Page |1

TABLE OF CONTENTS Sr.No. Name. Acknowledgement 1 Preface 2 Introduction 3 Companys Profile 4 Advertisement Policy 5 Sales Promotion Stretegy 5.1 Production Infrastructure 6 Electrical Wiring Accessories. 6.1 Industrial Plugs And Sockets: 6.2 PmaAg Switzerland:A Safe 6.3 6.4 6.5 6.6 6.7 6.8 6.9 7 7.1 7.1.a

And

Universal

Page no. 1 2 3 4 12 12 13 14 14 15 16 17 18 19 20 21 21 22 22

Electrical Wiring Protection System

Wohner Technology Environmental Management Systems (Ac): Electrical Panels: Enclosure Systems: Mcb Distribution Boards Switchgear Main Departments Sheet Metal Shop C.R.C.A (Cold Rolled Carbon Annealed) Sheet

7.1.1 7.1.1.a 7.1.a.2 7.1.1.b 7.1.1.b.2 7.1.1.c 7.1.1.c2 7.1.1.d 7.2 7.3 7.3.1 7.3.2 7.3.3 7.4 7.4.1 7.4.2

Machines Used Punching Machine Features Bending Machine Features Welding Machine Features Shearing Machine Press Shop Paint Shop Appratus Set Up Paint Process Test After Paint Electroplating Shop Steps For Electroplating Types Of Electroplating

23 24 25 26 27 28 29 29 31 32 32 34 37 37 37 38

Page |2

7.4.3 7.4.4 7.4.5 8 8.1 8.1.a 8.1.b 8.1.c 8.1.d 8.2 8.2.1 8.2.2 9 10 10.1 10.2 10.3 11 12 13 13.1 13.2 13.3 13.4 14 15 16 17 18

Inspection Treatment Methods Storage And Safety Switch Gear Divison Product Manufactured Rewirable Switch Fuse On Load Changeover Switch Double Break Fuse Switch Switch Disconnector Fuse Distribution Boards Features:Classification Of The Circuit Breaker Testing List Moulding Shop Machine Used Injection Molding Machines Grainer Machine Testing Labs Technical Performance Of Switches Panel Shop Panel Types Lt Power Panel For Ac Coach Panel Parts Panel Discription Ac System(Cool Pack) Product Range Of Ssk Observation Conclusion Appendix(Table & Fig)

40 40 41 41 41 41 42 43 43 44 44 44 49 59 59 59 64 65 70 72 72 73 74 75 80 81 100 101 102

Page |3

1. ACKNOWLEDGEMENT
We cannot achieve anything worthwhile in the field of technical education until or unless the theoretical education acquired in the classroom is effectively wedded to its practical approach that is taking place in the modern industries and research institute. Although an engineer can only be successful through sheer hard work, but the contribution of his teachers and all those who have been helpful cannot be overlooked. Today as a student, I am in high spirit and stepping forward into the challenging future. Any technical course is incomplete without some type of training. The course of B.Tech. of P.T.U. JALANDHAR also requires six months of technical training. I am thankful to ESS ESS KAY CO. PVT.LTD. KAPURTHALA for helping me to complete my industrial training. I would also like to express my gratitude towards my training manager, Mr. RAJESH KHANNA and Mr. DILBAG SINGH for rendering invaluable help and guidance during my training. I am also very thankful to Mr. GAGAN BHARDWAJ, in providing all the facilities towards the successful completion of my project. My thanks are also to all staff members of the division who helped directly or indirectly in completing my training. Last but not least I thank all the individuals who supported and criticized me in this period of training semester.

SAVYASACHI

Page |4

2. PREFACE

SWITCHGEAR is a common term used to mention all the protection and control devices that makes the electrical installation safe and easy to use. All the protection equipment such as circuit breakers and fuses to pilot devices such as push buttons are included in term switchgear.

ESS ESS KAY CO. PVT.LTD. KAPURTHALA manufactures a variety of protection and control switchgear. Equipped with the latest technology in the state of the art plane, the company has established itself in the field of the switchgear as a pioneer since its beginning.

The company manufactures MCB, MCCB, FUSE SWITCHES, RCCB, LOAD CHANGE OVER, CUBICAL FUSE UNIT, DISTRIBUTION BOARDS, CONTROL PANELS, AIR CONDITIONER(cool pack) and various other products.

During the six months industrial training at SSK ELECTRICALS CO. PVT. LTD., the departments and all the products of the company were analyzed as a part of the six months training schedule.

Page |5

3. INTRODUCTION TO COMPANY--A BIRDS EYE VIEW

Ess Ess Kay Engg. Co. was established for manufacture of electrical wiring accessories in 1935 at Lahore (now in Pakistan) under the leadership of a visionary and a dynamic entrepreneur. A pioneering effort for indigenous development of tumbler switches was undertaken for the first time in India amidst stiff competition from imported goods, nonexistence of skilled labour and raw materials and political turmoil culminating into partition of the country. In 1947 The Company therefore had to shift from Lahore and re-establish itself afresh and with a renewed vigor at Kapurthala, Punjab. In the infant stage itself, the product was awarded IS certification.

During the last 75 years the company has always kept itself abreast of latest technological developments, growing steadfastly and scaling new heights. At present, the organization is a conglomeration of six units spread over an area of 45000 square yards. The manufacturing range consists of a broad band of switches, wires, switchgear, electrical panels, bus bar systems, enclosures, cable protection systems, environmental management system, microprocessor control units, connectors, Industrial plugs and sockets, with an annual turnover of over 100 crores.

Our marketing centers are dotted all over the country to ensure efficient and reliable after sales service to our esteemed customers. We have, of late entered into foreign collaboration with four companies of proven record, defying International boundaries and opening up avenues in the international market. Expansion and diversification being our ongoing process, new ranges of Zen and Heritage switches have been added to the product range.

Page |6

4. COMPANYS PROFILE
1. Name ESS ESS KAY ENGG. Co. Ltd.

2. Status 3. Date of Incorporation 4. Total Factory Area 5. Contact

Private Limited Company 1935 at Lahore (Pakistan) 45000 Sq. Yards. Factory Area, P.O. Box 8, Kapurthala 144601 Punjab Phone 01822-232587, 232956 Fax no.- 01822-232668. Web page:-www.ssk.co.in, e-mail: info@ssk.co.in

6. Facilities

(a) Modern Tool Room. (b) Lab with latest equipments. (c) R & D cell.

7. Quality Certification

Most of SSK products carry Bureau of Indian Standard Certification Mark and ISO 9002 in process.

8. Products Profile (a) Household Electrical Accessories (Switches) (b) MCB Distribution Boards (c) Switchgears (d) Electrical Power Control and Distribution Panels (e) Switchboard Cabinets for LHB Coaches

Page |7 (f) Roof Mounted AC Package Units (g) Enclosures (h) Cable Protection System PMA (i) Wohner Bus Bar System (j) Pallazoli Connectors and Industrial Plugs

9. Vision

Page |8

Fig: 1

To develop a strong Client base with an equally effective Support structure which acts as a catalyst for effective deployment of futuristically complete and credible information solutions. They strive to achieve this by focusing individually on each project and build a healthy relationship with their Customers. 10. Quality Quality is a comprehensive & fundamental rule or belief, for leading & operating an organization. And this helps in continually improving performance over the long term.

11. Objectives of company

Page |9 I. SSK Engineering Company plays emphases on forming a long lasting relationship with its customers by offers optimum requirement and upgrade the quality of its human resource system machinery and equipment. II. The company has highly motivated work force of about 800 people and this is due to conviction that their employees are most valuable assets. It has got various schemes like SSK ENGINEERING COMPANY financing scheme, scholarships scheme for children of employees etc. III. Company has provided to its customer the safety of life from electrical hazards, security and growth for its employees, satisfactory return to investor and useful contribution towards development of community and society. IV. The company has a distinction of having the most beautiful and cleanest factory in Kapurthala region

12. Customer Satisfaction and Trust Schmittlein said - "An organization that is perceived as doing a relatively good job, or of being relatively forthcoming in one area of trust, is seen as doing well elsewhere, too .The value of that trust element has not been going down over time." We too believe that Customer Satisfaction and Trust will always be our Key for success!!!

13. Human Resource The success of SSK Engineering Company Depends upon the people working there. They are the foundation of this company. They are pillar holding the position of this concern. The SSK ENGINEERING COMPANY is proud to have people like these. The companys list of human resource is as follows. Table 1 Type Qualified M.B.A. Engineer Diploma holders Sales staff Workmen Resident Other No 140 70 65 450 35 150

The company has not lost a single man-day during its 44 years of existence. To take care of the workers of company has also introduced a SSK ENGINEERING COMPANY f-financing

P a g e | 10 scheme governed and managed totally by the workforce for their over benefit. The company is also laying a great emphasis on training and development of its employees as it leads to establish a motivated and harmonious work environment.

14. Environment of the concern The company has the distinction of having the mesmerizing infrastructure. The environment of SSK Engineering Company is fully workable, each and every person in the concern is filled with the spirit of doing their work in a different and specialized way. As a responsible corporate citizen, the company has built a beautiful round about at Kapurthala , which is being maintained by it. It has also been the pioneer in installing hundreds of tree guard to aid the greening of Kapurthala. 15. Expansion plans The company is professionally managed. It is continuously improving its product range and has plans to achieve over Rs. 100 crores turnover within next 6 years. With the economy of the country starting to emerge from recession and power industry being thrown open to private sector, the company is poised to perform better in coming years. It has very ambitious expansions plan in various stages of implementation. The director are confident that in years to come, the companys performance and operating result will go up. 16. Industrial relations The personnel policies and managerial philosophy of this group are people oriented. Human resources are fully encouraged to obtain maximum career development growth within the organization. The quality of the product working conditions and natural consideration and understanding between the management and the workers has resulted in extremely cordial industrial relations. The company has peaceful industrial relations from very inception since 1958. It is said that not even a single moment has been ever wasted nor there has been any instance of Industrial Relation breakdown throughout its history. The top management believes in running the organization with efficiency, devotion and high ethics of business. 17. Alliances To keep SSK ENGINEERING COMPANY excellent and technologically pioneer the company has gone in for technical tie up with reported manufacturing units. Following are its alliances: 1. Kasuga Electrical work Japan:- The company s into alliance for the manufacturing of Molded case circuits. 2. Lawson fuse Ltd. U.K.:- The alliance is for manufacturing of high breaking capacity fuses.

P a g e | 11 3. PC Electric Co. Australia:- The alliance is for the manufacturing of insulated plugs and sockets. 4. Havells New Delhi :- The alliance is for the manually sharing and development of market. Havells have invested in SSK Engineering Company and have 60 % profit sharing alliance.

18. Collaborations a. PMA AG, SwitzerlandCable Protection System b. Wohner Gmbh, Germany Bus Bar system. c. Pallazoli, Italy Connectors & Industrial Plugs. d. Aircotech, Switzerland AC Package Units.

19. Our Clients Domestic Clients

Overseas Clients Hidustan ltd, jalandahr Eaton Electric Limited, UK Syrian Electricity Board, Syria Electricity Board Bangladesh Electricity Authority of Cyprus Cylon Electricity Board, Sri Lanka Electricity Distribution Directorate, Bahrain

Rail coach factory (RCF) Larsen & Toubro Indian Oil Corporation Ltd. (IOCL) Tata B.H.E.L. Escorts Jaypee Group Jindal Stainless Steel, among others

Jordan Electric Power Supply Co., Jordan

20.1 Housing / Commercial Projects:

1. DLF 2. UNITECH 3. ESSEL Tower, Gurgaon 4. Raheja Builders 5. NIHO

24. Cotton City, Coimbatore 25. South Indian Shelters, Chennai 26. Shreenath Tower, Rajkot 27. Alaap, Rajkot 28. NRI City , Jaipur

P a g e | 12

6. ELDECO 7. Parsvnath 8. HEWO 9. AWHO 10. Ansals 11. Akashganga, Jaipur, 12. Brahma Majestic. Pune 13. Nike Nore & Associates, Pune 14. Sanghvi Builder / OM Builders, Pune 15. Esha Realators, Pune 16. Pharande Developers, Pune 17. Beharay Rathi Builders, Pune 18. Landscape Construction, Pajim Goa 19. Models Construction, Panjim Goa 20. Omaxe-Green City Faridabad 21. Safal Twins, Mumbai 22. Royal Chambers, Mumbai 23. Ansal City, Jodhpur, ..

