDSO after type testing & extensive field trials. Also ALIND
indigenously developed 25kV interruptor and vacuum breaker with magnetic actuator
mechanism which has completed field trials and approved by RDSO under development
source, thereby acquiring know -how and exposure to all the latest relevant technologies for
manufacture of medium, high and extra high voltage circuit, breakers.
Having imbibed the basic technologies in manufacture of circuit breakers, switchgears and
current transformers, ALIND Switchgear Division believed in the philosophy of inhouse R&D
for updating its technology base, uprating its product range, widening its application
engineering capabilities and innovative skills to come out with a wide range of customer
friendly equipments in the entire range of transmission and distribution. Alind Switchgear
Division has a well - built and modern R & D and manufacturing set up for faster adaptation of
its products to suit the varying needs of its prestigious clients from small scale, large scale,

megascale Industrial customers to Power Corporations,Indian Railways, State Electricity

Boards & most of the consultants, in addition to overseas clients like NEPA, Nigeria; NEA,
Nepal; MOD and MEW Dubai, Muscat etc.

ACKNOWLEDGEMENT

Without any effort no one gains anything .I know I got the chance to execute inplant training,
which is a part of my course, In ALIND, Switchgear Division, Mannar, Kerala,
only because of the efforts put forward by many persons and ther definitely needs to be
respected and thanked

First of all I thank the LORD ALMIGHTY, who is with me always in my needs and at all time,
without him the training would not haven been a success.
Next I would like say thanks to my Head of Department ,Dr.Ninan Chacko and my parents,who
tried to found me in the company as a part of my inplant training ,also I have pieasure to
thank all my teaching staffs and my friends,who encourage me a lot.

I thank each and every members of the organization, who permitted me to carry out the
training in there esteemed organization. Espectially,I would like to give my heart full of
gratitude and respect to Mr.Vijayan Personal Manager of the organization .In
addition to him there is one more person who deserves thanks and he is Mr.Jacob,Work
Manager of the organization, who very much interested in seein me going through each
and every sections in the manufacturing plant clearig doubts and in acquiring
knowledge.Also I say thanks to head of each department, who were very intensely
wanted me to grasp the knowledge from there respective departments.
It will be bad if I would not thank the workers ,supervisors and assistant supervisors in
the company, who spent their valuable time in explaining the jobs they perform and all
they know about the company. Without their effort this report would not have been

complete .So I express my great thanks to all the employees of the company.

And I too was lucky to complete my 10 days of inplant training with full success.
I am proud to say that I have been in a well-famous organization with well-educated and hard
working employees for about 10 days.

Once again ,I thank all those who were behind me always, pushing me, longing to see me
coming out from the job they gave completing in time and perfectly. And to all those, I
would like to convey one and only one thing-"Thanks, thanks a lot".

1.MACHINE SHOP

1.1 INTRODUCTION
A shop which does machining of components,so as to get the component in the required
dimensions is called Machine Shop or a shop with machine can also be called as Machine
shop.ALIND machine shop has machines like drilling machine,milling machine,lathe and grinding
machines .All the above mentioned machines machine or cuts components but in different
methods and thus the machining operation in each machines differs by name.Tools must be
harder than the work material,and then only a tool produces a cut on the work toshap the work
to the wanted dimensions.List of the machines available in the machine shop is tabulated in the
table 1.1 .The machines in the machine shop are arranged in process layout form.
Table 1.1
SERIAL
NUMBER
1.
2.
3.
4.
5.

ITEM

QUANTITY

Lathes
Drilling machines
Milling machines
Grinding machines
Boring machines

15
10
4
2
1

To understand the machine shop it is very necessary to get an idea about the
tool,gauges,fixtures,jigs etc .The tool room which has tools need for the machine shop,in the
machine shop contains all the above mentioned things;so let us see what the tool room has to
show

1.2 TOOL ROOM

Table 1.2

SERIAL NUMBER
1.

ITEM
Fixture

2.

Jig

3.

Snap gauge

4.

Plug gauge

5.

Vernier caliper
Screw gauge
Protactor etc

6.

9.

1.Drill
2.Reamer etc
H.S.S Tools
Chaser & Caesae
unit or Snapper
box
M.T Sleeve

10.

Slip Bush

7.
8.

USE
Used to clamp the work to the worktable
to prevent fluctuation
Used to guide the tool while machining
mainly in drilling machines
Used to check the outer dimensions of an
element
Used to check the inner dimensions of an
element
Used to measure the dimensions of an
element

Used to machine an element

Used to machine an element
Used to produce threads manually

Used to attach drills to the spindle of a

drilling machine
Used to guide tools through jigs

1.3 DEFINITIONS
1.3.1 GAUGES
It is necessary to check the dimensions of the machining and machined components ;for this
purpose workers use a device called gauge ;hence it can also be called as a measuring
instrument but there exits some difference between a pure gauge and a gauge etc are used to
measure the dimensions of components or elements.But a gauge is used for controlling the
dimension that is to keep the dimensions with the upper and lower tolerance limits
1.3.2 COOLANT
Coolant is supplied at the tool and wok contacting surface inorder to avoid the formation of
heat that may cause the work to ,tear and wear of both work and toll etc.There also exist a

chance to heat up the tool,which may tend the tool weaker leading to the breaking of the
tool.An expanded component does not have the correct dimensions just after the operation.It
takes time to get cool and the work contracts to its actual size.Then only its size should be
measured .If it is still high machine the work.Coolant used for an aluminium work is diesel or
kerosene because a light material needs only a light cutting oil.
1.3.3 CHUCK AND JAWS
Chuck is a part of lathe holding the work and the chuck is directly attached to the hollow
spindle .jaws are parts of a chuck ,which actually helps the chuck to hold the work.To have a
good hold atleast there must be three jaws ina chuck.On the basis of number of jaws a chuck
has is called by different names like three jae chuck ,four jaw chuck and so on.Jaws are of two
types differentiated according to the hardness of jaw like hard jaw and soft jaw .On soft jaws it
is possible so weld another parts but cant on hard jaws.Soft jaws are used to hold gears when
it is necessary to hold the gears from its outer periphery
1.3.4 COLOUR CODE
Diffeerent types of materials made works are machined in the machine shop.To differentiate
each material they are coloured by different colours .For a same operation for different works
of different materials will be carried out using different tools.Suppose if a tool of less hardness
than the work material is used that breaks the tool during operation.Since the tool is not
enough to produce a cut on the work as it is more harder.See the table 1.3

Table 1.3
SERIAL NUMBER
1.
2.
3.
4.
5.

MATERIAL
Mild steel
Half hardened steel
Nickel-Chromium steel
[EN8]or [M303]
Nickel-Chromium steel
[M305] or [EN24]
Soft iron[M216]

COLOUR
No colour
Yellow
Green
Red
white

1.3.5 FEED AND SPPED

Feed is the depth of cut in millimeter where as speed is speed of the spindle in RPM
1.4 LATHE FATHER OF MACHINES
In ALIND machine shop there are 15 lathes,in the 15 lathes 11 lathes are ordinary Center lathes
one turret lathe ,two Capstan lathes and one Coordinate lathe Lathes are used
in woodturning, metalworking, metal spinning, thermal spraying, parts reclamation, and glassworking. Lathes can be used to shape pottery, the best-known design being the potter's wheel.
Most suitably equipped metalworking lathes can also be used to produce most solids of
revolution, plane surfaces and screw threads or helices. Ornamental lathes can produce threedimensional solids of incredible complexity.
1.4.1 CENTER LATHE
The Centre Lathe is used to manufacture cylindrical shapes from a range of materials including;
steels and plastics. Many of the components that go together to make an engine work have
been manufactured using lathes. These may be lathes operated directly by people (manual
lathes) or computer controlled lathes (CNC machines) that have been programmed to carry out
a particular task. A basic manual centre lathe is shown below. This type of lathe is controlled by
a person turning the various handles on the top slide and cross slide in order to make a product
/ part.Since it was driven by engines ,still the name has importance because there are lathes
still now that is driven by engines
Table 1.4
SERIAL NUMBER
1.
2.
3.
4.
5.
6.
7.

SPECIFICATIONS
Type
Maximum speed
Minimum speed
Number of feeds
Minimum speed range
Normal speed range
Maximum speed range

VALUES
Center lathe
1600 RPM
32 RPM
3
32-100 RPM
125-400 RPM
500-1600 RPM

There lathes have a long and vibration absorbable is cast iron because it has the property called
Damping capacity .Pitch is the distance between the crests of two consecutive threads.Let us
now see the thread dial setting for center lathe ,which is explained with the aid of three
examples see table 1.5

Table 1.5
THREAD PITCH in mm
1.25
2.5
14

DRIVING PINION
36
33
35

NUMBER OF LINES ON DISC

12
3
5

1.4.2 CAPSTAN AND TURRET LATHES

A capstan lathe is a milling machine used to create the same parts over and over again. The cutting bits
are mounted on a rotatable turret known as a capstan, which allows the user to quickly change the
orientation of the bits for cutting without having to take off the first bit and then mount the second. A
piece of raw material, sometimes known as a blank, is mounted into the capstan lathe and is then spun
at high speed. The cutting tools, sometimes known as knives, are then used to cut into the blank to
create a new shape or design.
The turret lathe is a form of metal working lathe that is used for repetitive production of duplicate
parts, which by the nature of their cutting process are usually interchangeable. It evolved from earlier
lathes with the addition of the turret, which is an indexable toolholder that allows multiple cutting
operations to be performed, each with a different cutting tool, in easy, rapid succession, with no need
for the operator to perform setup tasks in between, such as installing or uninstalling tools, nor to control
the toolpath. The latter is due to the toolpath's being controlled by the machine, either in jig-like
fashion, via the mechanical limits placed on it by the turret's slide and stops, or via electronicallydirected servomechanisms for computer numerical control lathes

1.4.3 LATHE COORDINATE SYSTEM

Most lathes are 2D machines based on a Z-X Coordinate System. The Z-axis is parallel to the machine
spindle and the X-axis is perpendicular to the spindle. Normal spindle rotation is counter-clockwise,
though direction can be reversed for left-handed threads just like with a mill by commanding the proper
G-code.
Notice how the turret is set at an incline from horizontal. This so-called "slant bed" configuration keeps
cutting chips from accumulating on flat surfaces inside the machine.Also notice that the tool approaches
from the top of the part. This is known as an upper-turret configuration, and requires the tool be placed
in the holder upside-down

1.5 DRILLING MACHINE

Drilling is the operation of producing circular hole in the work-piece by using a rotating cutter called
DRILL.The machine used for drilling is called drilling machine.The drilling operation can also be
accomplished in lathe, in which the drill is held in tailstock and the work is held by the chuck.The most

common drill used is the twist drill. It is the simplest and accurate machine used in production shop.The
work piece is held stationary ie. Clamped in position and the drill rotates to make a hole.

