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ACKNOWLEDGEMENT
I am highly thankful to Mr. Y.P TYAGI (GM) for providing me the opportunity to undergo the practical training in the SOLAR PHOTOVOLTATAIC DEPRATMENT(SPV) of Central Electronics Limited. He guided me from time to time and gave me dynamic ideas and suggestions by which I am able to complete my training successfully. I am also thankful to manager of various department who during rotation guided me about the works & processing that were being done in their department . I am also thankful to all those employees of CEL who classified my doubts & confusion during rotation in the firm.I am thankful to the Administrator & Welfare (Dept.) of the firm for providing me the facility of canteen & transport.It was a great satisfying experience having worked in such a professional organization where the process of learning is never ending.
I also want to thank all the visible and non-visible hands, which helped me to complete the practical training with great success
CERTIFICATE
This is to certify that Mr. Abhilash tomar of KRISHNA ENGINEERING COLLEGE has undergone summer training at CENTRAL ELECTRONICS LIMITED (CEL); 4, Industrial Area, Sahibabad, Ghaziabad, (U.P.) in SOLAR PHOTOVOLTAIC from 10/06/2013 to 30/07/2013. They are dedicated to their work. Their conduct and performance is good. I wish them all the success in their future.
INTRODUCTION :Central Electronics Limited is a public sector Enterprise under the Department of Scientific and Industrial Research (DSIR), Ministry of Science & Technology, Government of India. It was established in 1974 on 26th june with an objective to commercially exploit the indigenous technologies developed by national laboratories and R & d Institutions in the country. CEL is one of the rare companies which utilized the homegrown technologies during all these years of its existence
CEL has developed a number of products for the first time in the country through its own R&D efforts and in close association with the premier National & International laboratories including Defense Laboratories. In recognition of all these efforts, CEL has been awarded a number of times with prestigious awards including NATIONAL AWARD for R&D by DSIR. CEL is pioneer in the country in the field of Solar Photovoltaic (SPV) and it has developed state of the art technology with its own R&D efforts. Its solar products have been qualified to International Standards EC503/IEC1215 by the European Commission, joint Research center, and ISPRA, ITALY .CEL, pioneer in the field of Railways Safety & Signaling, has been identified as a major indigenous agency for design an development of modern electronic signaling and safety equipment by Indian Railways. The equipment manufactured in CEL finds extreme usage in Railways in the form of Axle Counter, Axle Counter Block System and Train Approach Warning devices. CELs Digital Axle Counter is approved as per European CENELEC safety level SIL-4 by RDSO(Research Design and Standard Organization of Indian Railways )as an approved source in part-1 for various railway safety and signaling equipments for more than 25 years
CEL has developed a number of critical components for strategic application and is supplying these items to Defense.
Brief History of the Company and Collaborating Agency CEL IS A HIGH TECHNOLOGY COMPANY
Central Electronics Ltd. is a public sector enterprise, under the administrative control of the Deptt. Of Scientific & Industrial Research. CEL is a pioneer in the field of solar Photovoltaic in the country and is today ranked among the first few in the world in this area of activity. CEL is also credited with many firsts in the country, professional Ferrites being one of them. CEL is presently engaged in the development, production and sale of selected electronic components (Professional Ferrites, Electronics Ceramics and Phase Shifters), selected electronic systems, solar photovoltaic cells, modules and SPV systems and to take up engineering development & production based on indigenous technology developed through in house efforts or know how from National Laboratories / Institutions. The Operations of the company are divided into three Business Groups. Solar Photovoltaic Group (SPVG), Systems Group (SG) and Components Group (CG).
ORGANIZATION STRUCTURE
The organization chart of the company indicating the responsibility, authority an interrelation of all personnels who manage, perform and verify work affecting quality is shown in organization chart below
GENERAL MANAGER (CP & HRD) Jt. GENERAL MANAGER (FINANCE) EXECUTIVE DIRECTOR
(OPERATIONS)
AGM
(QUALITY ASSURANCE)
AGM (FERRITE)
Jt.GM
(CERAMICS)
(R&D)
CP/ HRD
Corporate Planning
MMD FAD R&D SPVG MED PFD CP Project QC PEG W/S PPC
Material Management Division Finance & Account Division Research & Development Solar Photovoltaic Group Microwave Electronics Division Professional Ferrite Division Cathodic Protection Project Railway Project Quality Control Production Engineering Group Work Shop Production Planning Control
Rly. Project -
iv. UNIVERSAL AXLE COUNTERS MICROVE ELECTRONICS i. PHASE SHIFTERS 3. OTHERS CATHODIC PROTECTIONS CERAMICS
For rural application: Street / Domestic / community / lightning system. Solar lanterns. Village power plants Rural telecommunication.