29. Royal En Sign , Jaipur 30. Sand Dune, Jaipur 31. Paradise Group, Jaipur 32. Suncity, Delhi 33. Unique builders Jaipur, 34. Index One, Jaipur 35. Brahma Builders, Pune 36. Parmar Builder, Pune 37. Goyal Ganga, Pune 38. Kolte Patil Builders, Pune 39. Rohitin Mehta Associates, Pune 40. K.D Builders, Pune 41. Kamat Construction, Panjim Goa 42. Richmont Builders, Goa 43. Krishna Residency, Mumbai 44. Aggarwal Residency, Mumbai 45. Ramoji Film City, Hyderabad 46. Rajtilak, Surat and many more

20.2 Hospitals

1. Escorts, Amritsar 2. Apollo, Delhi 3. DMC, Ludhiana

5. Sir Ganga Ram Hospital, Delhi 6. Batra Hospital, Delhi 7. Fortis, Mohali

4. Vintage Hospital, Panjim Goa and many more ..

20.3 Government / Public Sector / Private Sector / Others

1. Parliament House 2. THDC 3. PSEB 4. Chattisgarh Electricity Board

16. Rail Coach Factory, Kapurthala 17. NTPC 18. MPEB 19. LIC

P a g e | 13

5. United Bank of India 6. UTI Bank

20. ICICI Bank 21. BHEL 22. IOCL

7. PWD, Punjab,UP,Haryana,Rajasthan,Assam 8. AECL 9. ITI Rai Bareilly 10. HAL 11. CPWD 12. Kalpataru Power Transmission Ltd.

23. HCL 24. GNVF Ltd. 25. BEL 26. NFL 27. Biocon , Bangalore

13. National Institute of Oceanography, Goa 28. Krishi Bhawan, Panjim Goa 14. Office of GSIDC, Panjim Goa 15. Airport Authority of India
20.4 Religious Institutions

29. Ordnance Factory, Khamaria M.P 30. SBI and many more ..

Swaminarayan Temple, Baroda, Surat, Bharuch, Ahmedabad Golden Temple, Amritsar Radhaswami Dera Baba Jaimal Singh, Beas and many more.

We have long list satisfied customers in India as well as abroad. The following are very big customers for Woehner products. Their annual purchase of Woehner material is more than 2.5 million duetsch marks each. 1. CARRIER, France 2. SIEMENS, Germany 3. ALLEN BRADLEY 4. SCHNEIDER, France 5. KLOCKNER MOLLER 6. ABB 7. GE-Power Control We feel that using our Bus Bar System, troubles in the panels are reduced to the minimum and making the end product overall more sophisticated & reliable. We manufacture only LT panels. 1. PDB - Power Distribution Boards 2. CDB Control Distribution Boards 3. Feeder Panels

P a g e | 14 4. Motor Panels Star Delta / D.O.L Panel 5. Energy LT Panels

We do not manufacture AMF Panel with Synchronisation or HT Panels. We do not manufacture Motor Panels with PLC derive system. 21. Research, Development and Quality Maintenance. SSK being the market leader hence the secret of SSK Engineering Company success is quality maintenance. Company has become successful because of their research and development department. The company has been beaten the clock in achieving their objective. It happened because of their research and development department, which is highly equipped and maintained. The company has growing pains also but yet company able to carry away those pains and reached the new heights of excellence. Research and development department plays a key role in analyzing and finding solutions to various problems. Regarding the quality and in development new designs. The company uses CAD/CAM machines for entire design and development. It has fuel in house facilities of short circuit testing up to 10 KA and various other equipments for Electrical and mechanical tests. In this research and development after every four hours of manufacturing, the manufactured products are checked also before transferring to other divisions for assembling etc. The quality is checked. Workers of the SSK Engineering Company also give their suggestions to improve quality.All the goods manufactured at SSK Engineering Company are ISI marked. Also the company has achieved ISO 9001 from BVQI (Bureau verities Quality International). The emphasis on quality and constant technology up gradation has helped the SSK Engineering Company in creating a unique position for its products not only in the domestic but also in international market. Every year the company is spending more and on its research and development.

5. ADVERTISEMENT POLICY OF SSK ENGINEERING COMPANY

P a g e | 15 The general trend of SSK Engineering Company is to spend 1 % of sales target as advertising expenditure and on sales promotion techniques. The advertising expenditure will be given according to the target of the dealer and the rest 0.5 %is expand on manufacturing of complimentary gifts Calendars, Key chain, tolls kits, diaries, table clothes, slips pads etc. Some time dealers wants to make these gifts on their on their own, for that company provides 0.5 % of expenditure to them. SSK Engineering Company is trying to improve their sales in all over India. Company is using techniques of SWOT Analysis. A separate policy for replacement of good has been circulated. All defective goods to be sent to company deposit in copulation after approval of the concerned territory sales persons. The returned goods should be accompanied by dealers challan dearly mentioning the reason for return the products or issue a credit not after inspection and verification as per policy.

5.1 Sales Promotion Strategy

Full range of products: In order to cater to the demand of the demand of the market the business house has introduced a wide variety of products in full range. Timely supply: Timely supply of goods is an important factor of companys strategy which leads to increased sales. Competitive price: In the present competitive scenario only that products seems to survive which offers high quality goods at reasonable price. Qualitative approach: Todays customer is a quality conscious and demand high quality goods. The quality policy of the concern is ISO certified which speak highly of its World Class Quality. Effective Training of latest Technology From time to time employees are exposed to latest prevailing technology and practices so that they remain competent to the market environment. Effective marketing practice:

P a g e | 16 Advertisement is the most popular techniques of sales promotion. Launching of new product and creating a success story majority depends upon effective marketing advertising campaign. Close Contacts: Personal contacts in and outside the industry has helped SSK ENGINEERING COMPANY make rapid strides in the electrical good market. Stress on after sales service Goods after sales service are the plus points of any concern. To keep the customers satisfied long after the product has been sold is useful for the concern in the long run. Stress on Publicity: It has always been SSK ENGINEERING COMPANYs key policy to publicize its products from the awareness of the consumers. Flexible structure: Flexible structure has helped SSK ENGINEERING COMPANY to upkeep its products according to changing requirement and market conditions.

6. PRODUCTION INFRASTRUCTURE/ANALYSIS:
Production Standards: Quality management systems, being hallmark of our activities, quality standards are being followed in all production activities. Precision type machines are being used to ensure quality. The important machines in use are - Deckel Maho machining center, CNC wire cut machine, CNC grinder, Profile Projector with digital readout facility, CNC Punch Press and CNC Brake Press. Moulding section consists of L&T make Demag; machines and Injection moulding machines are being utilized. Electroplating facilities exist for gold plating, Silver plating, Nickel plating and tinning processes for different components which are being used for complete range of products

P a g e | 17 Testing Labs with the testing facilities have been equipped to ensure adherence to IS standards. Painting section consists of seven-tank arrangement for phosphating and pessivating process before powder coating of various components. Paints of superior quality are being used to provide anti rust characteristics to our products. Design and development activities: To aid and assist production activities, we have full-fledged design and development division. CAD facilities exist through Visicam software computers and a plotter.

6.1 Electrical Wiring Accessories. Switches and sockets conforming to IS 3854 1997, IS 1293 1998 respectively are being manufactured with a broad band of variants. The products with arc extinguishing and anti track electrical characteristics have wider applications in house electrical appliances, commercial and industrial establishments. Providing earthing pins and shutters over live pins has ensured safety of the users. The modular design and aesthetically manufactured switches are being extensively used in prestigious buildings like hotels, conference rooms and government establishments. Other products include Rewireable Switch Fuse Combination Units, Double Break Fuse Switch Combination Units, Changeover Switches, Porcelain Fuse Units, MCB Distribution Boards, Plug Socket Distribution Boards, Industrial Plugs & Sockets, Distribution Fuse Boards etc..

Our products are free from electric shocks and fire hazards and have applications in damp and explosive atmosphere. The switches available in matching colors are aesthetically superior and are removable and washable with convenience. They are economical because color changes in switches are possible without any change of the base. 6.2 Industrial Plugs and Sockets: Pallazoli industrial interlocked socket outlets, plugs and connectors are being used in potentially explosive atmosphere such as in pharmaceutical and chemical industries, car parkings, plastic industry, sugar mills, petrol and oil stations and similar installations prone to fire hazards.

The products have been created for the first time without screws for assembly of components and cable clamping. The outlets can be wired with convenience and are available with fuse monitoring system. These are available for a voltage range of 400 500 V and a current

P a g e | 18 rating from 10A to 125A with a protection category IP67. The products are available in 2 Pole, 3 Pole and 4 Pole versions. Wall mounting interlock socket outlets are available in ULSSE - Ex series, TAIS Ex series and ALUPRE Ex series whereas plugs are available in CEE Ex series, ATEX. The special features are:

1. Interlock system is a positive protection against electric shocks and opening arcs. 2. Explosions are prevented as the plugs and sockets are non sparking. 3. The products comply with international standards CEI EN 6039, CEI EN 60917, CEI EN 60742. 4. The components are robust and have high resistance to heat fire and chemical agents. 5. Socket outlets are pre wired and therefore save wiring time. 6. The sockets have ergonomic control with provision of fuses and MCBs. 7. Matching accessories like support plates aluminum alloy flanges and cable glands are readily available to suit different applications. 6.3. PMAAG Switzerland: A Safe and universal electrical wiring protection system.

PMA Leaders in the design and production of nylon cable protection system have over 6500 tested and proven products for cable protection system. The products have world wide access to traction applications, heavy plant and vehicle construction aviation, fiber optics, solar energy, metro rail systems, robotics and machine building industries. PMA conduits system can be tailor made to meet specific industrial requirements. Products have halogen free selfextinguishing properties and meet international quality and safety standards. The products have proven record during the last 30 years and have certification from the following. IEC 61386 / EN 50086, UL recognition, CSA, NF, SNCF, DB.

PMA conduit pipes have a large range of accessories like bends, clips, sealing rings, clamps, swivel connectors, adopters, terminals, protection sleeves, universal safety clips, oval clips, hexagon nuts and lock nuts. The conduits along with accessories can be assembled at site with convenience. The conduits find wide applications in hazardous damp and high

P a g e | 19 temperature environments. Fire retardancy make their applications safer in public installations such as railway coaches, theatres, conference halls, shops aviation and power control panels. Technical features PMA products: 1. The components are made from polyamide and nickel plated Aluminum and offers excellent screening characteristics as per European EMC regulations. These provide high shielding effectiveness and low transfer impedance. 2. The components withstand hostile temperature conditions between 75 C to 450 C and thus have given satisfactory performance all over the world. 3. These are safe and easy to install for various industrial applications. 4. Accessories like clips, bends reduces adopters swivel connectors, tube clamps, connectors, safety and sensing systems all add to provide IP 67 protection as per international standards. The system has excellent fire retardancy, neat and cleans layout and shielding properties.

6.4. Wohner Technology: Wohner a trend setter in Bus Bar system technology is continuously improving its systems. Convenient terminals which require no drilling are available for connecting conductors with cross sections from 1.5 to 120 Sq. mm. Bus Bar connecting terminals allow bus bar systems to be connected length wise. Other advantages are ease of rapid circuit change over, easy installation, supply of customers need based system. With universal terminals or terminal plates, cables up to 300 Sq. mm can be connected without drilling holes. The range includes:

1. Universal Bus Bar support 2. Standard copper Bus Bar 3. End Cover 4. Compartment section 5. Bottom trough 6. Trough edge section 7. Connection terminal 8. Connection accessories 9. Triple Bus Bar sections 10. Bus Bar adapter. 11. Plug in connector panel mounting components

P a g e | 20 12. Comb type Bus Bar 13. Barrier support 14. Barrier 15. Spacer 16. Cover frame Applications: 1. Low voltage power distribution panels 2. Power control and motor control centers 3. Overhead Bus Bar trunking. 4. LT Bus Bar ducts. 5. Customized Bus Bar systems. Special Features: o Compact in design. o Versatile technology for wide range applications o Patented technology Trend setter for new NH Bus mounting fuse switch disconnector. o Composite Bus Bar system and LAN Bus technology and control of components through PC. o Absence of drilling holes reliability and efficiency of Bus Bar system. o Adopters ensure easy and quick mounting of connectors, MCCBs and other components. o Snap on push fit arrangement. o Absence of hardware ensures no chance of heating and flash over. o Absence of use of crimping sockets reduces installation cost in a compact area. o Wiring layout is neat and clean and ensures total flexibility for upgradation and expansion without major changes in design. o Universal adoption for all types of equipments without hassels. o Conforms to IEC 947

6.5 Environmental Management Systems (AC): We have joined hands with Aircotech of Switzerland for development of roof mounted AC package units for Indian Railways, military shelters and for industrial and commercial installations. Our units have striking features - compact size, easy to install, cost effective per TR, rugged and antirust stain less frames. Equipped with air cooled condensers, requirement

P a g e | 21 and availability of water as a cooling medium is totally eliminated. Being compact and fully wired, the units can be installed within an hour and find convenient location on roof tops, thus eliminating the need for space which can be gainfully utilized for commercial purposes. Our units are energy efficient economical and cheaper in operational costs as the capacity of the system can be controlled as per the cooling load requirements during journey.