1.5.1 RADIAL DRILLING MACHINE

A radial drilling machine or radial arm press is a geared drill head that is mounted on an arm assembly
that can be moved around to the extent of its arm reach. The most important components are the arm,
column, and the drill head. The drill head of the radial drilling machine can be moved, adjusted in height,
and rotated. Aside from its compact design, the radial drill press is capable of positioning its drill head to
the work piece through this radial arm mechanism.
This is probably one of the reasons why more machinists prefer using this type of drilling machine. In
fact, the radial drilling machine is considered the most versatile type of drill press. The tasks that a radial
drilling machine can do include boring holes, countersinking, and grinding off small particles in masonry
works.
Although some drill presses are floor mounted, the most common set-up of radial arm drill presses are
those that are mounted on work benches or tables. With this kind of set-up, it is easier to mount the
drill and the work pieces. There is no need to reposition work pieces because the arm can extend as far
as its length could allow. Moreover, it is easier to maneuver large work pieces with the radial arm
drilling machine. Large work pieces can be mounted on the table by cranes as the arm can be swiveled
out of the way.

1.5.2 HIGH SPEED SENSITIVE DRILLING MACHINE

The sensitive Drilling machine permits drilling by fractional drills for nozzle,PCB and similar critical
applications.
Double column construction provides rigidly during sensitive Drilling.Short Spindle stroke through larger
pinion permits quick retraction for wood pecking operation
Special Features

Ground & lapped Columns from Seamless Pipes

Machined base with Accurate T slots.
Improved Lubrication.
Key less chuck directly mounted on spindle

Extra Accessories

Collent attachment
Machine lamp
Fabrication stand
Spindle with collet chucking nose

1.6 BORING MACHINE

Boring machine, device for producing smooth and accurate holes in a workpiece by enlarging existing
holes with a bore, which may bear a single cutting tip of steel, cemented carbide, or diamond or may be
a small grinding wheel. Single-point tools, gripped in a boring head attached to a rotating spindle, are
moved circularly against the sides of the existing holes. The diameter of the hole swept out by the tool is
controlled by adjustment of the boring head.
Grinding-wheel cutters have a planetary motion, rotating rapidly about their own axes, which in turn
slowly rotate with the boring head about the spindle axis; the hole diameter is controlled by adjusting
the distance between the wheel axis and the spindle axis. The spindles on boring machines may rotate

about vertical or horizontal axes.Boring machines used in toolmaking shops have one vertical
spindle and a work-holding table that can be moved horizontally in two directions
perpendicular to each other so that holes can be accurately spaced. On some machines the
spacing error is less than 0.002 percent. In mass-production plants, special boring machines
with multiple spindles are common.
Table 1.6
SERIAL NUMBER
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

FEATURE
Type
Maximum speed
Minmum speed
Type of current
Frequency
Operating voltage
Control voltage
Connected load
Nominal current of machine
Nominal current of supply
fuse
Total weight

VALUE
Horizontal type
1400RPM
40RPM
Altrnating
50Hz
420 V
220 V
35KW
68Amps
120Amps
15Amps
53tons

1.7 MILLING MACHINE

Used to produce one or more machined surfaces accurately on workpiece.Workpiece held on
work table or holding device and brought into contact with cutter.Vertical milling machine most
common,Horizontal milling machine handles operations normally performed by other tools.

Table 1.7 shows the maximum and minimum speed range for 1 st,2nd,3rd and 4th machines in
order
Table 1.7
SERIAL NUMBER
1.
2.
3.
4.
5.
6.
7.
8.

MAXIMUM SPEED
Maximum speed
Minimum speed
Maximum speed
Minimum speed
Maximum speed
Minimum speed
Maximum speed
Minimum speed

RPM
1270
25
1600
68
1800
45
635
34

1.8 MACHINED SURFACE FINISH

Operations,which are by removing material and not by removing material,and its rugosity in
microns are tabulated in table 1.9 and in table 1.10 respectively.
Table 1.8
OPERATIONS
Shearing
Gas cutting
Turning
Milling
Planning
Drilling
Reaming
Broaching
Grinding
Honing
Lapping
Polishing
Super finishing

RUGOSITY
2.5-6.3
-do6.3-0.4
-do-do5.8-1.2
5.2-0.8
-do2.8-0.1
0.4
0.3-0.025
0.4-0.025
0.2-0.025

Table 1.9
OPERATIONS
Sand casting
Hot rolling

RUGOSITY
27-6
18-5.2

Forging
Die casting
Cold rolling & drawing
Extrusion

7.8-3.2
5.8-1.2
5.6-0.4
-do-

Rugosity between certain limits is represented by triangles,which can be single triangle or

double triangle or poly triangle .As the rugosity decreases the number of triangles also
increases and vice versa.rugosity is said in microns.

1.9 CONCLUSION
Really it was worthy,the time I spent in the shop ,since I could find almost all the machines
working right infront of my eyes and also the tools used for each and every operation that
executed in the machines.i could know about the component drawings and also understood
some of the terms used in the drawings to express some facts.

2. FABRICATION SHOP

2.1 INTRODUCTION
ALIND Fabrication shop does operations like shearing, punching, welding, sawing etc.
Fabrication means constructing, with the aid of above noted operations the shop is
constructing new elements from the basic materials given to the shop. Lets us have a study on
fabrication shop in detail. Operations in the fabrication shop are divided into four as F1, F2, F3
and F4. F4 is the final operation in the fabrication shop and F1 operation discuss about the
cutting of the metal sheets, F2 discussing bending and punching. F3 discusses welding and
finally F4 doing the calibration operation.
An operation that has to be carried out before starting with the F1 operation is straightening.
In any company when there is a work to perform on a sheet metal, even if it is a small sheet, it
has to straighten.
Table2.1
SERIAL NUMBER
1
2
3
4
5
6
7

SPECIFICATION
Maximum pressure
Distance between housing
Length of stroke
Depth of gap
approximate approach speed
Approximate pressing speed
Hydraulic pump motor

VALUES
120tons
2080mm
180mm
320
75mm/sec
800/sec
15HP

It is possible to adjust the vertical movement length of blade towards down.The pressure
applying on the plate can be changed according to the thickness of the plate.if the
maximum pressure is applied to all the plates with thickness ranging from 1mm to 10mm it is
just wastage of energy and also some times that much pressure for a plates with less
thickness may brek it or may have a chance of uneven bending.

2.2 STRAIGHTENING MACHINE

The sheet or long plates, which are brought out from the company for further processing,
needs straightening because they might have some bends due to the rough handling of the
metal sheets during the carriage to the company. Before supplying these metal sheets for
cutting, punching or for any process it is must to straightening them, then only it is possible to
get accurate output. Rollers are used to straightening the metal sheet hence the machine is
sometimes called as rollers machine but the name straightening machine suits a lot for the
machine than the other as the operation conducted on the machine is straightening. Totally
and rollers are in the machine, 4 above and 4 below. Top and bottom rollers are kept at some
distance. Rotating the gap adjusting screws can change the gap between the top and bottom
rollers. Anti-clockwise rotation of the screws in the gap and vice versa. But the interesting thing
is that there are and screws in the machine and not even one of them are not for the bottom
rollers. All the bottom rollers are constantly positioned. There are 4 screws in the right side of
the machine directly above the right end of the top rollers and similarly 4 screws are available
at the left side of the machine directly above the left end of the top rollers. These screws are
rotated and the top rollers are positioned at the required height. See the table 2.1 to see some
specifications of the machine.
Table 2.2
SERIAL NUMBER
1
2
3
4
5
6

SPECIFICATION
Type
Supply voltage
Control voltage
Current
Current type
Motor HP

VALUE
Poly- high roll mill
440V
220V
3.8- 5Amps
3phase 50Henz
3

Type of straightening machine is named by seeing the number of rolls it has. Hence the above
studied machine can also be called as eight high roll mills.
2.3 F1 PROCESS
As 1 mentioned in the first paragraph F1 process deals with cutting operation. Three different
machines are used. List of machines under F1 proceed are tabulated in the table 2.2
Table 2.3
SERIAL NUMBER
1

MACHINES
Shearing machine

QUANTITY
2

2
3

Sawing machine
Gas cutting machine

2
2

2.4 SHEARING MACHINE

In simple words shearing means cutting and a machine doing such operation is called
shearing machine. Blade clearance, its done for the smooth shearing. As the thickness of the
plate or metal sheet increases and if we maintain the distance between the blades to be same
as kept for the previous less thickness plate the shearing will takes place roughly or even
sometimes no cutting. So it is necessary to increase the distance between the top and lower
blade [blades] as the thickness of the plane increases.
Blade clearance adjusting unit is provided in the machine to machine to change the distance
between blades. Before adjusting the blade clearance slacken off nuts at both ends of the
machine, Retighten after adjustment. In the adjusting unit 3 divisions make 1mm. Thus for a
1mm thick metal sheet the blade clearance should be coinciding the 3 division line. Another
method used for the same blade clearance is done with the help of feeler gauge. After the
preliminary steps metal sheets are sheared.
A machine is said to be mechanical or hydrolic or any other type based on the type of force
applied for the ultimate action. Mechanically controlled blades cuts the sheets, hence the
machine is called mechanical machine.
Safety grids or safety rods are available at the front of cutting blade to prevent the worker
hands to be free from injuries. Jackeys are also available behind the safety rods, which actually
keeps the metal sheet held at a position when the cut takes place.
Jackyes are operated hydraulically, if no jackeys are used the metal sheets will be dislocated
from its cutting position and may produce imperfect outputs or more than that the thrown or
dislocated sheets may harm workers.