For industrial application: Off shore oil / gas platforms. T.V. Transmitters. Obstruction warning lights at Airports. Railway signaling. Microwave Repeaters.
FLOW CHART
RAW WAFER
ALKALINE ETCHING
DIFFUSION
EDGE ISOLATION
FRONT CONTACT PRINTING BACK CONTACT PRINTING BACKREFLECTION EDGE ANTI FRONT PAD& FIRING PRINTING ISOLATION COATING CONTACT PRINTING
MATERIAL REQUIRED
Silicon Wafer, cassettes, D I water, H F solution, NaOH solution.
PROCEDURE
The p-type single crystal having pseudo square shape is loaded in cassettes. The cassettes are then placed in stainless steel coated jig. This jig is then transferred to process tank, which contain NaOH solution for fixed time. After this, the jig is transferred to running pressurized DI water for few minutes. Now transfer this jig to process tank containing HF solution for minutes. Now the Silicon wafers are ready for polishing.
PRECAUTIONS:
i) Use surgical gloves & mask while processing the silicon wafer. ii) Use cotton gloves while loading the wafer in the cassettes.
The purpose of polishing is to ensure that the wafers that the wafer surface is free from any saw cut marks. It shall result in a polished & smooth surface.
b) TEXTURISATION:
The purpose of texturisation is to get maximum absorption of sunlight and uniform texturisation surface on silicon wafer by formation of tiny pyramids.
MATERIAL REQUIRED:
Polished Wafers, NaOH solution, DI water, HCL solution, HF solution
PROCEDURE
The cassettes after fixing with the help of retainer are loaded in a jig with a retainer so that they do not float in the solution. The jig is transferred to NaOH solution & IPA solution under running pressurized DI water for fix time. This is again transferred to process tank containing HCL solution for fixed time. This is again transferred to process tank containing HF solution at fixed temperature for particular time. After that they are dried.
PRECAUTIONS:
i) ii) iii) Use weighting balance for NaOH & measuring flask for other chemical for solution preparation. Check the temperature of the process tank regularly. Use gloves & tweezers to handle the wafers.
3. DIFFUSION PURPOSE:
This process forms a negative junction over the p-type substrate. This, therefore, make a p-n junction.
MATERIAL REQUIRED:
Diffusion paste, Furnace, Tweezers.
PROCEDURE
The texturise wafer is placed on printing chuck. The diffusion paste is transferred on the silicon wafer with the help of screen by using squeeze. The printed wafers are then placed on the belt of diffusion furnace by using tweezers. The diffused wafers are then collected on the receiver & undiffused wafer side is marked by quartz for identifications of p-type.
PRECAUTIONS:
i) ii) iii) iv) Use cotton / nylon gloves while printing the wafers in cassettes. The diffusion furnace having different temperature at various zones. Print chuck should be clean. Keep the diffusion paste bottle mouth covered to avoid any contamination.
MATERIAL REQUIRED
Plasma etching machine, Freon gas, Oxygen gas, Nitrogen gas.
PROCEDURE
Diffused wafer are arranged in a coin stack & loaded in a jig of Al. The jig is then placed in a plasma chamber under perforated Aluminum base plate. Select the appropriate recipe and evacuate the chamber. The gas and RF generator is switched on for plasma. The plasma cycles are completed in fixed time & after then they are unloaded & then kept in a thermo Cole box.
PRECAUTIONS:
i) ii) Use surgical/cotton gloves while handling the wafers. The operation time has to be noted carefully in a case of power failure so that it does not exceed the actual time cycle.
MATERIAL REQUIRED
HF solution, DI water.
PROCEDURE
The plasma etched wafer are loaded in cassette. The cassettes are then dipped in HF solution-1 by using the Teflon handle. They are again dipped into HF solution-2 & move up & down to remove the phosphorus glass. The cassettes are then transferred to DI water for rinse.
PRECAUTIONS:
i) ii) Use surgical gloves before carrying out the operation. Do not leave the diffused wafer in concentrated HF solution for some time.
MATERIAL REQUIRED
Ammonia solution, Hydrogen peroxide, DI water, HCL & HF solution.
PROCEDURE
The phosphorus glass cleaned wafers are loaded in Teflon cassettes. These cassettes are then dipped in the solution of NH3 & H2O2. These cassettes are then transferred to rinsing tank containing DI water. These cassettes are then dipped in HCL solution. They are again transferred to DI water for rinse. The cassettes are then dipped in HF solution for few minutes. After that, they are finally rinsed in DI water. The wafers are then dried in the rinser dryer.