Our production activities get technical support from our collaborators who have expertise for equipments for traction applications and military shelters. The micro processor control of units provides diagnostic facilities through interface with laptop apart from automatic fine control of temperature, humidity, fresh air quality etc. Our units meet requirements of international quality standards such as UIC 553 OR, UIC 553 I, EN 50155, EN 55011, EN 50141 besides applicability of relevant Indian Standards. They have been specially designed to work satisfactorily under hostile environmental conditions such as high ambient temperature, damp and dusty atmosphere and under excessive vibrations and shocks. Being of approved and proven quality, the components are almost maintenance free and ensure trouble free operation during service.

Environmental control & testing facilities have been created to meet international standards. Microprocessor controllers, variable voltage and frequency measuring equipments, high voltage testing kits, evacuation and refrigerant charging machines, insulation resistance testing kits and instruments for testing and measurement of voltage current, power factor, frequency and electrical power have been installed for measurement and adjustment of various parameters for a close watch over the performance of AC units during testing.

6.6 Electrical Panels: Indian Railways are one of the major users of electrical panels and we enjoy the status of approved suppliers for Indian Railways. Other users are State Government, Central Government and private organizations of repute. The product range includes: MCC Panels PCC Panels PDB Panels Feeder Pillars

P a g e | 22 CDB Boards AMF Panels LT Panels General features: The Panels conform to IS standards with a degree of protection IP 55. Main features are: 1. Accuracy of dimensions 2. Aesthetically elegant Panels 3. Customised manufacture of Panels. Variants for railway coaches: Switch Board cabinets Buffet & Power Car Panels SG / EOG variants of Panels Non AC Panels Special Features of Panels for Railways: 1. Provision of disconnecting and earthing devices. 2. Insulation monitoring system 3. Anti Skid protection device control 4. Control of electrical appliances in pantry card heaters, fridges, water coolers, hot boxes etc. 5. Monitoring and control of AC package units with microprocessor controlled system and diagnostic facilities with interface with laptop. 6.7 Enclosure Systems: Sheet Metal enclosures of different variants were launched in 2005. The enclosures meet requirements for power panels, distribution panels, drive panels, machine tool applications and various other electrical and electronic applications. A wide range of CNC machines are being used to carry out various operations. These panels are modular in construction and have special features as given here under. A high quality joining frame with special profile enhances technical properties. These are self standing type with openable doors with degree of protection IP 55.

Constructional features:

P a g e | 23 1. Multi folded profile sheet metal channel: 2. Integrated special lock system with inserts and recessed handles. 3. Reliable protection from ingress of water and dust for the installed equipment with formed in PU seal. 4. Sturdy and elegant in looks with powder coating paint finish. 5. Modular design. 6. Rugged and self supporting base. 7. Easily openable door and easy installation. 8. Facility for removal of rear, top and side covers. 9. Facilities for accessories such as lifting hooks, cable gland entry holes, cut outs for display and control equipments. 10. Easy interior installation by using mounting plates( self tapping screws, u nuts, clip on nuts, earthing strips, Tri bars. 11. Also available as per specific customers requirements.

Product range: 1. Integra series: Floor standing frame type construction. Modular in design. 2. Magna series: Modular cabinet system custom built for specific applications and needs. 3. Versa series: Control desk type cabinets. 4. Reva Series: Wall / surface mounted welded enclosures and terminal boxes. 5. Dura Series: Outdoor enclosures / PC enclosures / 19 racks. 6.8 MCB Distribution Boards: MCB Distribution Boards have a universal design which can accommodate any type of MCB made as per IS Specification conforming to IS 13032 & IEC : 439 & 529. Quality, safety, flexibility and convenience of the distribution system are the hall marks of SSK products. Double Door Distribution Boards have additional feature for adjustment of MCBs through height adjustable Din Rail as per IS 11039. The body of the MCB DB is made from high grade CRCA sheet steel to withstand all types of tropical environment and sheet metal work is executed through CNC machines to achieve high degree of accuracy and quality, followed by seven tank phosphating and passivating process and powder coating with superior quality paint to ensure protection shield to protect the DB from rust, cement & concrete during construction. It ensures energy saving & economical operation achieved through use of high conductivity ETP copper tin plated Bus Bars. Suitable knockouts are

P a g e | 24 provided on all four sides at appropriate positions for wider application and ease of cable entry and sufficient wiring space provided to ensure easy and trouble free wiring. 6.9 Switchgear: Heavy-duty switchgear for inductive loads gives reliable and trouble free performance. These include Rewireable Switch Fuse Units, Double Break Fuse Switch Units, Changeover Switches, Porcelain Fuse Units, Neutral Links etc. with heavy duty double knife contacts and find extensive applications for electrical installations in Telecommunications, Railways, Power Systems, Hospitals, computers, public and industrial buildings and industrial undertakings. The products comply with the requirements of IS 13947 part 1 & 3 & IEC: 60947 part 1 & 2. They are available in ratings from 16A to 400A and above with double, three or four pole configuration.

The body of the switchgear is made from CRCA sheets and sheet metal work is executed through CNC machines, followed by seven tank phosphating and passivating process and special epoxy polyester, ionic bond powder coating achieved through electrostatic technique with superior quality paint to withstand tropical climatic conditions. Suitable interlocking is provided to ensure that the switch can be opened in OFF position only and can be switched ON when the cover is fully closed. Transparent polycarbonate shroud provided for protection of operator and direct visibility of contacts in high rating changeover switches. Heavy duty spring loaded ETP copper contacts provided for low watt losses & energy saving thus reducing operational cost.

SSK Switchgears have a long track record of high quality. Long time users of our switchgear vouch for good quality. Company has a large and rapid growing base of satisfied customers. SSK takes extreme pains in maintaining high standards of quality & perfection with an assurance that all SSK products are backed by genuine warranty of trouble free performance.

7. MAIN DEPARTMENTS The standard electrical limited is divided into 11 departments: Sheet metal shop Press shop Paint shop Research & development department

P a g e | 25 Electroplating shop Circuit Breaker Division Tool room Panel shop Moulding shop Switchgear assembly Quality assurance department

7.1 SHEET METAL SHOP:This department Manufactures the enclosures for the distribution board as well as the panel & do the sheet metal work as cutting, shaping, welding etc. The raw material used is CRCA (cold rolled carbon annealed) sheets. The operation cycle in the sequence it is performed is as shown below: -

C.R.C.A. sheet Cutter (blank sheet) Power press (punching) Tapping (if required) Bending Drilling Welding (spot or mig as required).

The board or cabinet formed is then sent for electroplating & painting process to respective departments. 7.1.a) C.R.C.A (Cold Rolled Carbon Annealed) Sheet It is imported from ESSAR STEEL INDIA LTD.(Ludhiana). One bundle contains 60 sheets. Weight is 2.8 MT. Sizes (2*1250*2500mm, 1.5* 250*2500mm)

The quality check is followed throughout the manufacture.

P a g e | 26 The welding is done to join the sheets to make the bodies for housing the components or the service cabinet.

Fig:-2 Two types of welding are as followed: -

1) Spot welding 2) Mig welding

7.1.1 Machines used: There are various types of machines used such as: Power press Shearing Machine(Mechanical cutter) Drilling machine Tapping machine Welding machine Punching machine Bending machine

a) Punching machine

P a g e | 27 Two types of punching machine are used at ssk. CNC (Automatic) TURRENT PUNCH PRESS

CNC (manually) PUNCH PRESS

A punch press is a type of machine press used to cut holes in material. It can be small and manually operated and hold one simple die set, or be very large, CNC operated, with a multistation turret and hold a much larger and complex die set. C type presses have a bed plate which is used to lock the die bottom bolster. For locking the die, T bolts are used and so this plate contains 'T - slots into which t- bolts are slid in. These slots are placed diagonally and with a slot horizontal to the longer side of the plate, is the general practice. These slots run up to a central hole made in the plate, the hole being large enough to accommodate another bush with a hole, the hole being used for dropping the punched part to the bottom of the press. The top of the tool butted against a vertical sliding ram with a clamping system which accommodates only a particular diameter of a threaded cylindrical member called the "shank" of the tool. The bottom portion of the tool is locked to the bottom bed plate and the top portion of the tool is locked to the sliding ram. Top and bottom portions of the tool are generally guided by suitable pillar and bush assemblies, (one or two pairs ), which gives safety to the punching elements of the tool. Generally the tool is placed slightly above the bottom bed plate by providing two parallel blocks accurately ground to the same size. This is a necessary action since many tools; scrap (cut pieces which are a waste) is discharged through the bottom element of the tool, not necessarily in the centre of the tool. The scrap or the blank ( the required portion ) come out from the die at different places . These have to be taken out horizontally from between the parallels placed. Otherwise they get accumulated inside the tool itself and cause severe damage to the tool. In very heavy presses with higher tonnage, The sliding ram has also a thick plate with T slots for locking the top plate of the tool (called the top bolster). In such cases the threaded cylinder called shank is not attached to the tool. The clamps are either mechanical (manually operated using spanners ) or air operated varieties. Turret type punch press machines have a table or bed with brushes or rollers to allow the sheet metal work piece to traverse with low friction. Brushes are used where scratches on the work piece must be minimized, as with brushed aluminum or high polished materials.

P a g e | 28 Turret type Punch presses are computer numerically controlled (CNC) able to be run in an automatic mode, according to a pre-built program, to perform the processing of the material. a.1) The punch press is characterized by parameters such as:

Frame type Mechanism of delivering power to the ram (mechanical, electro-mechanical or hydraulic) Size of working area (e.g., 2500 x 1250 mm) Force rating (for example, 20 tons) The type of tool shop and its capacity (e.g., store revolving type, capacity 34 tool) Speed or productivity (typically characterized by the speed of strokes with a step movement of 25 and 1 mm)

Speed of movement without shock (speed-load displacement) Maximum weight of work piece Safety features Power consumption The type of software

Punch presses are usually referred to by their tonnage and table size. In a production environment a 30 ton press is mostly the machine used today. The tonnage needed to cut and form the material is well known, so sizing tooling for a specific job is a fairly straightforward task. According to the requirement the tonnage may even go up to 2000 to 2500 ton presses.

a.2) Features of punching machine at ssk

Punching (VIPROS 225) by AMADA company (shown in Fig 3) Store revolving tool set used, capacity 34 tools. Co-ordinates are feed in CNC system (X-axis, Y- axis, Z- axis, Angle, Time delay, Tool operation) Capacity/Force:- 196 KN Power Required:- 27 KVA Wt. of Machine:_ 9800 kg Frequency:_ 50-60 HZ

P a g e | 29

Fig.3 Punching Press (Mech) Company:- Hindustan Hydraulics 3 Phase, 50-60 HZ Wt. of machine:- 9000kg Capacity:- 2000kN Supply I/P:- 415 V, 3.8 A

Fig 4 This is operated by Legs. Only coordinates are fed by CNC system by DELEM company. b) Bending machines:These machines are used for bending of sheet to give them a shape. They are of different types and types are based on their capacity. They may be manually operated or automatic. CNC system are used for feeding of size and co-ordinates.

P a g e | 30 b.1) Features of bending machine at ssk. Company :- Hindustan Hydraulics Capacity:- 10 ton Force :- 1100 KN I/P supply:- 415 V Working length:- 3100mm Wt. of Machine:- 8700kg Leg operated, Feeding system by DELEM.

Fig 5 Company:- AMADA Capacity:- 80 ton Power required:- 6KVA Wt of machine:- 5100 KG Max. bending length:- 2505mm, 98.6 inch Temp required:- 0-400c Different type of tools are used. Generally 14 -16 gauge tools are used.

Fig 6

P a g e | 31 c) Spot welding machine Spot welding (RSW) is a process in which contacting metal surfaces are joined by the heat obtained from resistance to electric current flow. Work-pieces are held together under pressure exerted by electrodes. Typically the sheets are in the 0.5 to 3 mm (0.020 to 0.12 in) thickness range. The process uses two shaped copper alloy electrodes to concentrate welding current into a small "spot" and to simultaneously clamp the sheets together. Forcing a large current through the spot will melt the metal and form the weld. The attractive feature of spot welding is a lot of energy can be delivered to the spot in a very short time (approximately ten milliseconds). That permits the welding to occur without excessive heating to the rest of the sheet.