CUT SECTION VIEW OF THE UPPER BLADE

Cutting face

Cutting edge
Fig 2.1
Two shearing machine are available in the fabrication shp. Capacity of these two machines is
different. 3200mm mild steel and 1mm- 10mm thick metal sheets are sheared on the machines.
First machine cuts mild steel sheets of size 3200mm 5-10mm thick whereas the second has a
lesser capacity cutting only mild steel sheets of 3200mm i-5mm thick. Upper Blades for both
the machines are kept at 3-5 degrees with respect to the lower blade ie: taking lower blade as
X-axis. Only when there is an angle between the cutting blades we get a cut ; the best example
is scissors. This angle cut also help in reducing the motor load there by increasing the durability
of the motor preventing the motor from sudden breakage. Jackeyss on the first machine is
operated hydraulically or mechanically just before the shearing of the sheet takes place. Since
this machine has larger capacity sometimes the simultaneously action of jackeys and shearing
may cause distorations. To prevent that we apply the jackeys before the cutting operations. If
the blades are kept straight there wont be any shearing instead besiding happens. Some
specifications of one of the shearing machine are shown in the table 2.3
Table 2.4
SERIAL NUMBER
1
2
3
4
5
6
7
8

SPECIFICATIONS
Capacity
U.T.M of work material
Force exerted for hold down
Main motor HP
Motor shaft speed
Air supply
Number of jackeys
Hydraulic oil capacity

VALUES
3200mm wide&6mm thick
45.540kg/mm2
500kg
10
1500RPM
5.50kg/cm2
11
40litres

Working note
An air compressor supplies compressed high pressure as the foot switch is pressed to the air
bucket a shaft, which has two cams at its extreme ends, gets connected to the rotating fly
wheel, which is rotated by the main motor, which started when the main switch was made on
and thus the long shift with cams eccentric rotates with the same speed. A follower that is
mechanically connected to the cum moves up and down once in one rotation. The follower is
connected to the part where the upper blade is screwed. The upper blade does the shearing
when the follower moves down. After the cut the solenoid valve stops the supply of air to the
air bucket and thus connection between the camshaft and flywheel disengage. Air compressor
has the following specification. See table 2.4
Table 2.5
SERIAL NUMBER
1
2
3
4

SPECIFICATIONS
Current
Speed
Power
Pressure in the container

VALUES
7.5mps
1420RPM
3.7KW
5.5kg/mm2

A query that naturally arises in us at this stage is what is the need of two shearing machines.
Answer is very simple, only two points. Increase in the machine numbers which does same
operation considerably help to increase the production rate that is mass production. Second
point is also important as above. Suppose you think that you want to cut a mild steel sheet of
length 3000mm with a thickness of 3mm, we can perform the operation very easily in the first
machine, that is the machine with higher capacity and perform the cutting operation in the
second machine also. Since the metal sheet size is within the capacity of the second machine is
could do the operation with ease. In these two cases much energy is consumed by the first
machine since the motors, air compressors etc using for that machine needs more power for its
working. So it is desirable to conduct the operation for that size sheet on the second machine.
Thus by using two machine of different capacities we can save energy.
2.5 POWER HACKSAW
Another cutting operation is performed on power hacksaw machine. Since sawing is the
operation carried out by the machine, it is commonly knows sawing machine. Irregular works
are cut in sawing machine. Only straight cuts are possible. Sawing blade is made of a material
called high speed steel. Different blades made of different materials are used for cutting
different materials. After the cutting stroke, on its return stroke, the blade moves back and at
the same time the blade is raised. This raising of blade during the return stroke is made

possible with the help of a valve intermitting oil, which is pumped used two pistons. Alternate
teeths of the blade are slightly tilted to either side. Thus the free movement of the blade
occurs while it raises. Top view of such 1 blade is shown in the figure 2.2.

Two power hacksaws are in the fabrication shop both of same specifications. Three different
speeds are available for both the machines. Speed of the machine can be changed by changing
the position of the power-transmitting belt by repositioning in any of the three pulleys available
at the motor shaft end and at the flywheel end. Need of three different speeds becomes more
important when the machine has to cut different Materials. Lets us see how the speed
variationtakes place when the belt is placed at different positions. See the figure 2.3

A motor shaft is connected to a set of pulleys [x1,x2 and x3] and an another set of pulleys [y1,
y2 and y3] is kept at some distance to which the rotating power is transmitted through belts
from the first set of pulleys. If the belt is placed on x1 and y1 pulleys. If the belt is on x2 and y2
pulleys, the speed is normal or an average of the other two speeds.
Another types of sawing machines in the fabrication shop are vertical sawing machine and
horizondal band sawing machine. They also have the similar features. The main difference
between these machines is the direction in which blade when cutting is performed on the work.
Whenever a cut is producing is during cutting action , coolant must be allowed to pass through
the cutting area. Coolant helps to reduce the heat generation while the blade moves over the
work , performing the cutting operation thereby the blade absorbs less heat , preventing from

the breakage of blade. Another important factor is that it helps to take away the minute tiny
chips from the utting area, increasing the time saving and energy saving.
In case of vertical sawing machine feed for the work is given manually. For a very hard material
the feed rate is less compared to the rate of a less hard material cutting. But in horizondal band
sawing machine the work is held stationary. The blade used for cutting in the horizondal band
sawing machine moves down as the cut occurs because of the self-weight of the blade
arrangement and rotating system for the blade. A spring connected at the slow downward
motion of the total blade arrangement.
Blade for the horizondal and vertical sawing machines are brought as a roll from outside the
company and then they are brazed to form a ring after cutting the required length out from the
roll. But weld can also done to weld band saw blade. The table 2.5 shown shows the welding
current, upsetting pressure etc needed for various widths of band saws when welded in the
butt welder machine.

2.6 F3 PROCESS

Welding is the only F3 process.Different types of welding machines are in the shop
through which permanent joints can be made.Different types of welding is carried out in
the fabrication shop and they are
1. Space welding
2. Electric welding
3. Gas welding

Process is carried out in the shop.Brazing is a process of producing temporary joints

at a temperature higher than the metal recrystalisation.
Electrodes used for electric arc welding should be treated for 4 hrs at around 100 degree
C and kept inside dry ovens.Remove 10/15 electrodes at a time as per requirement
and electrdes to the oven if not immediately required.Electrodes should be

kept in portable oven or atleast in packets in welding sites

movement it press the punch that is placed in the die and produce the required shape on
the work.

2.7 BENDING MACHINE OR PRESS BRAKE

Two bending machine one mechanically applying the bending force and the other one
hydraulically applying the forces are in the fabrication shop.because of difference in the
bemding force the machine are called by different names.A machine which applies
mechanical force for bending is called mechanical bending machine similarly the other
machine are called hydraulic bending machine. these machine are not only different by
its means but aiso wiyh there capacity.

Bending bladers are not sharp and they are in different form.The blade should act every
where on the bending surface uniformly otherwise the plate will deform in unwanted
way.Uniformely applying the force will lead the plate to blend in the required form.
Blades are clamped to a device called ram through nuts and bolts.

According to the bending angle required the beds could be changed.In case of
machanical bending machine the ram is connected to the two cams.These two cams are
economic.These cams convert the rotating moton of the camshaft which the cams are
connected to the reciprocating motion of the cam.

When the foot switch is pressed the clutch system connects the camshaft to the flywheel,
thereby rotating the camshaft.In the case of hydraulic bending machine hydraulic oil
filled in the two housings at the sides of the ram pushes down ram when the electric
foot switch is pressed.

2.8 PUNCHING MACHINE

Actually the machine is called machanical press but the operation carried out in
machine is 'punching';it is called as a punching machine.Manufacture of machine is
AMETEEP Company.The maximum punch hole size is 50mm. The maximum
thickness of the plate that can be punched in the machine is 15mm.Square punches and
rectangular punches can be produced with the help of dies and punches for such holes.