PRECAUTIONS:
i) ii) iii) Use surgical gloves before carrying out the operation. Use measuring flask to measure chemicals for solution preparation. Prepare fresh solution of NH3, H2O2, and HCL after fixed number of cycles.
MATERIAL REQUIRED
Silicon Nitride
PROCEDURE
The base electrode is heated upto 700degree celcius. the upper electrode is RF polarized ,water cooled with a shower. Automatic machine network located near the wafer. The system & process control unit is plc-pc based. The gas process control unit consist of flow in the range 0-100, 0-50, 0-20 sccm .
PRECAUTIONS:
. i) Use gloves, masks & tweezers during operation.
MATERIAL REQUIRED
Polypropylene cassettes, Silver paste, Tweezers
PROCEDURE
The passivated wafers are loaded in polypropylene cassettes in such a way that the diffused side i.e., n-side of the wafers are printed with the given pattern. Two such cassettes are loaded in senders platform keeping its n - diffused side upwards for printing. These wafers are then passed through three infrared zones of fixed temperature. The printed wafers is then obtained at receiver.
PRECAUTIONS:
i) Use nylon/cotton gloves while loading the wafers.
ii) iii)
Keep the rubber belt & print chuck clean. Keep the Ag paste covered to avoid any contamination.
MATERIAL REQUIRED
Ag Al paste, Tweezers, Polypropylene cassettes.
PROCEDURE:
The passivated wafers are loaded in polypropylene cassettes in such a way that its p-side is to be printed. Two such cassettes are loaded in senders platform keeping its p - side upwards for printing . Sensors senses the wafers & they are automatically placed under the printing chuck. The paste is applied as thick strips by using squeeze. Theses wafers are then automatically passed on to belt having fixed speed. These wafers are then passed through the heating furnaces of different temperature range. The printed wafers are then obtained at the receiver.
PRECAUTIONS:
i) ii) iii) Use nylon/cotton gloves while loading the wafers. Keep the rubber belt & print chuck clean. Keep the Ag Al paste covered to avoid any contamination.
MATERIAL REQUIRED:
Aluminum paste, Polypropylene cassettes.
PROCEDURE:
The wafers are loaded in polypropylene cassettes in such a way that its p-side is to be printed. Two such cassettes are loaded in a sender platform keeping its p-side upwards for printing. Sensor senses the wafer & they are automatically placed under the printing chuck. Al paste is poured over the nylon screen pattern. The remaining portion on the back side of the wafer is pasted wit Al by using squeeze. These wafers are then passed through the heating furnaces of different temperature ranges. The printed wafers are then obtained at the receiver.
PRECAUTIONS:
i) ii) iii) Use nylon/cotton gloves while loading the wafers. Keep the rubber belt & print chuck clean. Keep the Al paste covered to avoid any contamination.
MATERIAL REQUIRED
Al baked wafer
PROCEDURE:
The printed wafers are placed on the belt having fixed belt speed by using Tweezers in such a manner that its n - side remains upside. These wafers are passed through different furnace of temperature ranges. The firing cells are obtained which are transferred for testing.
PRECAUTIONS:
i) ii) iii) Use nylon/cotton gloves while loading the wafers. Keep the rubber belt & print chuck clean. Clean the stainless steel belt once in a month by vacuum cleaner.
RURAL APPLICATIONS
SOLAR WATER PUMPING SYSTEMS FOR IRRIGATION/DRINKING WATER
Water is an absolute necessity for human survival. In a scenario of fast depleting fossil fuels and increasing ecological concerns, tapping of ground water with a Renewable Source of Energy which is abundant, dependable and pollution-free is very much desirable particularly in a developing country. One such renewable energy source uses abundantly available sunlight and the physics of Photovoltaic (PV) by which sunlight is directly converted into DC electricity by means of a Photovoltaic (PV) module. A Solar Photovoltaic Water Pumping System essentially consists of an SPV panel or array directly powering a water pump. Water pumped during day can be stored in the storage tanks for use during night. CEL offers SPV Water Pumping Systems for both shallow as well as deep well conditions . Such systems have been deployed all over the country. System has also been exported to many developing countries. The generated electricity from the SPV array is fed to the pump through a switch. Normally low storage batteries are provided, as the water can be stored in the storage tanks if required.