Fig. 7 c.1) Processing and equipment Spot welding involves three stages; the first of which involves the electrodes being brought to the surface of the metal and applying a slight amount of pressure. The current from the electrodes is then applied briefly after which the current is removed but the electrodes remain in place in order for the material to cool. Weld times range from 0.01 sec to 0.63 sec

P a g e | 32 depending on the thickness of the metal, the electrode force and the diameter of the electrodes themselves.

The equipment used in the spot welding process consists of tool holders and electrodes. The tool holders function as a mechanism to hold the electrodes firmly in place and also support optional water hoses which cool the electrodes during welding. Tool holding methods include a paddle-type, light duty, universal, and regular offset. The electrodes generally are made of a low resistance alloy, usually copper, and are designed in many different shapes and sizes depending on the application needed. The two materials being welded together are known as the work pieces and must conduct electricity. The width of the work pieces is limited by the throat length of the welding apparatus and ranges typically from 5 to 50 inches. Work piece thickness can range from 0.008in. to 1.25in. After the current is removed from the work piece, it is cooled via the coolant holes in the center of the electrodes. Both water and a brine solution may be used as coolants in spot welding mechanisms.

Using a copper wire as the welding element does the MIG welding. Whereas the spot welding does not use a welding element as the metals are joined by the action of heat.

c.2) Features of welding machine at ssk. Company:- Sunrise mek welding Type:- spot/projection welding p.f:- 0.4 i/p:- 50 hz, 415 V 2phase Water cooling system, 1.5 litre

d) shearing machine:-

Used for cutting of sheets of different shapes.

P a g e | 33 Company:- Hindustan hydraulics I/P:- 415 V Wt of machine 6200 kg Capacity 6mm Working length 3100 mm 3phase Length is feed , & cutting process is done manually.

Fig 8

P a g e | 34 7.2 PRESS SHOP Press shop is divided into two parts: 1) Switchgear press shop 2) MCB press shop In switchgear press shop main contacts for double break switch and cubical switch, interlocking strip for cubical switch, arm for double break switch and solid links & link strips for rewire able, cubical and change over switches are prepared.

In MCB press shop arc chute assembly, fixed contact, moving contact, bimetal carrier, arc chute plate, stopper, control rail, mounting clip etc. required for the completion of MCB are prepared. The dept. Also manufactures dyes needed for tool manufacturing used in the plant. Details: The press shop operations are set up dominant. Dyes for various operations are maintained. New dyes are got approved of quality assurance dept. If any fault is found in the dye it is repaired and re-approved from QAD. Quality check is followed throughout, first piece inspection procedure is adopted as well as the random inspection is followed and the reports are made and if any problem exists it is rectified. First piece evaluation is done by in charge press shop. Whenever the dye is loaded in press for production. If the first piece meets the acceptance criteria, the set up is approved and production is allowed however, if the first piece fails to meet the acceptance criteria, production is not allowed and the dye worked out or resetting is to make the production conforming the acceptance criteria. There are following machines used in press shop: Mechanical power press Pneumatic power press Hydro-pneumatic power press Hydraulic power press

They are used for small work like making small cutting & different symbols. E.g. ground symbol , Danger symbol, SSK.etc. Their rating depends on gauge, different tools are used for this purpose.(12-14 gauge, 18 20gauge, 20-25 gauge). Marks & holes are made on cabinets & others.

P a g e | 35

7.3 PAINT SHOP

In this shop, powder paint is applied on the enclosure of the following items: Rewireable switches Double break switches Change over switches Cubicle fuse switches MCB Distribution boards All export items and cabinet

7.3.1 APPARATUS SET UP: 1) 2) 3) 4) 5) Powder coating guns (electrostatic application) Powder baking oven Thermic fluid heater Spray booth Micro test thickness gauge

The powder coating guns are used to spray the powder paint on the components in the spray booth, which then sent to the baking oven. The thermic fluid heater is to produce the steam required to operate the oven. Micro test thickness gauge is used to check the thickness of coating of the paint.

1) Powder coating guns

Fig.9 Powder coating is a type of coating that is applied as a free-flowing, dry powder. The main difference between a conventional liquid paint and a powder coating is that the powder

P a g e | 36 coating does not require a solvent to keep the binder and filler parts in a liquid suspension form. The coating is typically applied electrostatic ally and is then cured under heat to allow it to flow and form a "skin". The powder may be a thermoplastic or a thermoses polymer. It is usually used to create a hard finish that is tougher than conventional paint. Powder coating is mainly used for coating of metals, such as household appliances, aluminum extrusions, and automobile and bicycle parts. Newer technologies allow other materials, such as MDF (medium-density fiberboard), to be powder coated using different methods. There are several advantages of powder coating over conventional liquid coatings: 1. Powder coatings emit zero or near zero volatile organic compounds (VOC). 2. Powder coatings can produce much thicker coatings than conventional liquid coatings without running or sagging. 3. Powder coating overspray can be recycled and thus it is possible to achieve nearly 100% use of the coating. 4. Powder coating production lines produce less hazardous waste than conventional liquid coatings. 5. Capital equipment and operating costs for a powder line are generally less than for conventional liquid lines. 6. Powder coated items generally have fewer appearance differences between horizontally coated surfaces and vertically coated surfaces than liquid coated items. 7. A wide range of specialty effects is easily accomplished which would be impossible to achieve with other coating processes. Powder coatings have a major advantage in that the overspray can be recycled. However, if multiple colors are being sprayed in a single spray booth, this may limit the ability to recycle the overspray. 1.1) Principle of powder coating guns Charging of powder Various systems are used to charge the powder. The choice of the process depends on the application and the desires of the user. Generally, three different charging processes are distinguished: electrostatic charging, charging with low ionization and tribe charging. Virtually all manufacturers attain the reduction of air-ionization by the use of a special centerpiece on the top of the gun (called Super Corona at ITW Gama)

P a g e | 37 Electrostatic charging The corona discharging is the unrestrained escape of free electrons from an electrical conductor. The electrostatic gun is equipped at its top with an electrode that expels electrons. When exiting the powder gun, the powder particles are charged through the deposition of air ions. The resulting ionized powder particles, similar to the free ionized air particles, are attracted to all earthed objects. In practice, the earthed object is the work piece, thus the powder remains bonded to it. The charging principle with constant feed of electrostatic charge allows the use of this gun type in all application cases and for virtually all powder categories available on the market.

Fig 10 7.3.2) paint process has five steps: Phosphating Priming Painting Baking Sealing

P a g e | 38 PHOSPHATING: By the process of Phosphating, impurities are removed from the surface of the body & body is coated with a layer of phosphorous. And it includes nine-tank process.

Table 2
Sr.No. Description Operating Ph. Temp. Of the liquid in degree Celsius Time for which object is kept insidethe liquid for minutes 1. 2. 3. Degreasing Tank Water Rinsing Tank Derusting Tank 4. 5. 6. 7. 8. 9. Water Rinsing Tank Water Rinsing Tank Activation Tank Phosphating Tank Water Rinsing Tank Sealing --------8.5 9.5 1 ----3-4 Normal Normal Normal 30-35 Normal 75 - 80 1 1 1 1 10 --1 75-85 Normal 50-60 10 1 5

Degreasing tank contains the caustic soda & soda ash. Its purpose to remove the oil etc. from the surface of object. Water rinsing tank contains simple water so that the chemical of one tank does go into the other tanks. Rustodene tank contains the acid. Its purpose is to remove from the surface of the object. Phosphatizing tank contains zinc phosphate. It is done for better bonding of paint with the metal base. Passivation tank contains the dichromate solution & it is to done to increase the resistance of the metal against the humidity

P a g e | 39 PAINTING: In this process is sprayed on the body by the electrostatic gun Electrostatic has two pipes, one contains the compressed air & another contains powder. Power is positively charged & body is negatively charged, this makes the powder adhesive.

Fig 11 BAKING: In this process painted body is passed through the diesel-fired furnace up to required temp. Of 182-220 degree Celsius & the powder melt & from a paint layer on the surface &the thickness of the paint layer is 55 microns

Fig 12

P a g e | 40 SEALING: It is done for fast drying and to increase the resistance to humid conditions. The chemical used is sodium dichromate at 70-80 degree Celsius for rinsing.

7.3.3 TESTS APPLIED AFTER PAINTING THE BODY:-

1) Scratch test:
a) Take painted object b) Make the crossed line on a part of the body. c) Put the cell tape of 1-inch width on the marked area. d) Then pull it & again put it on the same area. e) Pull it again. Repeat the test 5-6 times using the same piece of cello tape f) Observe the peeling of the paint. If it peels off, then it is rejected.

2) Bend test:
a) Fix half of the painted panel in vice, keep one of bakelite piece on each side of panel to avoid scratches from the vice. b) Bend it up to 90 degree by exerting the pressure by hand. c) Observe cracks on the coating of the paint. If it shows the cracking, piece is rejected.

7.4 ELECTROPLATING SHOP

Electroplating is done on the basis of electrolysis. Electroplating is a act of depositing a superior or noble metal on an inferior or a baser metal by means of electrolysis of an aqueous sol. of a suitable electrolyte. For example metals like iron, which are easily corroded by air, moisture & carbon dioxide, are coated electrolytic ally with deposits of nickel and chromium, which are highly resistant to chemical attack. The electrolytic bath used in the plating has an electrolyte that depends on the nature of metal to be deposited. 7.4.1 STEPS FOR ELECTROPLATING: 1) Loading 2) Degreasing in kerosene 3) Soaking in wooden 4) Acid cleaning 5) Washing 6) Plating

P a g e | 41 7) Drying 8) Unloading 9) Thickness measurement

Here the electroplating process is done as per the document work instruction on various components. All copper and brass component, fuse switches change over switches, all MS components, in fact all metallic components, are electroplated and painted (if required).The pieces are checked for cleanliness. The whole process is quality controlled. 7.4.2 TYPES OF ELECTROPLATING Acid zinc electroplating Acid tin electroplating Silver electroplating Copper electroplating

ACID ZINC ELECTROPLATING: Zinc electroplating is done on iron to protect it from rust. Equipment used: - Barrel and tank. Temp. : - Room temp. Voltage applied to barrel: - 9-12 volts Anode: - zinc Cathode: - iron Thickness: - 10 15 microns After plating zinc is passivated. Passivation is done: a) For decoration b) To increase the resistance against humidity. ACID TIN PLATING: Tin plating is applied on the copper and brass components. Chemical composition: - stannous sulphate, sulphuric acid and brightener. Equipment used: - barrel and tank Temperature: - room temp. Voltage applied to barrel: - 5 -8 volts Anode: - pure tin

P a g e | 42 Cathode: - copper, brass Thickness: - 8 12 microns Procedure: Bleach the tank with sulphuric acid. After leaching, drain the leaching solution & rinse the tank with water. Then fill the tank with distilled water. Add stannous sulphate & dissolve it. Then add brighter & start plating. Give anode to pure tin & cathode to brass or copper & supply voltage. Tin with be plated on brass or copper.

SILVER PLATING: Chemical composition: - silver salt, silver cyanide, potassium cyanide, brighter. Equipment used: - barrel and tank Temperature: - room temp. Voltage applied to barrel: - 1.5 volts Anode: -pure silver Cathode: - copper, brass Thickness: - 2-4 microns PROCEDURE: Silver sol. is prepared in the storage tank. For it leach &clean the tank. Then fill it with 2/3rd by water. Add silver salt and activated carbon. Provide anode to silver and cathode to brass and copper as anode metal losses weight and collects over cathode metal.

COPPER PLATING: Copper is coated on mild steel. Chemical composition: - copper salt, sodium cyanide. Equipment used: - barrel and tank Temperature: -50 degree Celsius. Voltage applied to barrel: - 7 -8 volts Anode: - pure copper Cathode: -steel Thickness: - 4 6 microns

P a g e | 43

PROCEDURE: Fill half of the tank with water. Heat it up to 50 degree Celsius. Add copper salt and dissolve it. Now filter the solution. Give anode to copper and cathode to iron & supply the voltage. Before the start of electroplating work, the material is checked for cleanliness. The water layer on the parts must not break up. If it breaks material is not cleaned. The cleaning process is done with use of nitric acid and sulphuric acid.

7.4.3 INSPECTION: Coating thickness: -it is measured and compared with the required thickness. Incase of deviation the process is adjusted. Surface finish: - it is compared with representative sample. Correction action is followed when required.