Table 2.6
SERIAL NUMBER
1
2
3
4

SPECIFICATION
TYPE
MAXIMUN PRESSURE
FLYWHEEL SPEED
MOTOR HP

VALUES
MECHANICAL PRESS
IN TONES
100
45RPM
10

Compressed high pressure air from the compressor goes to the air filter and
remove all dust particles in the air and from there to the solenoid valve.Solenoid
valve opens the path for the air to the air bucket and aiso it disengages the breaker
from connecting shaft simultaneously the compressed air in the bucket connects the

rotating fly wheel and connecting shaft.Small gear which is a part of the shaft is
externally interfaced with a large /big gear and rotates which in turn rotates the
camshaft.Cam on the cam shaft moves up and down the follower;ie here the
follower is pressing unit.Pressing unit transfers 100ton pressure on the punch,which
moves through a die.After one rotation of the camshaft such an arrangement has done
that the solenoid valve stops the air to the air bucket simultaneously putting breaking to
the connecting shaft by engaging the breaker to the connecting shaft.

The fullpunching machine can be tilted vertically backward.At this position large
works can be accomodated in the machine.Upto 10mm thick works can be punched in
the machine.There should be some allowance between the die and the punch to allow the
free or smooth movement of the punch in the die.

2.9 TURBET PUNCHING MACHINE

Two mechanical presses are presented in the fabrication shop.We saw the first machine in
the above paragraph.Now let us deal about the second punching machine.The second
machine is manufactured by EDEL group of companie hence the machine is called
'EDEL press'.It can produce holes with a maximum diameters of 50mm for 4mm
thick and 100mm for 2mm thick plate.Twelve punch holders are placed in the form of
half circle.

WORKING:

The template is fixed to the machine.Template is a replica of the work that is needed
after the complete operation,which are going to be performed on the machine.Switch
on the machine.The mator start rotataing.The filwheel connected to the motor shaft
rotates.The work is clamped.A table which automatiacally works is provided with
the machine to support long and heavy works.As we move the work away from
the punch a limiting switch opens the path for the hydraulic oil and pushes up
the table.When the work is taken back to the working position the table goes down as the
limiting
switch stops the supply of hydraulic oil.By pressing the right and left switches in the
machine moves the 12 punches arranged in the form of half circle towards right or left
according to the bottom pressed.When the required punch has come to the form or
punching portion that punch is clamped.

Table2.7
ELECTRODE
2.00
2.50
3.15
4.00
5.00
6.30

ELECTRODE LENGTH
3.00
350
350/400
450
450
450

CURRENT APPLIED
50-70
70-100
100-140
140-180
180-220
240-280

In case of gas welding addition metal is added separetely.The addition metal is coated

with the appropriate flux by the worker and is used as the filter metal.Mostly 'Eutector
flux' is used.Nozzle is made up of 'tungsten-carbide' material because this material has
greater withstanding capacity aganist high temperature.Electrodes used for holding the
works for other welding methods are made up of tungsten-cooper alloy.Since it conduct
electricity as well as it has withstanding capacity is high.

2.10 F4 PROCESS
f4 is nothing but just 'finishing process'called calibration. Surface table are used for
checking the flatness of the works.Deburning machines are also used with the help of
emery papers and abrasive discs.As the grain size increases of the deburning papers
increases the ability of the paper to produce more finished surface.

2.11 CONCLUSION
From the fabrication shop I learned about machines like shearing machines,bending
machines,punching machines and much more. A special study was done on mechanical
press

3.ENGINEERING SERVICE DEPARTMENT

3.1 INTRODUCTION
Servicing through engineering is the main aim of engineering service department. This
department mainly works in other four departments in the plant. They are:
Machine shop
Fabrication shop
Assembling shop and
Auxiallary shop
Major jobs of engineering service department are:
1. Manufacturing of jigs and fixtures.
2. Design review and
3. Workers performance analysis

3.2 MANUFACTURING OF JIGS AND FIXTURES

Fixtures and Jigs are things that help a worker to carry out the operations on a work with
lets and fixtures.. jigs guides the tool where as the fixture fixes the work in a constant
position during operation that is it does not allow the work to move while the operation is
performed. They are mandatory in almost all shops to increase the production rate, to
increase the accuracy of the end product and to reduce the stress on the worker during
conducting the operation. Jigs and fixtures are manufactured according to the need. Things
that have to keep in mind while constructing jigs and fixtures are many. The worker feel
Earlness to fix the fixtures on the table and also while clamping the worker to the fixture. It
should take only less time to do the initial settings. Clearance, it is another important that is
needed with jigs and fixtures to increase the workability. All the dealings and manufacturing
of jigs and fixtures takes under engineering service department.

3.3DESIGN SERVICE
Design department has the authority for designing new products or parts of products.
This design is in the form of drawings are transferred to the engineering service were it
is student clearly and put positive suggestions or sometimes the design are rejected.
The drawing that is coming to the engineering service department from the design
department is called uncontrolled copy, Incase of perfect drawing, which suits in every
aspect, the drawing is send back to the design department with acceptation form, then
the drawing is passed to the department were that product is going to be
manufactured. Such a copy accepted by the engineering service department and passed
into the respective manufacturing department is called as controlled copy.

3.4 IN CASE OF VACUUM QUENCHING MEDIUM

The contact surface in case of vacuum quenching medium is called butt-contacting surface. In
figure 4.4 the contacting surface and adjacent parts are shown. The two contacting surfaces
come in contact as the closing coil operates. The wipe spring connected towards the down end
of the araldite and serves two purposes, which are very important for the safe working of
circuit breaker. The wipe spring is compressed towards the end of closing operation. Always the
wipe spring used will be a compression spring or called open spring. Through the compression
the wipe does the two important jobs, the are
1. The contacting surface must be tight or strong. There should not be any gap,which leads
to sparking. A force from the wipe springs aids to hold the contacting surface tightly.
2. The second purpose is that it allows to absorb by itself the extra energy when not need
for the closing while in normal working period

INCASE OF MINIMUM OIL QUENCHING MEDIUM

The name minimum oil circuit breaker came from quenching medium it has and also from the
quantity of quenching medium used. The sparking area is entirely different from the former
type. A rod is used which is penetrated into the fixed holder. The rod is made up conducting
material. A silvered copper rod is used in the minimum oil circuit breakers. The rod is always
fixed to the lower holder. When the power from the closing coil acts all of a sudden the lower
with the rod moves up and penetrates into the arms of upper holder which is kept in
compression.
The compression force is provided on both the holder with the help of springs attached at the
sides of the arms. Since the rod does not have an easy movement get its position inside the
upper holder arms, the entering process if called penetration of the contact rod . At the time
of penetration spark occurs. It is always advisable to take very less time to finish of the closing
operation.
The rod has a sharp pointed end at the penetrating point or at its upper end. This helps to have
lesser energy for the closing operation. During tripping the lower holder moves down with the
contact rod and disengages the rod from the upper holder. The oil is circulated in an
orthojector principle i.e. [self blast]. Diagrams for holder arms holding the penetrating rod and
the diagram for contact surface of the surface is shown in figure 4.5 and 4.6

3.5 IN CASE OF SULPHUR HEXA-FLOURIDE QUENCHING MECHANISM

Here a nozzle type arrangement is provided. When a spark is formed, piston which is a part of
the arrangement goes down compressing the SF6 gas under it. As the piston goes down
through the sides of the piston compressed gas is supplied to the spark point reducing the
effect of spark. This whole process is called Puffer Process .
Note: all the above mentioned techniques have wipe spring. Since it is not shown in some
diagrams there is nothing like that it does not exist for that particular type.
MECHANISMS
Heart of circuit breaker pumps the energy to the system to close or trip according to the
situation. Three different mechanisms are used to control the closing and opening of the
breakers. Selection of a particular mechanism for a circuit breaker depends upon the amount of
energy needed to trip and close the circuit. Energy to the mechanism can be provided through
spring energy system , hydraulic energy system and solenoid energy system . Mostly spring
energy system is applied. In this energy system the internal energy of a spring, the spring may
be either closed spring or open spring. When it is stretched or compressed is supplied to the
mechanism to work to produce the ultimate result. We will discuss about the BLR spring energy
mechanism; other mechanisms are similar to this mechanism.
BLR mechanism is incorporated in medium tension or normal tension circuit breakers. Normally
circuit breakers which are forwarded to Indian Railways, are of medium tension. When the
Railway request a circuit breaker with single pole, the mechanism fitted to it will be BLR
mechanism. Single pole indicates single phase. Suppose a three pole is manufactured it is
incorporated with BNR mechanism since it has the capacity to operate all the three poles at a
time. Three pole circuit breakers are used where a three phase supply is presented. Three poles
are separated by the alphabets R, Y and B indicating Red, Yellow and Blue. Mainly three pole
circuit breakers are used in substation were three pole supply comes.
In BLR mechanism which has equipments like precision limit switch, motor, redactor, redactor
shaft, pinion, sprocket wheel, springs(open or closed springs), latches, tripping coil, closing coil,
axial switch and power shaft. Consider the circuit is open. As the first process the limit switch
remains on all the time. Then the motor switch is pressed on. Motor speed is 15000 RPM.
Motor rotates at this high speed which is not at all needed for the working of mechanism.