SPV Array
Features
Applications
Modular and hence Minor irrigation easily field Drinking Water for upgradeable unelectrified villages Noise and Pollution- and remote locations Free operation Horticulture, Poultry Does not require farming Silviculture, any fuel Fish culture Uses the Farm House abundantly Wild Life Sanctuary available sunlight Tourist Resort Simple to Install, operate & maintain Designed to give optimum output even during low sunshine period Minimal operation and maintenance cost
A view of 100 kWp Grid Interactive Power plant installed & commissioned by CEL
MEDICAL REFRIGERATION
CEL has developed refrigeration system for medical health centre at the remote villages in India and abroad.
RURAL TELECOMMUNICATION
SPV system powers the telephone system for Rural application as also the VHF Transmitter which connects the rural telephone with the nearby District Telephone Exchange through single channel VHF Radio link. The system comprises SPV Panel, charge controller & battery.
SOLAR LANTERNS
SOLAR LANTERN is a versatile and reliable source of lighting. It comprises a Lantern, Solar Photovoltaic ( SPV ) module and a connecting cable. The SPV module when exposed to sunlight charges the battery in the lantern. This stored energy in the battery is used to operate the lamp when required.
Solar Lantern consists of a 7W CFL ( light out put equivalent to a 40W incandescent lamp) which can be used for 3 -4 hours daily. The system comprises
SPV Panel , lantern ( with maintenance free lead acid battery) and a detachable connecting cord.
SPV
Street
Lighting
System:
These systems use a weatherproof 18-Watt or 20- Watt fluorescent tube light
CEL's SPV Street Lights in Muscat, Oman fittings . Two models SLS - 03 and SLS-06 are available depending on hours of operation in day Compact Fluorescent Lamps(CFL) has the unique feature of Switching 'ON' at dusk and 'OFF' at dawn automatically. The system comprises SPV Panel, battery and luminaire fittings mounted suitably on a pole.
INDUSTRIAL APPLICATIONS
SPV MODULE
A number of high grade crystalline Si Solar Cells , interconnected in a series combination and hermetically sealed with a toughened and highly transparent front glass cover, from the SPV Module . CEL's Solar Lantern is the final and latest answer to many lighting problems.
Specifications
Wattage 10 -12Wp 3-4 Hrs. 7 Watt Compact Fluorescent Lamp 12 Volt/7AH Sealed maintenance free. 3.0 Kgs. Approx (Lantern).
FEATURES
Uses mono crystalline silicon Solar Cells.
Suitable for DC 12V systems or multiple there-of. Encapsulation of cells using UV stabilized polymer (EVA) and protective back cover using Tedler-Polyester-Tedlar. High transmission toughened glass superstrate and anodized aluminum frame for mounting. Long service Life.
PRODUCTS OF CEL
The organization manufactures different products that can be classified according to the divisions of CEL as follows:
Components Group :
Piezoelectric transducer elements Special Bearings used in Heavy Water Plants Direction Finding Systems Frequency / Phase Correlators
Conveyor Belt Diffusion Furnace of BTU, USA for n-doping silicon wafers with capacity to handle up to 3 million wafers in a year.
Screen Printers of DEK, Japan for metallization of silver, silver Aluminium and Aluminium prints on diffused silicon wafers.
Plasma Etcher of March, USA for edge separation of diffused silicon wafers.
Solar Cell Tester of Astro Power, USA and New Sun, Canada for computerized testing and sorting of solar cells.
Sun Simulators of Spire, USA and New Sun, Canada for solar Photovoltaic modules testing.
QUALITY POLICY
The complete manufacturing operation, marketing and installation services of the company is certified under ISO 9002 : 1994. The
company has enunciated the following quality policy to meet customer needs and expectations through supply of quality products and services. CEL is committed to strive for leadership in the product marketed by the way of continuous improvements in the quality of its products and services and meeting the consumers needs in time and every time at a competitive price.
These shall be achieved through continuous upgrading of technology and process improvement by involving all the employees, vendors, dealers and customers. Quality is our basic business principle.
Quality objective On time delivery of defect free products Providing effective customer support Continual improvement of processes Improvement of infrastructure Development of human resources
PHOTO GALLERY
His Excellency Dr. Sam Nujoma, President of Namibia walking on CEL's Photovoltaic module to check the strength of the module
A close-up view of Anechoic Chamber installed in CEL used for indoor testing of antenna
A view of CEL's Solar Photovoltaic system installation for running water pumping system in Punjab
SELF EVALUATION
These 6 weeks Industrial Training has led us to understand the various designing, assembling and the manufacturing processes of equipments in the industry, CEL. It has also enhanced our knowledge about the functioning and management of an industry, which we are sure, will be beneficial to us in our career.
(NODIA)
(2013-2014)