Pollution control: - effluent from process of plating is fed to the DM. Water plant and the processed water is reused for washing of plated or un-plated components. The treatment is done as per the work instruction. 1) There are two types of streams coming out of electroplating plant: a) Cyanide base stream stored at side 1. b) Chrome (hexa), heavy metals stored & acid stream (stored at side 2). 7.4.4 TREATMENT METHODS Cyanide base stream 1) Add bleaching powder through feeding tanks fitted with stirrer for proper mixing. This breaks cyanide into CO2 + N2. 2) The components removal of cyanide in water is indicated when starch iodide paper turns blue. Chrome, heavy metals & acid stream Treat the stream with sodium metal bisulphate at ph=2. If ph is more than 2, add dilute sulphuric acid to bring the ph = 2. Hexavalent chrome gets converted into the trivalent chrome. 3) The conversion of the hexavalent chrome to trivalent stage is indicated with the change of light yellow co lour of water. 4) Raise the ph of the solution between 10 11 with the help of lime and polywin.

P a g e | 44 5) 6) 7) At ph= 10-11, the heavy metal & trivalent chrome gets precipitated. After this the water of both the stream is fed into the sludge-setting tank. Sludge setting tank water is allowed to stand for 8-10 hours. As a result sludge settles down. 8) 9) The clean water is then brought to ph adjustment tank through the clarifier. In the tank ph is adjusted between 6-9 with the help of dilute sulphuric acid.

10) The settled sludge is stored in polythene bags. 11) After adjusting the ph, the water is fed into the DM water plant. The following parameters are required before the water used for washing purposes. 7.4.5 STORAGE AND SAFETY: The chemicals are stored in section store (chemical). Potassium cyanide, copper cyanide sodium cyanide etc. that are highly toxic in nature are stored in separated sub-section. These are stored and handle as per documented work instruction. Gas mask are provided and used while handling chemicals of toxic nature.

8. SWITCHGEAR DIVISION
8.1 PRODUCTS BEING MANUFACTURED ARE: Rewirable Switch Fuse Unit Double Break Fuse Switch Cubicle Fuse Switch Cubicle Isolator Changeover Switch MCB Distribution Board

8.1.a) REWIRABLE SWITCH FUSE:INTRODUCTION:-

Rewirable switch fuse unit is used for the protection of electrical appliances against over voltage. Its design is most ideal for effective control of repeat switching operations of airconditions, refrigerators, geysers and other house-hold electrical appliances. Extensively used as industrial main control switch.

P a g e | 45 Range : 16 -100A

No. of poles

: SPN, DP&TPN

Rated voltage

: 240/415A.C

Insulation voltage

: 660V

Utilization category

: A.C-23A

Fig 13 8.1.b) ON LOAD CHANGEOVER SWITCH:-

INTRODUCTION:On load changeover switches are designed for application in low voltage distribution circuit and motor circuit. They are used at place where continuity of supply from main supply and vice versa is required. These compact on load changeover switches having a unique modular construction capable of making, carrying and breaking current under normal condition with a utilization category of 23A at the rated operational current. The entire switch mechanism is

P a g e | 46 housed in a polyester reinforced moulded frame having high dielectric strength and thermal with stand capacity. Range No. of poles Rated voltage Insulation voltage Utilization category 63 1000A four 415A.C 660V A.C-22A

8.1.c) DOUBLE BREAK FUSE SWITCH:INTRODUCTION:Double break fuse switches are designed for safe & efficient power distribution. They have double break isolation enables incoming supply to be connected to either bottom or top terminals. Range No. of poles Rating insulation voltage Utilization category Specification 63-400A TP TPN & FP 415V 660V IS: 13947(P-3) &IEC; 947-3

8.1.d) SWITCH DISCONNECTOR FUSE:A wide range of front operated panel mounting switch disconnector fuse is offered for various power distribution applications. These switches have high short circuit making and breaking capacity and are suitable for stringent AC-23 utilization category. These can be used for both AC and DC applications. Range: - 32A to 800A EXECUTION: Double pole Triple pole Triple pole with switched neutral Four pole

APPLICATIONS: 1) These have been specially designed for most stringent motor duty inductive and capacitive load applications.

P a g e | 47 2) These switches are compact in size and front operated and thus ideal for power panels.

8.2 DISTRIBUTION BOARDS:Distribution boards provide flexibility and a systematic approach to ever increasing need for effective methods of the electrical distribution in domestic, commercial and industrial application. Distribution boards have been specially designed to meet all the technical requirements and ensure the distribution boxes blend with the dcor of the place of the installation.

Distribution boards with their features and their range offer a compact, practical and economic solution to any electrical network in residential/commercial complexes, industries etc.having single phase or three phase connections. The distribution board is not merely an enclosures but complete system in itself comprising of ETP copper bus bar, brass neutral link, earth link,earthing studs and interconnection wires for effective distribution of current.

8.2.1 FEATURES:

All DBs painted in epoxy polyester powder coating

. Earth bar fitted on upper end plate, having same number of holes as number of MCBS. Neutral has same number of outgoing holes as number of MCBS. Upper and lower end plates are detachable, have knockout and inter replaceable.

8.2.2 Classification of the circuit breaker a) According to the number of poles Single pole circuit breaker Two pole circuit breaker with one protected pole Two pole circuit breaker with two protected poles Three pole circuit breaker with three protected poles

P a g e | 48 Four pole circuit breaker with three pole protected Four pole circuit breaker with four pole protected.

b) According to the protection against external influences Enclosed type Unenclosed type

c) According to the method of mounting Surface-type Flush- type Panel board type

d) According to the method of connection Circuit breaker the connection of which of it is associated with mechanical mounting, for example Plug in type Bolt on type Screw in type

e) According to the instantaneous tripping current B-type C-type D-type

P a g e | 49 f) According to the I2T characteristics MCB RATING CHAT FOR DOMESTIC APPLICATIONS SR.NO 01 02 APPLIANCES REFRIGERATOR 165LT/350LT T.V. V.C.R MUSIC SYSTEM CAPACITY 400W/750W 400W MCB RATING 4A-6A 4A

03

VACCUME CLEANER WASHING MACHINE

400W

4A

04

WASHING MACHINE WITH HEATER IRON

1300W

10A

05 06 GEYSER

750W 1000, 2000, 3000W

6A 6A10A16A

07

HOT PLATE

1000W

10A

08

AIR CONDITIONING

1TON

10A

1.5TON

16A

2TON

25A

09

PHOTOCOPIES

1500W

16A

10

WATER COOLER

700W

6A

11

POWER PLUG

1000W

10A

12

ONE LIGHTING CIRCUIT

10 PTS 1000W

10A

P a g e | 50 13 ONE POWER CIRCUIT 2 PTS 3000W 20A

Table 3

MCB RATING FOR MOTOR APPLICATIONS MOTOR H.P STAR - DELTA D.O.L KW MCB RATING (AMPRS)

1.0 1.5

0.75

2A

1.10 2.0 1.5 3.0 2.25 4.0 3.00 5.0 3.75 6.0 4.50 7.5 5.50 10.0 7.50 12.5 9.30 15.0 11.00 17.5 13.00

3A

4A

6A

6A

10A

10A

10A

10A

16A

16A

16A

16A

20A

20A

25A

25A

25A

32A

P a g e | 51 20.0 15.00 25.0 18.50 40A Table 4 50A 32A 40A

Construction:-

P a g e | 52

9. TESTING LIST
For certification purposes, Type test are carried out in sequences Each type test (or sequences of type test ) is carried out on circuit breakers in a clean or new conditions.

Test conditions
The circuit breaker is mounted individually, vertically and in free are at an ambient temperature between 20 degree c to 25 degree c. unless otherwise specified , and is protected against undue external heating and cooling .Circuit breaker installation in an individual enclosure are tested in the designed for

smallest of such enclosures

specified by the manufactures. unless otherwise specified, the circuit breaker are wired with the appropriate cable specified in table and are fixed on a dull ,black printed ply wood board of about 20 mm thickness ,the method of fixing the complying with any requirements related to the mean of mounting required by the manufacturer. Where a tolerance is not specified, type test are carried out at values not less severe than those specified in this standard. Unless otherwise specified, test are carried out at a rated frequency tolerance of 5 HZ .During the test , on maintenance or dismantling of the sample is allowed.

Fig 14

9.1 For the test of sub clauses the circuit breaker is connected as follows
The connections are made by means of single core, PVC insulated copper cables, according to the IEC Publication 227. 1. The test are carried out with single phase current ,with all poles connected in series , except for the tests sub clauses 8.10.2 and 8.11. 2. The connection is in free air and spaced not less then the distance between the terminals. 3. The minimum length of each temporary connection from terminal to terminal is: 1m for cross section up to and including 10mm2,

P a g e | 53 2m for cross section larger than 10 mm2.

The tightening torque to be applied to the terminal screw are two third of those specified in table . Cross sectional (S) areas of test copper conductors Corresponding to the rated currents. S mm2 1 1.5 2.5 4 6 10 16 25 35 50 Values of the rated current In A In< 6 6< In < 13 13< In<20 20<In <25 25<In<32 32<In<50 50 < In<63 63<In<80 80< In<100 100<In<125 Table-5 9.2 List of test on Miniature Circuit Breaker (M .C.B.) as per the IS: 8828 IEC: 898 1. Indelibility of marking. 2. Reliability of screws. 3. Current carrying parts and connection.

4. Reliability of terminals of external conductors. 5. Protection against electroshock. 6. Dielectric properties. 7. Temperature rise. 8. 28 days test. 9. Tripping characteristics. 10. Mechanical &electrical endurance. 11. Short circuit. 12. Resistance to mechanical shock & impact. 13. Resistance to heat. 14. Resistance to abnormal heat & to fire. 15. Resistance to rusting.

P a g e | 54 9.2.1 Test of indelibility of Marking The test is made by rubbing the marking by hands for 15sec with a piece of cotton soaked in a water and again for 15 sec with a piece of cotton soaked in aliphatic solvent hexane with a content of aromatics of 0.1% by volume, a kauributanol value of 29,an initial boiling point is approximately 65 degree c a dry point of approximately 69 degree c and a density of approximately 0.68 g/cm3.Marking made by impression ,molding , pressing, or engraving is not subjected to this test. After this test marking shell be easily legible .The marking shall also remain easily legible after all the test of this standard .It shall not be easily possible to remove label and they shell show on curling. 9.2.2 Test of reliability of screw, current carrying parts and connections Compliance with the requirement of sub clauses 7.1.4 is checked by inspection and for screw and nuts which are operated when connecting up the circuit breaker by the following test.

Fig 15 The screw and nut are tightened and loosened: Ten times for screw in engagement with a thread of insulating material, five times in all other cases. Screw or nuts in engagement with a thread of insulating material are completely removed and reinserted each time.

Fig. 16 The test is made by means of a suitable test screwdriver or spanner applying a torque as shown in table The screw and nuts shell not be tightened in jerks. The conductor is moved each time the screw or nut is loosened.

P a g e | 55 Nominal diameter of thread mm Torque Nm 1 Up to and including 2.8 over2.8 Up to and including 3.0 over 3.0 Up to and including 3.2 over 3.2 Up to and including 3.6 over 3.6 Up to and including 4.1 over 4.1Up to and including 4.7 over 4.7 up to and including 5.3 over5.3 Up to and including 6.0 over 6.0 Up to and including 8.0 over 8.0Up to and including 10. 0.2 0.25 0.3 0.4 0.7 0.8 0.8 1.2 2.5 2 0.4 0.5 0.6 0.8 1.2 1.8 2.0 2.5 3.5 4.0 3 0.4 0.5 0.6 0.8 1.2 1.8 2.0 3.0 6.0 10.0

Table 6 Column 1: Applies to screw without head if the screw, when tightened, does not protruded from the hole, and to other screw which cannot be tightened by means of screw driver with a blade wider than the diameter of the screw. Column 2: Applies to other screws which are tightened by means of screw driver. Column 3: Applies to the screw and nuts which are tightened by means other than the screw driver. 9.2.3 Test for reliability of terminals for External Conductor In this test a rigid copper conductor having the larger cross section areas is placed in a terminal (for nominal cross section areas exceeding 6mm2 ,a rigid stranded conductor is used while for other nominal cross section areas , a solid conductor is used).