Hence a reducer is used, which reduces the speed with the help of the gear arrangement in the
redactor. The power transfers from the redactor to a pinion through redactor shaft. From the
pinion to sprocket wheel the power conveyed through chains.
A spring is fixed to a surface through nuts and bolts. Consider the spring to be closed spring.
Another chain from the other end of the spring is attached to the sprocket wheel. Because of
the power from the pinion form the motor sprocket wheel rotates. As the wheel rotates the
chain from one end of the spring attached to the wheel also moves resulting in stretching the
closed coil and before one full rotation of the wheel the spring is fully charged with energy that
is its is fully stretched and at the point a latch stops the further rotation of the wheel. Then the
closing coil is charged and it pushes the latch. Thus in the next rotation of the wheel the energy
stored in the spring is discharged to the power shaft which rotates in anti-clockwise direction
when viewed from back of the breaker pushes up the araldite rod to close the circuit.
Simultaneously the tripping spring is charged. As the next process when the tripping spring is
fully charged the tripping latch stops the further movement of sprocket wheel. When a fault
comes as per the message from the relay the tripping coil gets charged and pushes the latch.
When the obstruction (latch) is removed the sprocket wheel rotates discharging the tripping
spring energy to the power shaft. Which rotates in clockwise direction at this point when
viewed from the back of breaker and the power shaft pulls the araldite rod resulting in the
tripping of the breaker axial switch supplies the current needed for the coil to be charged and
after the operation of the coils, automatically the axial switch cuts the supply. Relay supply is
first coming to the axial switch and from there the axial switch decides which coil to open.
Closing coil and tripping coil can also be operated manually. Separate switches for each coil are
provided in the mechanism. Thus even there is no fault an operator can cuts off the supply to
any region. Sometimes some amount of air very rarely have a chance to go inside the oil
breaker cylinder not in the bottle which has to be restricted to the most but again air goes. This
does not create that many problems ion the durability of the circuit breaker if it does not have
moisture content.
So when the prevention of air is not fully possible another step taken is to prevent the moisture
that may go inside with the air. A silica gel breather is attached at the place where the chance
for the entering of air exists. This silica gel breather absorbs all the amount of moisture in the
air that goes inside. Tripping spring is smaller size than the closing spring. This difference
depends upon the energy needed to do the operation by each spring. When the closing
operation is carried out simultaneously the tripping spring is charged or stretched to maximum.
So the closing spring should have sufficient energy to close the circuit as well as energy for
stretching or charging the tripping coil fully.

Energy of a spring depends upon its size. So naturally a spring which more energy will be larger
in size when compared to a spring with less energy.
3.6 WORKING OF CLOSED COIL AND TRIPPING COIL
Working of both coils is identical. We will take into account the tripping coil to study the
working. The coil has two temporary magnets and a coil surrounding them and when the supply
from the axial switch reaches the coil, the temporary magnets are energized or magnetized and
become strong magnets. They are so strongly magnetized that the temporary magnets
becomes like permanent magnets with high magnetic attracting property. The arrangement is
so made that the top magnet attracts the bottom magnets moves very fast towards the top
magnets pushing it up, that the upward movement of the top magnet move some distance that
it goes and its the latch. When the magnet strikes the latch, the obstruction due to the latch is
removed and the sprocket wheel rotates and ultimately performing the tripping operation.
3.7 CONCLUSION
A shop, were the product is brought to final shape and size, is assembly shop and great effort is
put to give out rigid structured CBs. The time I spend in the assembly shop, which also deals
with a lot about electrical items, found to be a profitable when thinking of the knowledge I
gained.

4.MAINTANANCE DEPARTMENT
4.1 INTRODUCTION
Maintenance department maintains the company with healthy machines; machines may be
electrical type or mechanical type. Maintanance department also undertakes even plumping
maintenance. Maintanance department shows their service in all other departments in the
company some way or other but once again the most important or frequent departments using
their helps are machine shop, fabrication shop and auxillary shop. Maintenance department
keeps all the manuals of the machines in the plant and study them well. This helps them to
execute the maintenance with ease. The department consists workers specialized in the
mechanical and electrical type machines. All through the report on the maintenance
department, machines mean mechanical or electrical type.
4.2 TYPES OF MAINTANANCE
There are three major divisions in the types of maintenance; they are preventive maintenance,
predictive maintenance and breakdown maintenance. A maintenance department following all
these types of maintenance is said to be an ideal or standard maintenance department.
1. PREVENTIVE MAINTENANCE
It is nothing but the maintenance doing after finding a minor problem in a machine and clearing
them to prevent major problems, which may affect the machine as an aftereffect of the minor
problem. In most case minor problems are identified from the abnormal sound of a machine
while it is in running condition by an experienced operator of the machine.
2. PREDICTIVE MAINTENANCE
This is another very important and very difficult type of maintenance. Even before occurring of
a problem in a machine, the machine is checked for any mistakes in its working. Predictive type
maintenance has a schedule the maintenance is carried out.
3. BREAKDOWN MAINTANCE
Maintenance after a problem has occurred is called so and becomes very difficult task
sometimes. So it is always to cure the problems that have the chances to occur through
predictive maintenance. But sometimes it is very difficult to identify the initiation of any

problems; sometimes it may be a sudden breakdown of the machine. In that cases breakdown
maintenance does the job

4.3 MACHINES THAT WILL COME UNDER MAINTENANCE DEPARTMENT

Only three machines comes under this category and they are air compressors, generator and
substation. Air compressors are used mainly in the auxillary shop for shot blasting and some air
compressors are used in the fabrication shop. Generator supplies current to the whole the
plant when there is a need. The 1 KV substation is the last item directly under the control of
maintenance department. It is the supply centre of current to different shops or departments in
the plant and also has the provision to open the current circuit to any departments.
4.4 FREQUENT CHECK UP NEEDED DEPARTMENTS AND MACHINES
Under this category, shop like machine shop, fabrication shop and auxillary shop exists. In
mechanical shop centre lathes finds to be most mistake affecting machine because of their
aging and heavy use. In fabrication shop EDEL press seems to be the most complicated
construction and has sophisticated working mechanism so this machines comes under frequent
checkups.
4.5 PROCEDURES
Procedures means the way by which a problem occurred in shop is presented or informed to
the maintenance department and its followings. Suppose a shop supervisor has come to know
about a machine, which needs maintenance , the supervisor writes the need as a complaint in
the complaint register kept in the maintenance department. Maintenance department then
goes through the complaint register book and then identifies the complaints and method of
solving the problem. As the first step, the maintenance operation the worker from maintenance
department checks when the machine was last undergone the predictive maintenance and gets
the idea about all the problems the machine had in part. Then machine is operated to check
two things; one to know how the operator operates the machine and second is to check up the
supply to all parts of the machine. After the maintenance or solving problems, the maintenance
department gets satisfaction of the respective problems associated department supervisor and
the worker who operates the machine.
4.6 IDENTIFICATION OF PROBLEMS
Identification of what type of problem is linked with the machine is not very difficult but it is,
sometimes, very difficult to identify where the problems has occurred. In case of a mechanical
problem, the problem will be most of times visible to the naked eyes or can be identified by

hearing the sound. To solve a mechanical problem there is no need of much theory knowlwdge,
but by having little logic most of the mechanical problems can be carried out. But it is always
best to have mechanical specializes workers because they do not consume a lot of time in
clearing the problem.In case of an electrical problem the above statement doesnot find any
importance.A person who is going to do the electrical maintence should need sufficient theory
knowledge.Spare parts if essential are taken
from the store after the paper work are completed.Sometimes some machines wont be
available in the store;in that case the spare parts are brought from outside the
companythrough purchase department.

4.7 CONCLUSION

Maintenance section serves as a doctor to the company.From this shop I learned on

different types of maintenance,some of the problems and its identification and many
more.

5.QUALITY ASSURANCE DEPARTMENT

5.1 INTRODUCTION
Quality Assurance department is a body with three sectors, which being Incoming sector,
Inspection sector and Testing. All these three sectors are very important in view of the quality
of the product of the company. To keep going the interest of the customers on buying the
product the product should be free from any type of faults and work more effectively and
efficiently than their expectations. Different sectors of QA department will be discussed in the
following paragraphs. Most of the times Incoming sector and Inspection sector work together
to reduce the time that needed to complete the work when done separately.
5.2 INCOMING SECTOR
This is the place where the items that are brought from outside the company come, which may
be half finished or finished or raw materials. Incoming items contain sub contract works, nuts
and screws, energy springs, bearing etc. At some point of time when the work load in the plant
is heavy, the works that has can perform in the plant is transferred to subcontractors .
Incoming divisions check the items that are brought from outside the company are as per the
need specified by the design and other departments in the company and convey the items to
inspection sector. Some items are brought even when there is no need of it at that time
considering on the availability and the cost of those items at the present moment, such things
are transferred to the main store, where it is kept safely to take at any time of need.
In short, the departments records items came from outside and sometimes checks the number
of items and according to the need and no need at the present moment they are moved to
other departments in the plant or to the main store respectively, after the inspection.
5.3 INSPECTION SECTOR
It is the second sector that ensures the quality of the out coming product. As the part of
inspection, the departments checks the specifications of the items, transferred to the
department from the incoming department, comparing with the required or mentioned

specifications recorded in each item drawings. If any of the actual specifications of the items is
not suiting, the item is rejected.
Specification checking involves the material of the item, its strength at some certain loads, and
its withstanding capacities under different conditions and etc, sub contractors, with the item
also give a rod or square or rectangular piece [with particular size] of the material of the item to
use them for checking the hardness, sensible or compressive items breaking load and etc. To
measure all the above values, machines like Universal Testing Machine [UTM] and Rock Well
and Brinell hardness testing machine. The maximum load that can be applied by this machine is
20tons.
To types of springs are used in the mechanism, they are tension spring and compression spring.
Measuring the energy of the strings, which depends on the number of turns of spring, height
of spring, outer and inner diameters etc. Measuring instrument or machine that used for the
ensuring the energy value of the springs is called spring energy testing machine . in simple or
rarely it is called by its manufactures name.[REICHERTER].
The sector division benches are available in machine shop, fabrication shop etc, which are
known by the respective department names. The inspection bench checks out the first
component that is produced in its respective shops before producing identical components in
bulck. The bench has the authority to reject and accept the components. By comparing the
drawings of that particular component machined or fabricated by the worker and gives out the
result.
Another part associated with inspection sector in the pressure testing. The name Pressure
testing seems to put this section under testing but it is under inspection. To main jobs are
performed in the section, impervious test [IT], and pressure test[PT], usually they are called just
as IT and PT, IT test is conducted to find out any portions in the component that has holds or
gaps and also find blowholes. The component were internationally holes are gaps are closed
properly in the same way how these portions are going to be closed during assembling. After
that, the component is suspended in to liquid [water].
5.4 TESTING
Testing involves testing of the final product and its parts mainly electrical items. About 9 major
tests are conducted in the testing sector to ensure the quality of the product. A failed item in
the tests are carried out will be rejected and the tests overcome items are further transported
for the next operation to its respective departments.
The major tests performed in the testing sector are listed out below:

1.
2.
3.
4.
5.
6.
7.
8.
9.

Verification of Manufacturing Specifications and Purchase or order.

Tuning of closing spring and tripping spring.
Giving security for closing spring and tripping spring.
Measuring closing time and Tripping time
Minimum voltage operation of Closing coil, Tripping coil and Master
Measurement of Milli volt test.
Measurement of Insulator resistance
Verification of Auxillary Switch , local resistance , Inter Lock[IL], and manual operations
High Voltage[HV] test on main circuit and 2KV test and LT circuit.

The First test of similar to that of that worked out in the inspection sector by the inspectors but
again it is must to ensure the needs. Tuning of CS and TS spring means adjusting these springs
to get the required energy. By adjusting the screws attached to the down end of the springs, it
is possible to change the height of the spring when maximum closing or tripping energy is
stored, there by the next result also changes and gets the adjusted energy. In some cases large
energy and in other only a low energy is much sufficient to do the closing and opening of the
circuit. The energy required depends on the mechanism applied with the circuit breaker.
Due to the continuous use of the circuit breaker there are chances that the minimum energy
required to perform the closing and tripping may reduce, which is insufficient to do the same
previous operation. Friction lose can also be another major factor effecting the energy. At such
times a fault does not produces the desired output, which even may cause the whole place,
where the breaker has located to heavy damage.
To prevent such happenings security for the springs are provided or charging extra energy to
the springs, so in case of the above mentioned faults this extra energy helps to make the
contract and tripping. This is what is called giving security to the springs-both closing and
tripping.
The minimum voltage needed for the working of closing coil and motor is same and it is 85% of
the rated voltage. For the tripping coil, the minimum voltage for its smooth working needs
only 70% of the rated voltage. Mill volt drop test is executed to find or measure the Pole
Resistance [PR]. Through this test it is possible to understand how much resistance is offered by
the pole or poles, incorporated with the circuit breaker, to free flow of electricity. A very low
pole resistance is always preferred and accepted.

Whereas the resistance put by insulators must be very high to the flow of electricity. If the
insulator resistance is not appreciable, the full circuit breaker does not do the desired effects,
instead works as a short circuit terminal. To improve the resistance of insulator, its creepage
length should be high enough to obstruct. Even in fault conditions that are when abnormal high
voltage causes the insulator then work as an insulator only not as a conductor. Except panels all
other circuit breakers are kept in open atmosphere, which is directly affected with rains,
lightening etc. In all these times the insulator must not conduct electricity. Taking all these
factors the manufactures of insulators increases the creepage length of insulators. The test
carried out in the testing sector to know the value of the resistance offered by an insulator is
called insulator resistance test.
Next testing is to check the working of the electrical items incorporated in the control cables.
Axiallery switch, local resistance switch,
and manual operations are the sections
that comes under this test. The circuit breaker can be repeated manually and automatically.
Most of times it is kept to automatic conditions, but there are timers where the operations
needs the put off the current through a particular sector, adjustments the manual operations
are needed hence they are provided in the contact cables, verifications of manual
operations is therefore secondary to conduct.
High Voltage [HV] test is performed on main circuit with the aid of two 250volts transformers.
High Voltage test is carried out with the circuit breaker in off condition. The circuit breaker is
applied with high voltages than its breaking voltage and checks the occurrence of sparking
between the contact rods leading to the flow of current through the circuit breaker to the out
terminal, such thing should not happen. This test is conducted with very high voltages since the
circuit breaker when used is going to come in direct contact with lightening etc, at that stages it
should not work as a closed circuit. In special cases velocity graphs for Vacuum Circuit Breakers
[VCB] are taken for all minimum oil circuit breakers the velocity graph is taken. Velocity is the
time taken by the contacts to close and trip in m/s, from a clear study on the velocity graph, it is
easy to understand any presence of obstructions during the operations [closing and tripping].
Testing sector also verifies the standards and drawings as per the need.
5.5 CONCLUSION
The department put full energy to ensure the quality of their product to the most since their
products are going to compete with similar products in the market. Each and every time all the
specifications and associated factors are put in check. Most of times the job founds to be risky
one, then also the department workers does not hesitate to carry out it

6.AUXILLARY SHOP
6.1 INTRODUCTION
Manufacturing of oil cylinder for circuit breaker,electroplating like galvanizing and
silvering to get some of the properties more high and painting are very inportant
operation.The shop include Araldite shop,Electrochemical shop and painting.

6.2 ARALDITE SHOP

INTRODUCTION

In this shop breaker cylinder is manufactured.The cylinder is called by this name

because oil is used in the conducting medium for electric current inside the cylinder.It is
very imprtnt that the cylinder should be of accurate dimensions,should withstant high
pressure and temperature and should not conduct electric current out of it.Hence it is
necessary to make proper and careful means with safety to give birth to an efficient oil
breaker cylinder.

6.3 OPERATIONS

* Winding machines:This winding machine is nothing but "centre lathe or an engine

lathe".between the two centres a mandrel or a core is fixed whose size depends on
the required dimensions of oil breaker cylinder.Lathe has aiso some additional
press the filter glass cloth which rools over the mandrel to get a rough cylinder
shape.Pressing rod in a cylindrical rod fixed lengthwise to the mandrel and is
lighter than mandrel.Highly compressed air from the air compressor is supplied through tubes
to the pressing rod
as keep in touch with the mandrel.
6.4 ELECTROCHEMICAL SHOP
6.5 INTRODUCTION
Circuit breaker does consist of parts that has to be silvered or galvanized in order to get
conduction of electricity or to avoid rusting.The shop were these operations are
carried out in called electrochemical shope.The full componenet or a part of it is
electroplated according to the need.A chemical laboratary is associated with the shop for
checking the concentration of acids used in the electrochemical shop

6.6 CHEMICAL LAB

Chemical lab takes part an important role in the quality assurance department.It is
working twice in a week and analyzing the quality of electroplating [silver and zinc]
solutions,pre painting solutions and the quality of both drinking and effluent water.The
test conducted in the lab are
Test for free cynide in silver and zinc plating solution.
Test for zinc and silver metal in plating solution.
Test for finding pH of silver plating solution.

Test for finding the concentration of etching solution [HCL] in plating and painting.
Test for finding the percentage of iron in the etching solution.
Test for finding the acid percentage of phosphating solution in the painting

To measure the pH value of the water a measurind instrument called pH meter is used.
Neutral value of pH for water is 7;a slight change in the value may increase acidity
contents which is toxic to human body.The amount of zinc and sodium
cynaide [NaCN] needed to be available in the electrolyte solution,which is used for
galvanizing should be 35-40gm/liter and 110-120gm/liter respectively.

6.7 ELECTROPLATING SECTOR

Galvanizing and silvering are the two electroplating process conducted in the
electroplating sector.It aiso has provision to comduct the acid pickling operation.
Thickness of electroplating depends on time and the amount of current passed through
the electrolyte;hence the electroplating process is said to agree Faraday's law about
electroplating.

6.8 PURPOSE FOR GALVANIZING AND SIVERING

The use of zinc plating is rapidly increment or the rust protection and decorative
applications primarly due to the escalation in cost of cadmium and nickel metal.electro-

galvanizing is fast replacing dip galvanizing especially in engeering products made

so fine dimensional limits since it offers different advantages,in that itprovide a more
attractive finish and doesnot cause distortions as is possible in the molten dipping process.
Mixture inside the inner cylinder to a liquid form.Liquid form bonding mixture is taken
out and is placed in an electric furnace to heat it to 150 degree Celsius and makes the
mixture less viscous. (Viscisity is the property of a flowing liquid that provide a
resistance to the adjacent flowing layers).Amount of araldite used for the bonding differs
for different dimensions of oil breaker cylinders.

Need of mould releasing agents: Before pouring the bonding araldite two more things has
to be ensured .The inside wall of the cylindrical pit or mould in the electric furnace have
to be spread with mould releasing agent before keeping the oil breaker cylinder with the
mandrel in it .The importance of mould realising agents is very much.The name itself
revel's the use of reagent .If it is not used the mandrel cannot be removed from the oil
breaker cylinder after the application of bonding material araldite aiso it will be very
diffulcult or even can't to remove the cylinder and the mandral from the electric oven heating
moud.hence the mould releasing agent here used is such a material that prevents the
formation of bond or sticking between two different materials.Releasal 7 orQZ13 OR
SRC110 are the releasing agents used.

* Remover and operation:Remover is used to remove the mandrel from the oil breaker
cylinder.The oil breaker cylinder with the mandrel is fixed to the remover.As the
machine starts working a push rod pushes the mandrel from the oil breaker cylinder
and thus the mandrel is removed.