P a g e | 56

Fig.17 These last test are made by means of a suitable screwdriver or spanner applying a torque as shown Cross section of conductor Up to 4 Up to 6 Up to 10 Up to 16 Up to 50

accepted by the terminal (mm2) Pull(N) 50 60 Table 7 9.2.4 Test of protection against Electric shock The test is made with a standard test finger on the sample mounted on the as for normal use and fitted with the conductor of larger or smaller cross section. The stranded test finger is designed that the each of the joined section can be turned through an angle of 90 degree with respect to the axis of the finger ,in the same direction only. The test finger is applied in every possible bending position of a real finger, an electrical contact indicator being used to show contact with live parts. It is recommended that the lamp is used for the indication of the contact and that the voltage be not less than 40 V.Circuit breaker with enclosure of thermoplastic is subjected to the additional test, which is carried out at a ambient temperature of 35 degree c tolerance 2 degree c .the circuit breaker being at this temperature circuit breaker are subjected for 1 min for a force of 75N ,applied through the tip of a straight un jointed test finger of the same dimension of the standard test finger. This finger is applied to all places where yielding of insulating material could impair the safety of the circuit breaker, but not applied to the knock outs. During this test , enclosures and covers shell not deform to such an extent that live parts can be touched with the un jointed test finger. 9.2.5 Test of Dielectric properties Following test are done under this: Resistance to humidity. 80 90 100

P a g e | 57 Insulation resistance of the main circuit. Dielectric strength of the main circuit. Dielectric strength of the auxiliary circuit. Value of test voltage.

Fig.18 9.2.6 Test of Temperature rise The Ambient air temperature shall be measured during the last quarter of the test period by means of at least two thermometer or thermocouples symmetrically positioned around the circuit breaker at about half its height and at a distance of about 1meter from the circuit breaker 9.2.7 28-Days test The circuit breaker is subjected to the 28 cycles .each cycle comprising of 21 h with a current equal to the rated current at an open circuit voltage of at least of 30 V and 3 h without current under the test condition. The circuit breaker is in the closed position the current is being established and interrupted by an auxiliary switch .during this test the circuit breaker shell not trip. During the last period of current flow the temperature rise of the terminal shell be measured .The temperature rise shell not be rise the value measured during the temperature rise test by more than 15 k .Immediately after this measurement of this temperature rise the current is steadily increased with in 5 s to the conventional tripping current. The circuit breaker shell trip with in the tripping time. 9.2.8 Test of tripping characteristics Various tests which are performed to know these characteristics Test of time current characteristics

P a g e | 58 Test of instantaneous tripping Test of effect of single pole loading on the tripping characteristics of multi pole Circuit breaker. Test of effect of ambient temperature on the tripping characteristic

9.2..9 Test of mechanical and Electrical Endurance The circuit breaker is fixed to a metal support unless it is designed to install in any other enclosure .the test is made at a rated voltage, at a current adjusted to the rated current by means of resisters and reactor connected in series to the load terminals .If air cored reactors are used, a resistor taking approximately 0.6% of the current through the reactors is connected in parallel with each reactor. The current shell has sustainable sign wave form and the power factor shell be between 0.85 and 0.9. For single pole circuit breaker and for two pole circuit breaker with two protected poles, the metal support is connected to the one part of the supply for the first half of the total no of operation and to the other side of the second half. For two poles circuit breakers with one protected pole ,the metal support is connected to the neutral of the supply .For single pole circuit breaker the shell be carried out at the lower voltage values . (Preferred values: 220 v or 240 v) 9.2.10 Short circuit test Standard test for the verification of the short circuit performance consist of sequence of

Fig.19 Making or breaking operation ,appropriate to the performance to be checked which are summarized in the table. Kind of test Test at reduced short circuit current Test at 1500 A Test at service short circuit capacity I cn > 1500 A Circuit breaker to be tested All circuit breaker

P a g e | 59 Test at rated short circuit capacity Table 8

Fig.20

Fig.21 All circuit breaker are tested at 500 A or In which ever is the highest , and at 1500 A. Circuit breaker having rated short circuit capacity above 1500 A are additionally tested 9.2.11 Test of resistance to mechanical shock and impact The circuit breaker is subjected to the mechanical shocks by using an apparatus as shown in figure. A wooden base A is fixed to a concrete block and a wooden platform B is hinged to

P a g e | 60 base A this platform carries a wooden board C which can be fixed at a various distance from the hinge and in two vertical positions.

Fig.22 The end of board B bears a metal stop plate D ,which rests on a coil spring having a constant c of 25 N/mother circuit breaker is secured to the vertical base board in such a way that the distance of the horizontal axis of the sample is 180 mm from the platform ,the vertical board being in turn so fixed that the distance of the mounting surface is 200 mm from the hinged as shown in figure On the surface C opposite the mounting surface of the circuit breaker ,a supplementary mass is fixed so that the static force on the metal stop plate is 25 N in order to ensure that the movement of inertia of the complete system is substantially constant . 9.2.12 Mechanical Impact test Compliance is checked on those exposed parts of the circuit breaker mounted as for normal use which may be subjected to mechanical impact in normal use by the test for all type of apparatus (circuit breaker)

Fig: 23 For screw in type circuit breaker For circuit breaker to be mounted on a rail For plug in type circuit breaker

P a g e | 61

Fig: 24 Circuit breaker only intended to be totally enclosed are not submitted to this type test. typical impact apparatus has been shown .the pendulum consist of steel tube with a external diameter of 9.0 mm and a thickness of 0.5 mm ,it is suspended in such a way that it can swing in a vertical way panel . A striking element of 0.15 kg is rigidly fixed to the lower end of the pendulum with its axis below one meter below axis of suspension the striking element has a hemispherical face. 9.2.13 Test of resistance to heat the samples without removable cover ,if any are kept for 1 h in a heating cabinet at a

temperature of 100 +- 2 degree c ,removable cover if any are kept in a heating chamber at a temperature of 70=- 2 degree c .during the test they shell not undergo any change impairing their further use and sealing compound if any shell not follow to such an extent that lives parts are exposed . 9.2.14 Resistance to the abnormal heat and to fire The external parts of the circuit breaker made of insulating material necessary to retain in position current carrying parts and parts of the protective circuit by the test made at a temperature of 960+- 15 degree c.for other external parts made of insulating material by the test made at a temperature of 650 =- 10 degree c 9.2.15 Test of resistance to rusting All greases is removed from the parts to be tested by immersion in a cold chemical degreaser such as Methyl chloroform or refined petrol, for ten min. the parts are then immersed in for ten min in a 10% solution of ammonium chloride in water at a temperature of 20+-5 degree c without drying but after shaking off any drops the parts are placed for 10 min in a box containing air saturated with moisture at a temperature of 20+- 5 degree c. After the parts have been dried for 10 min in a heating cabinet at a temperature of 100+-5 degree their surface shell show no sign of rust. For small springs and for in accessible parts exposed to abrasion a layer of grease may provide sufficient protection against rusting. Such parts are

P a g e | 62 only subjected to test if there is doubt as to the effectiveness of the grease film and the test is made without previous removal of the grease

10. MOULDING SHOP

Activities: The machines- molded components manufactured here are used in switchgear assembly and MCB assembly.

10.1 Machines used: There are following machines as given below: 1) Injection molding machine Type-1 2) Injection molding machine Type-2 Machines are CNC based. And of Larson & Tubro Company. In the first type of machine the raw material is plastic granules of POLY CARBONATE Resin. And the main parts are: hopper and barrel.

The plastic beans are injected in the dye in almost fluid state and they get the required shape as per dye and are cooled for required shape.

Water is used as the coolant for the mould and the hydraulic oil is used for maintaining the required pressure at various points. Different dyes are used for making or obtaining the different shapes.

In the machine of type-2 the basic difference is of raw material. Here the raw material is BAKELITE. In this case no cooling is required or provided rather heaters are provided for moulds as, Bakelite has a property of hardening when heated.

10.2 Injection molding machines Injection molding is a manufacturing process for producing parts from both

thermoplastic and thermosetting plastic materials. Material is fed into a heated barrel, mixed, and forced into a mold cavity where it cools and hardens to the configuration of the

P a g e | 63 cavity. After a product is designed, usually by an industrial designer or an engineer, molds are made by a mold maker (or toolmaker) from metal, usually either steel or aluminum, and precision-machined to form the features of the desired part. Injection molding is widely used for manufacturing a variety of parts, the smallest component of switches & other plastic Frames.

Fig.25 10.2.1 Process characteristics

Utilizes a ram or screw-type plunger to force molten plastic material into a mold cavity Produces a solid or open-ended shape that has conformed to the contour of the mold Uses thermoplastic or thermoses materials A parting line, spruce, gate marks, and ejector pin marks are usually present. None of these features are typically desired. They are the results of the parting of the mold for ejection of the formed part.

10.2.2 Equipments Injection molding machines consist of a material hopper, an injection ram or screw-type plunger, and a heating unit. They are also known as presses, they hold the molds in which the components are shaped. Presses are rated by tonnage, which expresses the amount of clamping force that the machine can exert. This force keeps the mold closed during the injection process. Tonnage can vary from less than 5 tons to over 9,000 tons, with the higher

P a g e | 64 figures used in comparatively few manufacturing operations. The total clamp force needed is determined by the projected area of the part being molded.

Fig. 26

Fig. 27

This projected area is multiplied by a clamp force of from 2 to 8 tons for each square inch of the projected areas. As a rule of thumb, 4 or 5 tons/in2 can be used for most products. If the plastic material is very stiff, it will require more injection pressure to fill the mold, thus more clamp tonnage to hold the mold closed. The required force can also be determined by the material used and the size of the part, larger parts require higher clamping force.

10.2.3 Molds
The mold consists of two primary components, the injection mold (A plate) and the ejector mold (B plate). Plastic resin enters the mold through a sprue in the injection mold; the sprue bushing is to seal tightly against the nozzle of the injection barrel of the molding machine and to allow molten plastic to flow from the barrel into the mold, also known as the cavity. The sprue bushing directs the molten plastic to the cavity images through channels that are machined into the faces of the A and B plates. These channels allow plastic to run along

P a g e | 65 them, so they are referred to as runners. The molten plastic flows through the runner and enters one or more specialized gates and into the cavity geometry to form the desired part.

Fig.28

The amount of resin required to fill the sprue, runner and cavities of a mold is a shot. Trapped air in the mold can escape through air vents that are ground into the parting line of the mold. If the trapped air is not allowed to escape, it is compressed by the pressure of the incoming material and is squeezed into the corners of the cavity, where it prevents filling and causes other defects as well. The air can become so compressed that it ignites and burns the surrounding plastic material. To allow for removal of the molded part from the mold, the mold features must not overhang one another in the direction that the mold opens, unless parts of the mold are designed to move from between such overhangs when the mold opens (utilizing components called Lifters). . The standard method of cooling is passing a coolant (usually water) through a series of holes drilled through the mold plates and connected by hoses to form a continuous pathway. The coolant absorbs heat from the mold (which has absorbed heat from the hot plastic) and keeps the mold at a proper temperature to solidify the plastic at the most efficient rate.

P a g e | 66 To ease maintenance and venting, cavities and cores are divided into pieces, called inserts, and sub-assemblies, also called inserts, blocks, or chase blocks. By substituting interchangeable inserts, one mold may make several variations of the same part.

Fig 29

Fig 30

P a g e | 67 The temperature Control is done by the machine panel. The machine panel is also feeded with the Time delay of every process. Before giving the polycarbonate material to moulding machine, it is firstly heated at 40degree Celsius.then it is feed to machine. The poly carbonate resin is melted at 4000 c. then moves onward towards the dye. At 50 bar pressure the required frame is made. 10.3 Grainer machine The waste material are send for recycle to grainier machine. This machine converts all waste to grains, which is further used for moulding.

Fig 31 These frames are further used in making switches, holders, door bells, and other underground wiring components.

fi

Fig 32

P a g e | 68

11. TESTING LABS

11.1 Heating oven test In this test the various poly carbonate and urea switches and holders are to be kept at a Test: 80 degree c for approximate of 8 hours after that the pieces which are been tested are to be taken to the terminals which are approximately at 80 degree c if this

Fig.33 will create the smoke while testing and after that if it will converted to the fire then the pieces under test is dejected this ensures that the switches or the other accessories which are installed in the home is free from fire and all up to a temperature of 80 degree c if the piece will create smoke only while touching it to the terminals then it will be fine but after that if it will got ignited then it will never be taken in the account. 11.2 Mechanical strength test apparatus This test is to be taken on the lamp holder to check that whether the holder is reliable to sustain the behavior of being with the same characteristics features.

Fig.34 In this test a weight of approximate of 1 tone is to be hanged with the pins of the holder to which the lamp is to be supported to give the light source. This test is to be performed for a long period of hours. 11.3 Tumbling barrel test

P a g e | 69 In this test the mechanical strength of the plug socket is to be taken under consideration in this process the 3 core wire is to be tightened to the socket and then the whole combination is to be put in the tumbling barrel then the tumbling barrel strength of the connection is to be tested out . starts revolving and then the

Fig.35

Fig.36 11.4 Mechanical impact test In this test the switching unit is fixed to the wooden baseband then the whole unit is fixed to the apparatus the mechanical strength of the switch is tested in such a manner that the 5 stops are to be taken at the distance range of 10cm. another is to be taken at a distance of 15 cm this is to be taken in the account for 10 times.

P a g e | 70

Fig.37

11.5 Endurance test for switches In homes the approximate amperes is about 2A but in the SSK labs we test it for 6A from the load bank.

Fig.38 According to standard the switch will work for 4 thousand operations but in lab we test it for 3times multiplier times to the standard .we put resistive and inductive load to it .as per the rated loads and check its operation. Apparatus for various types of switches testing

P a g e | 71

11.6 Mille volt drop test In this test it is to be tested that the there should not be any gap in between the electrical contacts so that there should not be any losses created .due to it some times melting of contacts may happen.

Fig 39 11.7 Conditioning wire test In this test CU wire is placed in a temperature of around 15 degree c .then after some times it will be twisted on a metal rod to check that weather any cracks or breaks are generated . 11.7 Ampere test

Fig.40

P a g e | 72

Fig 41

P a g e | 73

12. Technical performance of SSK modular switches

Technical performance of SSK modular switches in comparison with the required specification of ISS conforming to IS : 3854 : 1997 (IS ( test conducted at highly sophisticated lab)

Nature of test

ISI requirement

Performance

of

SSK

modular switches tested in lab Electric strength Should withstand for 2KV It withstood 3KV (rms) for (rms) for one minute Temperature rise Should degree not exceed 2 minutes 45 It did not increase 14

Celsius

,about degree Celsius after 50,000 operations in 6amp

40,000 operations on load

accessories and 18degree Celsius after

50,000operations in 16 amp accessories. Milli volt drop Should not exceed 20mV Not exceeded 7mv

(in 6 Amp & 16 Amp after1,20,000 operations in accessories) after 40,000 6 amp and 9 mv in 16 amp . operations on load .

Insulation resistance

Should not be less than Found more than 500 M 100M ohms (before ohms ( after humidity

humidity treatment)

treatment )

Electrical endurance test Switches should be tested We tested our switches at (ON-OFF) test at 40,000 operations(ON- 120,000 OFF) on load load.( operations even after on this

switches worked properly).

P a g e | 74 Mechanical strength Specified only at 0.4Nm Tested at maximum impact impact energy energy 1 nm for all rating designs .(hammer stroke

test from a distance of 270 mm)

Making capacity

&breaking The switches and sockets Our switches and sockets are required to be tested at were tested at 130% of the 130% of the rated current rated current and 110% of and 110% of the rated the rated voltage for 1500 voltage for 500 continues operations and were found operations, with an interval to be in good working of 30 seconds conditions. not affected by

Resistance

to

heat

at The outer body of the Was

125degree celcius

molding should be heated abnormal heat and fire at to the temperature of 125 850 degree Celsius degree Celsius for 60

minutes. Thereafter the ball pressure test should not make an impression deeper than 2mm Resistance to abnormal The test is performed on heat & to fire (glow wire parts of insulating material test) which might be exposed to thermal electric stress effects due to and

decoration shall not unduly be affected by abnormal heat and by fire at a temperature of 650 degree Celsius Table 8

P a g e | 75

13. PANEL SHOP

Panel department is also known as application department. Panels are systematic arrangements of different electrical equipments. They are used to control of different machinery.

13.1 TYPE OF PANELS

PLC PANEL

L.T. PANEL

TOUCH PANEL

SCADA SYSTEM

CONTROL PANEL

H.T. PANEL

RMOTE CONTROL PANEL

HEAT TRACER PANEL

AMF PANEL

APFC PANEL

TOUCH PANEL

PLC PANEL

MCC PANEL (MOTOR CONTROL CENTRE)

P a g e | 76 At ssk I have studied L.T. Panels, Which was ordered from RCF. 13.2 LT Power Panel for AC coach (for RAJDHANI, SHATABDI, GARIBRATH,e.t.c.) SSK manufacture a wide range of main LT panel with bus coupler, which come with DG incoming (2 in number) and a transformer incoming of 500KVA (2 in number). Some of the specifications of our product include:

ACB 1600A 4 pole MDO as transformer incoming (2 in number) The product have different types of outgoing such as 800A, 630A, 400A, 100A, 250A etc

All the bus couplers are electrically and mechanically inter locked ACB 1600A 4 pole MDO as bus coupler (1 in number)

Fig 42

P a g e | 77

13.3 The panel consists of:1. Lay & Circuit diagram As per RCF requirement. 2. Enclosure or Cabinet a/c to design. 3. Bus bar (woehner) 4. Contactor (ABB Company) a. SINGLE POLE b. THREE POLEF c. FOUR POLE 5. Relays a) OVR (over voltage relay) b) UVR(under voltage relay) c) DC Time Delay Relay d) OSR(over speed relay) e) LOP(low oil pressure) f) AFR(Alternator fault relay) g) AEL(Alternator earth leakage) h) Generator protection relay 6. Wire Ducts 7. Wire needed near about 6Km in one panel. 8. Fuses (kit kat, HRC) 9. Circuit breakers a) MCB b) MPCB c) MCCB d) RCCB/ELCB e) ACB(abb company) 10. DC to DC Converters 11. Rectifiers 12. Transformers a) shell type(3 phase) b) core type(1 phase) 13. Selector switch 14. Pilot lights (indicators)

P a g e | 78 15. Buzzer 16. Push buttons 17. Clipping tool(multi cutter) 18. Current transformers 19. Bus Coupler 13.4 Description of components Bus bar (woehner):- made of copper . Busbars can have a cross-sectional area of as little as 10 mm but electrical substations may use metal tubes of 50 mm in diameter (1,963 mm) or more as busbars Comparision between Woehner Bus Bar system and Traditional Bus Bar system Panel with Woehner Bus Bar Panel with Traditional Bus Bar system

This system is space saving. There is no need ofseparate In this system separate bus bar chamber is required bus bar chamber. Switchgear can be mounted directly on which increase the size of the panel even the cost bus bar with base material of Woehner There is no need of bus bar drilling to take connections for switchgear with this there is no need of using extra In this one has to use extra X-section area of bus bar, extra wires, lugs, hardware is required to take input

X-section of bus bar & there are no heat losses. With this tappings. Drilling is required in bus bar which produce one can save time for fitting switchgear very low costs of heat where wires are tight with nut and bolts. wire and lugs & hardware for taking input on switchgear as compared to traditional Any make of switchgear can be replaced with each other Where as In this if you have to replace switchgear of in panel without going for any changes & time consumption is vey less. another make lots of mechanical alterations like drilling etc.

This system helps to bring panel almost maintenance free In this more time is require for maintenance which resu Less than half of area remains where tightening is required. If there is no losing the life of switchgear will automatically increases. Table 9 more production loss.

P a g e | 79

Fig 43 Contactor (ABB Company) Rating:- 300A , 600V AC UVR(under voltage relay):- operation range 750V ac, 50-80HZ,+-15% (25VA@750V/AC/50HZ OVR (over voltage relay):- operation range 12- 48V DC Time Delay Relay:- operation range 12- 48V OSR(over speed relay):- operation range 12- 48V LOP(low oil pressure):- operation range 12- 48V AFR(Alternator fault relay):- operation range 12- 48V AEL(Alternator earth leakage):- operation range 12- 48V Wire Ducts:- Halogen free material is non toxic, lead free , environmentally safe and will not release non toxic or corrosive gas which is endanger public safety or damage sensitive electronic equipment. Fuses :Wohner HRC fuse(100 A, 690 V) Kit kat fuse(415-240V, 16 A- 32A, fuse wire 0.5mm) Siba HRC Fuse(80A, 25VA) Ammeter:- range 0-800A Frequency meter:- 45-55HZ

P a g e | 80 Fuse size Wire Gauge 00 awg 0 awg 1 awg 2 awg 4 awg 6 awg 8 awg 10 awg 12 awg 14 awg 16 awg Table 11 Voltmeter:-range 0-800V MCB:240/415V ac & 60/220V Recommended Maximum Fuse Size 400 amps 325 amps 250 amps 200 amps 125 amps 80 amps 50 amps 30 amps 20 amps 15 amps 7.5 amps

MPCB MCCB:- MOULDED CASE CIRCUIT BREAKER Range Rated Voltage : 25A to 1600A : 240/415V AC. DC Mccbs also available

Execution

: SP, TP&FP with switched neutral

Breaking Capacity

: up to 50KA Fig 44

RCCB/ELCB

P a g e | 81 ACB(abb company) shell type(3 phase) transformer:- 750V primary, 415-110V Secondary, Capacity 0.3KVA core type(1 phase) transformer:- 750V primary, 24 V Secondary, Capacity 200VA Selector switch:- 4 way selector switch Pilot lights (indicators):- For different relays & faults. Operated at 24 V. Buzzer:- solid state type, 24V dc, 96-104Db,Range:-50m Push buttons:- for starting alternator, Buzzer & other relays. Clipping tool(multi cutter):-Used for climping the ends of wire(1.5mm). Range is 1.5--6mm. Panel Feed Wires These wires are also type THHN, like the main feeders. A typical 100-amp service would have a #2 THHN set of wires. They would then be rated at 125 amps. This would protect the wires if the amperage was a full 100 amps Non-Metallic Sheathed Wire (NM) This wire, commonly called Romex, is a plastic coated wire that has either two or three conductors and a bare ground wire. This is the typical wiring used in most homes. The rating for this wire is either 15 amps, 20 amps, or 30 amps, depending on the installation. Residual Current transformers:- 690V,12KV Connectors:- Patchbays make it easier to connect different devices in different orders for different projects, because all of the changes can be made at the patchbay. As well, patchbays make it easier to troubleshoot problems such as ground loops; even small home studios and amateur project studios often use patchbays, because it groups all of the input jacks into one location. This means that devices mounted in racks or keyboard instruments can be connected without having to hunt around behind the rack or instrument

P a g e | 82 with a flashlight for the right jack. Using a patchbay also saves wear and tear on the input jacks of studio gear and instruments, because all of the connections are made with the patchbay.

Comparison between Fuse Disconnector and MCCB S.No. 1. 2. 3. 4. 5. Disconnector with HRC Fuse The breaking capacity is >80KA Cost of HRC Fuse less It must be repairable Not affected by ambient Fusing 1.6 time Non Fusing 1.2 time 6. After heavy short circuit only HRC Fuse to be replaced 7. The incoming, outgoing terminals are suitable as per cable size 8. Not defected by vibrations Due to electromechanical design, more affected by vibrations 9. 10. 11. 12. 13. 14. Less temperature rise Not affected by weather Un-interrupted duty Less weight Unbreakable Dielectric strength is more after short circuit/overloading 15. Insulation resistance is more after overload/short circuit Table 10 High temperature rise Affected by weather Interrupted duty Heavy weight Breakable Dielectric strength is less after short circuit/over loading Insulation resistance is less after overload/short circuit MCCB Not more than 20KA More expensive Not repairable Fully depend on ambient Tripping time not controlled on overload After heavy short circuit MCCB is totally damaged Fixed terminals

P a g e | 83

14. Air Conditioner(Cool Pack)

An air conditioner is a system, or machine that removes heat from an area using a cycle in which heat is moved out of the area where it is hot. In construction, a complete system of heating, ventilation, and air conditioning is referred to as HVAC. Its purpose, in the home or in the car, is to provide comfort during hot days and nights.

Refrigeration cycle

A simple stylized diagram of the refrigeration cycle: 1) condensing coil, 2) expansion valve, 3) evaporator coil, 4) compressor.

Fig 45 In the refrigeration cycle, a heat pump transfers heat from a lower temperature heat source into a higher temperature heat sink. Heat would naturally flow in the opposite direction. This is the most common type of air conditioning. A refrigerator works in much the same way, as it pumps the heat out of the interior into the room in which it stands. This cycle takes advantage of the universal gas law PV = nRT, where P is pressure, V is volume, R is the universal gas constant, T is temperature, and n is the number of moles of gas (1 mole = 6.0221023 molecules). The most common refrigeration cycle uses an electric motor to drive a compressor. In an automobile the compressor is driven by a pulleyon the engine's crankshaft, with both using electric motors for air circulation. Since evaporation occurs when heat is absorbed, andcondensation occurs when heat is released, air conditioners are designed to use a compressor to cause pressure changes between two compartments, and actively pump a refrigerant around. A refrigerant is pumped into the cooled compartment (the evaporator coil), where the low pressure causes the refrigerant to evaporate into a vapor, taking heat with it. In the other compartment (the condenser), the refrigerant vapour is compressed and forced through another heat exchange coil, condensing into a liquid, rejecting the heat previously absorbed from the cooled space. Ratings:COOL PACK:-Model no. Capacity-1000 Watt Temp range:- 100C to 450C Refrigerant :- R22, 132A, 400 gm Voltage 230VA, 50HZ, 3.5 FLA

P a g e | 84

15. DIFFERENT PRODUCT RANGE OF SSK

15.1 Switchgears Cat No. 813

REWIREABLE SWITCH FUSE COMBINATION UNITS 63A ,415V AC, T.P. . Cat No. 816

REWIREABLE SWITCH FUSE COMBINATION UNITS 100A 415 VOLTS AC T.P. ISI

P a g e | 85 Cat No. 819

DOUBLE-BREAK FUSE SWITCH COMBINATION UNITS 400A 415 VOLTS AC FOUR POLE Cat No. 831

METAL CLAD CHANGE OVER SWITCHES 200A 415 VOLTS AC TPN (FOUR POLE) .