* Machining operation:Final operations like turning,facing and drilling holes on the

oil cylinder breaker is performed on these machines.The lathe and radial drilling
machines have the same spacification of lathe and radial drilling machines in
machine shop.

* Inspection and proceedings:

1.Mechanical inspection for dimension.

2.Pressure testing /IT as per the specification on the drawing.
3.send the accepcted items to the store with proper documentation.

6.9 ACID PICKLING

Acid pickling is the removel of matallic oxides by the immersion in acid solution.
pickling falls into several category,heavy duty to eliminate heat scale,light duty to remove the
light rust and moderate oxidation such as spot welding marks and finish.it
also provide activation to remove passive films and bright dipping to bright out a fresh,clean
and lustrous surface

6.10 GALVANIZING
Table 6.1
CATHODE
Component
Degreasing:

ANODE
Zinc rod or plate [Zn]

ELECTROLYTE
Zn+NaCN

Calisole or tricholoroethylene is used as the claening reagent,which removes the oxides or any
other type of unwanted particles from the components

Zinc plating:
Arotary barrel is used to carry small component in the electrolyte.Large
components are tied with copper wire and are suspended inside the chemical tank.Supply
given is Direct current [DC].For barrel plating 10-15 volt DC is applied while for
suspended artiles 5-8volt DC is applied.For both type of plating zinc bright 16 zinc
salt with zinc 16 brightner are used in recommended proportions.After certain time,after
getting the required galvanization,the component is taken off from the liquid electrolyte
and is washed in water to clean away the acid moisture on the surface.After the
completion of the galvanization [zinc plating]tje component is immersed in passivating
solution,which is nothing but ginthox 983 and the after result is a pale yellow
component with some shining. The component is coloured so to identify the galvanized
components from the non-galvanized components.

Points to be remembered:
1.Clean the electrical connection's every day.
2.Fill the solution periodically
3.Do chemical analysis and make up the baths in a balanced conditions.
4.Claen the condiments from the tanks periodically.

6.11 SILVERING
Table6.2
CATHODE
Component

ANODE
Silver rod or plate [Ag]

ELECTROLYTE
Ag+KCN

Degreasing and acid pickling:

The component which is going to be silvered has no under
go degreasing process:trichloroethylene is used.HNO3 is used as acid for pickling
process because as silvering is usually done for copper and copper alloy components and
the acid pickled components are rinsed in water.

Pre-coating;
Copper components are pre-silvered using pre-silverig salt bath.This is for
obtaining better adhension of silver deposits on the components;the operation is carried out
without the application of current.

Silver plating:
After pre-silvering,the component is electroplasted in the plating bath
using barrel [for small components] or tied up using copper wire.A DC current supplyof
2volt is given for suspended components and 4volt is appliede for barrel holding
components.The time taken depends on the thickness of coating required.
Galvanizing is performed on almost all parts of the circuit breaker were there is a chance

of rust form. Mainly this is performed on the oytdoor circuit breaker parts,since it is
in continous attack from atmoshere.But silvering is not performed to prevent
rusting,then also it helps in restricting the rust formation to a certain extend.The main
aim of silvering is to increase the conductivity of the component towards electricity.
6.12 PREVENTIVE MEASURES

Safetl first,then everything follows even quality.Get the instruction from the shop
supervisor or from any authorized books by the company before starting any operations.
ensuring the safety of the workers in the electroplasting sector and the oter workers in
the plant is done through preventive measures.A safer job is a pleasure to do.
1.Personal protective equipment's
* Rubber gloves
* Shoes
* Face mask
* Apron
* Goggles

2.Engineering controls
* Ventilations
* Exhaust fans

3.Waste disposal
* Dispose into concrete pits after neutralizing

4.Storage requirement
* Porcelain jars
* Polyurethane tanks

Note: First aid measures

For eye accident with calisole,mix 2% of sodium bicarbonate [NaHCO3] and 2% of
boric acid in pure water and irrigate the eye for 20 minutes.Then treat with a drop of cod liver
oil and apply bandage.

6.13 SOME MATERIALS OR SOLUTIONS AND ITS USES

Table6.3
COMPONENT NAME
Zinc brite 16
Zinc brite 20
Monicol purifier
Ginthox Z983
Silver mix silver salt
Hydrochloric acid [HCL]
Nitric acid[HNO3]
Strike silver salt
Calisole[Trichloroethylene]

USE
Zinc salt in zinc plating
Zinc brightner in zinc plating
Additive in zinc plating
Chromate bright single dip for zinc in Zn
plating
Brightness silver salt in Ag plating
Acid pickling
Pre-silvering
Cleaning

6.14 HAZARDOUS INGREDIENTS OF SOME MATERIALS

Table 6.4
COMPONENT NAME
Zinc brite 16
Zinc brite 20
Monicol purifier

HAZARDOUS INGREDIENTS
Sodium cynanide and sodium hydroxide
None
Inorganic sulfhur containing compounds

Silver mix silver salt

silver potash cyanide

potash cyanide
potassium hydroxide
potassium carbonate

6.15 PAINTING SHOP

6.16 INTRODUCTION
Painting is mainly done to prevent the rusting of components and also it gives out a
pleasent look.Painting in ALND plant is divided into two;they are pre-treatment and
pointing.

6.17 PAINTING INSTRUCTIONS

* Degreese all metal works by dipping in trichloroehtylene ie Calisole.Remove

oxides,tins and scales by pickling with HCL and wash in running water.For
structures this is done by short blasting.Do phosphating in Asfocost solution by
dipping the piece in for 10-15minutes.wash the piece in running water.
* Dip the components in Asfocost solution for passivating.
* Wash the component in running water and dry them in oven.
* Do the final painting as per specification.

Degreasing tank has two floors;the upper floor or sector contains the liquid calisole and
the lower floor has oil.The oil is heated so that the temperature of the calisole reaches
atleast 135 degree C,which is its vapourizing temperature.Cooling water is provided
around the upper floor tanks inside which cools the vapour coming up and the transferred

calisole in liquid state goes down because of larger density and is again heated up into
vapour state the process goes as that automatically.The cooling medium id cool
water circulating through the pipes attached around the inner surface of the upper tank or
upper floor tank.The component which is to be degreesed is suspended into the vapour
calisole area and is held in the position for certain times.After the completion,the
component is taken out.

6.18 PHOSPHATING
Phophate coatings are predominantly applied to ferrous metals although they are used to some
extend for zinc and aluminium. The phosphate on its own is insufficiently protective for the
treated metal surface but it is excellent as a pretreatment before painting and as a base for
impregnation with enamels, paint, lacquers, oils and waxes. The phosphate coating is thin and
adherent to the substrate metal whilst being both porous and insulating consequently, the
coating permits keying or mechanical interlocking of the applied paint film whilst the
electrical intervness of the coating localizes corrosion beneath adjacent unbroken painted
areas of the base metal surface. Phosphating coatings may be produced by the immersion
brush application or spraying since surface conversion depends only on contact between the
substrate and the phosphating solution. Phosphate coating is also used in the cold forming
operations such as drawings, stampings, and cold extraction operations.

6.19 VARNISHING INSTRUCTIONS

1. Backing method
This system is mainly used for araldite components. The properly curved varnish film
should have excellent moisture ,grease hot transformers oil resistance, dielectric
strength coupled with super insulating property in high humid conditions.

Do vapour degreasing of araldite components with trichloroethylene [ calisole ].

Apply silicon carbide abrasive of 120GD for obtaining a smooth surface.
Pre-heat at 120-150 degree C for 2 hours.

Apply 2 coats of varnish[ VBR555 or VBR1043 or VBR99 or Doctor Beacks ELMO65 with
205 Thinner ] to obtain thickness to be formed after the flash drying .
After applying varnish do backing for 4 hours at 120-150 degree C in a baking oven.
Offer for inspection and after acceptance send the items to high voltage lab.
2. Air drying method
The film formed by this type varnish is very tough and is will not become brittle even with
continuous working under high temperature and also required where resistance to hot
transformer oil, heat moisture etc.

Apply varnish [ V70 or V30 ] after degreasing and applying silicon carbide abrasive.
Surface dries within 2 hours and dries hard with in 3 hours of application.
All sheet stoel work shall be degrease, phosphared in accordance with the following
procedure and in accordance with IS6005 code of practice for phosphating from steel.
Oil, grease, dirt and sward shall be thoroughly removed by emulsion cleaning order, tins
and scales shall be removed by pickling with HCL acid followed by washing with
running water and after do the phosphating for about 10-15 minuets. After phosphating
rinsing shall be carried out with overflow water and them over drying. The phosphate
coating shall be scaled by the application of one or two coats ready mixed with storing
type/air drying suitable primer as per specification. The first coat may be flash dried
while the second coat shall be air-dried stored as specifications. After the application of
primer one or more coats of finishing as per the manufacturing specification [ synthetic
enamel, epoxy or polyurethane ] paint shall be applied. A final finishing coat for external
and internal surface of panels shall be applied after the completion of tests. Each coat of
primer and finishing paint slightly different shade to enable inspection of painting.
Finished painted appearance equipments or components shall presents aesthetically
pleasing appearance force from the dents and uneven surface.
6.20 SHOT BLASTING
Onside film removed from the material surface by using compressed air chilled iron
shots [ S-230 OS6 ]. Shot blasting is done for most of the sand castings and structural
components. This is to clean the component surface and remove all sand deposits and
small irregularities of casting. It is also done before metalizing which required rough
surface of aluminum castings so as to get better adhesion on the surface.

6.21 METALIZING
In aluminum casting machining those surface where copper contacts and connections
are coming copper metalizing is done to get a corrosion free connection. Proper fixtures
are used while metalizing and short blasting to protect the reading and other finished
machined surface. The exposed areas are short blasted and the cleaned using calisole to
avoid any traces of acid, oil, dusts, grease etc. thick components are heated to 100
degree C. and then sprayed copper using metalizing oxy-acetylene flame and
compressed air is used in the gun to atomize the copper wire. The pressure used for
spraying is as follows; oxygen 1kgs, acetylene 1kgs and dry compressed air 5-6kgs/cm2.
After metalizing the components are cleaned for any excess copper spray.

6.22 CONCLUSION
From the study of Auxillary shop I could understand the overall working of the shop
with much clear knowledge on each of its divisions especially in the shot blasting
sections, the need of silvering and copper components, electric oven and etc.

7. QUALITY ASSURANCE DEPARTMENT

7.1 INTRODUCTION
Quality Assurance department is a body with three sectors, which being Incoming sector,
Inspection sector and Testing. All these three sectors are very important in view of the quality
of the product of the company. To keep going the interest of the customers on buying the
product the product should be free from any type of faults and work more effectively and
efficiently than their expectations. Different sectors of QA department will be discussed in the
following paragraphs. Most of the times Incoming sector and Inspection sector work together
to reduce the time that needed to complete the work when done separately.
7.2 INCOMING SECTOR
This is the place where the items that are brought from outside the company come, which may
be half finished or finished or raw materials. Incoming items contain sub contract works, nuts
and screws, energy springs, bearing etc. At some point of time when the work load in the plant
is heavy, the works that has can perform in the plant is transferred to subcontractors .
Incoming divisions check the items that are brought from outside the company are as per the
need specified by the design and other departments in the company and convey the items to
inspection sector. Some items are brought even when there is no need of it at that time
considering on the availability and the cost of those items at the present moment, such things
are transferred to the main store, where it is kept safely to take at any time of need.
In short, the departments records items came from outside and sometimes checks the number
of items and according to the need and no need at the present moment they are moved to
other departments in the plant or to the main store respectively, after the inspection.
7.3 INSPECTION SECTOR
It is the second sector that ensures the quality of the out coming product. As the part of
inspection, the departments checks the specifications of the items, transferred to the
department from the incoming department, comparing with the required or mentioned
specifications recorded in each item drawings. If any of the actual specifications of the items is
not suiting, the item is rejected.
Specification checking involves the material of the item, its strength at some certain loads, and
its withstanding capacities under different conditions and etc, sub contractors, with the item

also give a rod or square or rectangular piece [with particular size] of the material of the item to
use them for checking the hardness, sensible or compressive items breaking load and etc. To
measure all the above values, machines like Universal Testing Machine [UTM] and Rock Well
and Brinell hardness testing machine. The maximum load that can be applied by this machine is
20tons.
To types of springs are used in the mechanism, they are tension spring and compression spring.
Measuring the energy of the strings, which depends on the number of turns of spring, height
of spring, outer and inner diameters etc. Measuring instrument or machine that used for the
ensuring the energy value of the springs is called spring energy testing machine . in simple or
rarely it is called by its manufactures name.[REICHERTER].
The sector division benches are available in machine shop, fabrication shop etc, which are
known by the respective department names. The inspection bench checks out the first
component that is produced in its respective shops before producing identical components in
bulck. The bench has the authority to reject and accept the components. By comparing the
drawings of that particular component machined or fabricated by the worker and gives out the
result.
Another part associated with inspection sector in the pressure testing. The name Pressure
testing seems to put this section under testing but it is under inspection. To main jobs are
performed in the section, impervious test [IT], and pressure test[PT], usually they are called just
as IT and PT, IT test is conducted to find out any portions in the component that has holds or
gaps and also find blowholes. The component were internationally holes are gaps are closed
properly in the same way how these portions are going to be closed during assembling. After
that, the component is suspended in to liquid [water].
7.4 TESTING
Testing involves testing of the final product and its parts mainly electrical items. About 9 major
tests are conducted in the testing sector to ensure the quality of the product. A failed item in
the tests are carried out will be rejected and the tests overcome items are further transported
for the next operation to its respective departments.
The major tests performed in the testing sector are listed out below:
10. Verification of Manufacturing Specifications and Purchase or order.
11. Tuning of closing spring and tripping spring.
12. Giving security for closing spring and tripping spring.
13. Measuring closing time and Tripping time
14. Minimum voltage operation of Closing coil, Tripping coil and Master

15. Measurement of Milli volt test.

16. Measurement of Insulator resistance
17. Verification of Auxillary Switch , local resistance , Inter Lock[IL], and manual operations
18. High Voltage[HV] test on main circuit and 2KV test and LT circuit.

The First test of similar to that of that worked out in the inspection sector by the inspectors but
again it is must to ensure the needs. Tuning of CS and TS spring means adjusting these springs
to get the required energy. By adjusting the screws attached to the down end of the springs, it
is possible to change the height of the spring when maximum closing or tripping energy is
stored, there by the next result also changes and gets the adjusted energy. In some cases large
energy and in other only a low energy is much sufficient to do the closing and opening of the
circuit. The energy required depends on the mechanism applied with the circuit breaker.
Due to the continuous use of the circuit breaker there are chances that the minimum energy
required to perform the closing and tripping may reduce, which is insufficient to do the same
previous operation. Friction lose can also be another major factor effecting the energy. At such
times a fault does not produces the desired output, which even may cause the whole place,
where the breaker has located to heavy damage.
To prevent such happenings security for the springs are provided or charging extra energy to
the springs, so in case of the above mentioned faults this extra energy helps to make the
contract and tripping. This is what is called giving security to the springs-both closing and
tripping.
The minimum voltage needed for the working of closing coil and motor is same and it is 85% of
the rated voltage. For the tripping coil, the minimum voltage for its smooth working needs
only 70% of the rated voltage. Mill volt drop test is executed to find or measure the Pole
Resistance [PR]. Through this test it is possible to understand how much resistance is offered by
the pole or poles, incorporated with the circuit breaker, to free flow of electricity. A very low
pole resistance is always preferred and accepted.

Whereas the resistance put by insulators must be very high to the flow of electricity. If the
insulator resistance is not appreciable, the full circuit breaker does not do the desired effects,
instead works as a short circuit terminal. To improve the resistance of insulator, its creepage
length should be high enough to obstruct. Even in fault conditions that are when abnormal high
voltage causes the insulator then work as an insulator only not as a conductor. Except panels all

other circuit breakers are kept in open atmosphere, which is directly affected with rains,
lightening etc. In all these times the insulator must not conduct electricity. Taking all these
factors the manufactures of insulators increases the creepage length of insulators. The test
carried out in the testing sector to know the value of the resistance offered by an insulator is
called insulator resistance test.
Next testing is to check the working of the electrical items incorporated in the control cables.
Axiallery switch, local resistance switch,
and manual operations are the sections
that comes under this test. The circuit breaker can be repeated manually and automatically.
Most of times it is kept to automatic conditions, but there are timers where the operations
needs the put off the current through a particular sector, adjustments the manual operations
are needed hence they are provided in the contact cables, verifications of manual
operations is therefore secondary to conduct.
High Voltage [HV] test is performed on main circuit with the aid of two 250volts transformers.
High Voltage test is carried out with the circuit breaker in off condition. The circuit breaker is
applied with high voltages than its breaking voltage and checks the occurrence of sparking
between the contact rods leading to the flow of current through the circuit breaker to the out
terminal, such thing should not happen. This test is conducted with very high voltages since the
circuit breaker when used is going to come in direct contact with lightening etc, at that stages it
should not work as a closed circuit. In special cases velocity graphs for Vacuum Circuit Breakers
[VCB] are taken for all minimum oil circuit breakers the velocity graph is taken. Velocity is the
time taken by the contacts to close and trip in m/s, from a clear study on the velocity graph, it is
easy to understand any presence of obstructions during the operations [closing and tripping].
Testing sector also verifies the standards and drawings as per the need.
7.5 CONCLUSION
The department put full energy to ensure the quality of their product to the most since their
products are going to compete with similar products in the market. Each and every time all the
specifications and associated factors are put in check. Most of times the job founds to be risky
one, then also the department workers does not hesitate to carry out it.

REPORT CONCLUSION
ALIND
A-ACTIVE
L-LIVELY
I-INDUSTRIOUS
N-NIMBLE
D-DETERMINED
They are absolutely correct, very active in all aspects with a good strength of lively and
industrious hard working workers determined to carry out any hard and risky jobs with their full
heart and makes very quick changes according to the customers growing interest. ALIND-is now
one of the well known organization in India and is more familiar for Indian Railways and
different State Electrical Boards since they use most of the products manufactured by ALIND.

Being is ALINDs Switchgear division for 10 days, I could learn many things, which never I can
get from within the four walls of classrooms. From each the shops that I visited and put under
my study found with many valuable knowledge, which then I acquired and presented in this
report. The report was prepared with great effort, so that it would be understandable to all
those who reads it carefully. You can see detailed study on some matters and brief notes on
some other. The order of shops recorded in the report is the same order of my visit to those
shops or departments . The report has introduction and conclusions for each department.

I encourage these types of implant trainings, since it is the best way a student get hold of
practical knowledge and it also gives him/her how he/she should manage themselves when
going to be a member of working community in such companies, also helps him/her to know by
themselves their interesting fields.