P a g e | 86 Cat No. 826

METAL CLAD CHANGE OVER SWITCHES 32A 415 VOLTS AC TPN (FOUR POLE) Cat No. 843

DISTRIBUTION FUSE BOARDS 4 WAY 16A 240 VOLTS AC

P a g e | 87 15.2 Electrical switches 15.2.1Heritage collection Gold finish HGF-701, HGF-708, HGF-752 (Rs.3310.00)

ONE WAY SWITCH 16A 230V AC, FLAT PIN SOCKET 13A 230V AC WITH COVER FRAME 2 MODULES 5"X3" WITH 24KT GOLD PLATED. HGF-701, HGF-710, HGF-753 (Rs.5080.00)

02 PCS.ONE WAY SWITCH 16A 230V AC, STEP FAN REGULATOR FOR FAN ONLY WITH COVER FRAME 3 MODULE 8"X3" WITH 24KT GOLD PLATED .

HGF-701, HGF-710, HGF-754 (Rs.6170.00)

03 PCS.ONE WAY SWITCH 16A 230V AC, STEP FAN REGULATOR FOR FAN ONLY WITH COVER FRAME 4 MODULES 5"X5" WITH 24KT GOLD PLATED

P a g e | 88 Antique finish HAF-701,HAF-707,HAF-752 (Rs.3020.00)

JONE WAY SWITCH 16A 230V AC,3 PIN SOCKET 6A 230V AC WITH COVER FRAME 2 MODULE 5"X3" WITH ANTIQUE FINISH COVER . HAF-701,HAF-710,HAF-753 (Rs.4800.00 )

02 PCS.ONE WAY SWITCH 16A 230V AC,STEP FAN REGULATOR FOR FAN ONLY WITHCOVER FRAME 3 MODULE 8"X3" WITH ANTIQUE FINISH COVER . HAF-701,HAF-707,HAF-754 (Rs.5375.00)

03 PCS.ONE WAY SWITCH 16A 230V AC,3 PIN SOCKET 6A 230V AC WITH COVER FRAME 4 MODULE 5"X5" WITH ANTIQUE FINISH COVER . Chrome finish HCF-701,HCF-708,HCF-752 (Rs.3135.00)

P a g e | 89
ONE WAY SWITCH 16A 230V AC,FLAT PIN SOCKET 13A 230V AC WITH COVER FRAME 2 MODULE 5"X3" WITH CHROME FINISH COVER .

HCF-701,HCF-707,HCF-753 (Rs.4340.00)

02 PCS.ONE WAY SWITCH 16A 230V AC,3 PIN SOCKET 6A 230V AC WITH COVER FRAME 3 MODULE 8"X3" WITH CHROME FINISH COVER . HCF-701,HCF-707,HCF-716,HCF-720,HCF-715,(Rs.8140.00 )

02 PCS.ONE WAY SWITCH 16A 230V AC,3 PIN SOCKET 6A 230V AC, TELEPHONE LINE JACK 2 WIRE T.V. SOCKET SINGLE OUTLET COMPUTER JACK RJ45 FOR DATA TRANSFER COVER FRAME 6 MODULE 8"X6" WITH CHROME FINISH COVER . Satin finish HSF-701,HSF-707,HSF-753 (Rs.4340.00)

2 PCS. ONE WAY SWITCH 16A 230V AC,3 PIN SOCKET 6A 230V AC WITH COVER FRAME 3 MODULE 8"X3" WITH SATIN FINISH COVER .

P a g e | 90 HSF-701,HSF-710,HSF-707,HSF-754 (Rs.5835.00)

02 PCS.ONE WAY SWITCH 16A 230V AC,3 PIN SOCKET 6A 230V AC AND STEP FAN REGULATOR WITH 8"X3" CHROME FINISH COVER . HSF-701,HSF-707,HSF-716,HSF-755 (Rs.7835.00 )

04 PCS.ONE WAY SWITCH 16A 230V AC,3 PIN SOCKET 6A 230V AC, TELEPHONE LINE JACK 2 WIRE COVER FRAME 6 MODULE 8"X6" WITH SATIN FINISH COVER

15.2.2 Modular series Signature ZEN series ZEN-159

P a g e | 91

ELECTRONIC ENERGY SAVER FOOT LIGHT WITH 5"X3" COVER PLATE (L.E.D BASED) ZN-157

ENERGY SWITCH 30A WITH KEYTAG

ZN-146

STEP FAN REGULATOR FOR FAN ONLY . Signature NV Series

NV-102

BELL PUSH 6A 230V AC

P a g e | 92 NV-219

5 PIN SOCKET 6A 230V AC SHUTTERED

NV-211, NV-220A

DOUBLE POLE SWITCH 32A 230V AC WITH PORCELAIN BASE & INDICATOR AND 6 PIN SOCKET6A/25A 230V AC SHUTTERED . Signature LX Series LX-209

SINGLE BELL PUSH 6A 250V AC IS WITH L.E.D.

P a g e | 93 LX-243

SWITCH SOCKET COMBINED 5 PIN (6A 250V AC) FITTED WITH POWDER COATED STEEL PLATE & COVER FRAME (SUITABLE FOR 4X3 BOX)

LX-135

ENERGY SWITCH 30A WITH KEY TAG HORIZONTAL

Signature EL Series

EL-243

P a g e | 94

SWITCH SOCKET COMBINED, 5 PIN (6A 250V AC) FITTED WITH POWDER COATED STEEL PLATE & FRAME (SUITABLE FOR 4"X3") . EL-208

SIGNATUE EL 8"X6" FITTED PLATE EL-201. EL-200, EL-220

TWIN SWITCH 6A 250V AC ONE WAY ISI AND SINGLE SWITCH 6A 250V AC ONE WAY ISI AND 5 PIN SOCKET 6A 250V AC SHUTTERED Euroline series

P a g e | 95 SS-105

SINGLE BELL PUSH 6A 250V AC ISI SS-101, SS-124

TWIN SWITCH SP 6A 250VAC ISI AND STEP FAN REGULAR SS-101, SS-140

TWIN SWITCH SP 6A 250V AC ISI AND 2/3 PIN SHUTTERED SOCKET 6A 250V AC . Fantasy PLUS series F-955, FP-002

P a g e | 96 BELL PUSH 6A 250V AC ISI SOCKET SIZE WITH INDICATOR FITTED 3"X3" FRAME F-950, F-951, FP-005

SWITCH SP WITH INDICATOR 16A 250V AC ISI AND SOCKET UNIVERSAL 6A/16A 250V AC SHUTTERED ISI FITTED 5"X3" FRAME

F-900, F-911, FP-005

SWITCH 6A 250V AC ONE WAY ISI AND STEP FAN REGULATOR FITTED 5"X3" FRAME

P a g e | 97

Signature TL Series

1) 3 Gang Two Way 10AX Switch

2) 6 Gang Two Way 10AX Switch

3) Single 13A Socket with Single 13A SP Switch

15.3.3 SSk Accessories

P a g e | 98 F-900

SWITCH 6AMP 250V AC ONE WAY ISI F-904

5 PIN SOCKET SHUTTERED 6AMP 250V AC F-952

SWITCH DP WITH INDICATOR 16A 250V AC ISI Topline PC

Cat No. PC-506

P a g e | 99

INDICATOR 250V AC

Cat No. PC-505

WALL SOCKET UNIVERSAL 2/3 PIN 6A 250V AC

Cat No. PC-581

STEP FAN REGULATOR SWITCH SIZE FOR FAN ONLY

Topline series

Cat No. 509

P a g e | 100

T.V. CONNECTOR SOCKET SIZE

Cat No. 555

WALL SOCKET 2 PIN 6A 250V AC SSK 555series

TL-7031

T.V. CONNECTOR SWITCH SIZE TL-7041

P a g e | 101

STEP FAN REGULATOR SOCKET SIZE

TL-7011

WALL SOCKET UNIVERSAL 2/3 PIN 6A 250V AC

Topline super plus

Cat No. N-128

WALL SOCKET UNIVERSAL 6/16A 250V AC ISI

Cat No. N-596

SWITCH SOCKET COMBINED UNIVERSAL 6A 250V AC ISI 2/3 PIN

P a g e | 102

Cat No. N-125

SWITCH SP WITH INDICATOR 16A 250V AC ISI

P a g e | 103

16. OBSERVATIONS
The observation of this study made on advertisement and sales promotion policy are as follows:

1. SSK Engineering Company is trying to involve or adopt new schemes to promote sales. 2. Some machines are old, company should require to change for more efficiency. 3. The trend of 1 % advertisement expenditure is not too rigid and can be changed market
situation.

4. Proper marketing setup like sales engineer and filed staff has smooth relations with
authorized dealers and generate new business.

5. Special attention is given to attend the complaints from the customers of authorized
dealers by providing them with reliable after sales service.

6. The placement of goods by company is also speedy. 7. Some operational & maintainance engineers are required for fast service. 8. Strictly quality control consists consumer service also promotion sales. 9. While managing advertisement campaigns, the SSK ENGINEERING COMPANY. Keep
a regular watch on activities of competitors so that their sales are not affected at all.

10. Most of the customers [me also :)] are not satisfied regarding the price policy.

P a g e | 104

17. CONCLUSION
SSK ENGINEERING COMPANY is big and popular company. It is scaling new heights of expectance. The company is started in 1958 in kaputhala and from there it is trying to reach the heights of excellence. I come to know about the achievement form company profile where all the departments of the company is mentioned and environment of the concern is also depicted from there. Categorization of product is given so to know the details of the product range. The industrial training of six months at SSK has given us a chance to polish the theoretical knowledge of three and a half years into the very effective practical knowledge. In last 3 years, No doubt we had gone through a lot of labs, and thereby, learnt a lot of things but SSK teaches us how important those labs are for our Engineering, how those labs help in achieving the targets in industries. We worked in Electroplating shop, Phosphate shop, Paint shop, sales department and many more. The most interesting thing in SSK was that we always learnt something new or for that matter a new aspect of a job every time out of the same workshops. In this training, I realized where my interest lies in real. I understood my strengths and weaknesses in my field of Electrical Engineering, thereby, now I have a chance to improve myself in my weaker areas. I also got aware of few things out of my discipline, such as I worked with advertising department; sales department etc. and I realized that these things are equally necessary to know to work in a company. Lastly, these six months were the most important part of my under graduation. Indeed, this training part has actually turned out us as Engineers. I am blessed to have such training in my hands.

P a g e | 105

18. APPENDIX

I
Fig no:1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 Discription Company motto Mig Welding CNC punching machiine Punching press HH bending machine, CNC Amada bending machine Spot welding machine Shearing machine(front & Back) Powder coating gun Cabinet & Supply for gun Painting process Baking of paint Rewireable switch fuse Short circuit testing device of change over switches Thread forming tapping screw Thread cutting tapping screw Reliability test Dielectric property test Short Circuit test diagram Abbreviations Second diagram test Test of resistance to shock Mechanical impact test Test figures Moulding machine Dye of moulding machime Preheater system for polycarbonate resin Moulds View of machine Different frames Waste polycarbonate & Grainer machine Switch internal part Heating oven for switch Mechanical strength test Tumbling barrel test Circuit diagram Mechanical impact test Endurance test device Milli volt drop test Ampere test Components used to manufacture modular switches Outer look of panel Page. No. 5 23 26 26 27 27 28 30 32 34 36 36 41 49 51 51 53 54 55 56 56 57 57 58 60 61 61 62 63 63 64 64 65 65 66 66 67 67 68 68 69 73

P a g e | 106
43 44 45 Bus bar Mccb Refrigeration cycle 76 77 80

II
Table no 1 2 3 4 5 6 7 8 9 10 11 12 13 Description Human resource in company Phosphating process MCB rating chart for domestic application MCB rating for motor application. Cross sectional area of copper Screw parameters Cross sectional Test kind Technical performance of ssk switch Comparison of different bus bar Fuse size Comparison b/w fuse & Mcb Page no 6 35 46 47 50 52 53 55 70 75 77 79