DEPARTMENT OF TECHNICAL EDUCATION

GOMATESH VIDYAPEETH

GOMATESH POLYTECHNIC COLLEGE

HINDHWADI BELAGAVI-590001

DEPARTMENT OF ELECTRONICS AND COMMUNICATION

A INPLANT REPORT ON

“GOKUL POWER SERVICES “

Inplant report submitted in partial fulfillment of requirement for The

Award of diploma in ELECTRONICS AND COMMUNICATION by The

board of technical examination bangalore during the academic

Year 2018/2019

UNDER THE GUIDANCE OF

R.N.GANDHI

SUBMITTED BY :

SOMASHEKHAR.H.SUTAGATTI
 IMPORTANCE OF IN PLANT TRAINING

in plant training has its own importance in a career of a student who is

pursuing a professional degree. It is considered as a part of college
curriculum and objectives of industrial visit is to provide students an
insight regarding internal working of companies. We know,theoretical
knowledge is not enough for making a good professional career. With
an aim to go beyond academics, industrial visit provides student a
practical perspective on the world of work.

Industrial visit is considered as one of the most tactical methods of

teaching. The main reason behind this – it lets students to know things
practically through interaction, working methods and employment
practices. Moreover, it gives exposure from academic point of view
and provides exposure to practical working environment, increases
practical awareness of various Industrial sectors; acquaint students
with Interesting facts and breath-taking technologies. In addition to
industrial exposure and knowledge, this will increase the internship
and placement opportunities.
 TIME SCHEDULE

DATE TIME WORK

27/09/2018 10:00to3:00 1) Introduction of the plant

2) Introduction of Generators and electronic components used in
Generators

28/11/2018 10:00to3:00 1) Details and working of alternator ( AC generator )

29/11/2018 10:00to3:00 1) Introduction of AVR ( Automatic voltage regulators )

30/11/2018 10:00to3:00 1) Introduction and working of stator used in generator

01/12/2018 10:00to3:00 1) Introduction and working principle of rotor

02/12/2018 10:00to3:00 1) Introduction and working of exitation field

03/12/2018 10:00to3:00 1) operation of step-up and step-down motor used in generators

04/12/2018 10:00to3:00 1) Detailed structure and working of P-N Junction diode used in
generators
05/12/2018 10:00to3:00 1) Studied about control panels and how they operate in different
generators
06/12/2018 10:00to3:00 1) Studied about Governer system (software ) used in generators

07/12/2018 10:00to3:00 1) Studied detailed structure and specification and cost of the
different generators
DAY 1 : 27/09/2018

On the first day when we visited the insustry the manager of the
industry provided their workers to explain the things done in the plant
(Gokul power services ) and explaind all the procedures how generators are
assembled.

In the GOKUL POWER SERVICES they assembled the following

generators

1) freedom series 12 KVA to 32 KVA generator

2) DG Sets Republic series 40 KVA to 200 KVA

3) AC Generators 5 to 90 KVA

4) Portable generators

Generator and its uses :

A generator is a machine that converts mechanical energy into electrical

energy in the form of AC or DC current. AC generators are called as
Alternators and DC generators are called as Dynamos. for reasons of cost and
simplicity most alternators use rotating armature with a stationary magnetic field
is used in the principle. Usually the term refers to small rotating machines driven
by automotive and other internal combustion engines an alternator that uses
permanent magnets.

Its magnetic field is called as magneto. Alternators in power stations driven by

steam turbines are called turbo alternators. Large 50Hz three phase alternators
in power plants generates most of the worlds electric power, which is distributed
by power grids.

Sources of mechanical energy include steam turbines, gas turbines, water

turbines, internal combustion engines and even hand cranks. The first
electromagnetic generator, the Faraday disk, was invented in 1831 by British
scientist Michael Faraday.

Electromagnetic generators fall into one of two broad categories, dynamos and
alternators.

 Dynamos generate pulsing direct current through the use of a commutator.

 Alternators generate alternating current.

Mechanically a generator consists of a rotating part and a stationary part:

Rotor

The rotating part of an electrical machine.

Stator

The stationary part of an electrical machine, which surrounds the

rotor.
One of these parts generates a magnetic field, the other has a wire
winding in which the changing field induces an electric current:

Field winding or field (permanent) magnets

The magnetic field producing component of an electrical machine.

The magnetic field of the dynamo or alternator can be provided by
either wire windings called field coils or permanent magnets.
Electrically excited generators includes an excitation system to
control the field winding flux. A generator using permanent
 magnets (PMs) is sometimes called a magneto, or permanent magnet
synchronous generators (PMSMs).

Armature

The power-producing component of an electrical machine. In a

generator, alternator, or dynamo, the armature windings generate
the electric current, which provides power to an external circuit. The
armature can be on either the rotor or the stator, depending on the
design, with the field coil or magnet on the other part.

Day 2 :- ( 28/11/2018 )

On the second day of our inplant training the trainer explained us about the
saftey precautions to be taken while servicing the Generators. those all
generators are produces high voltage for commercial needs. They explained
me how to identify the components and disassembling process.

After this process they explained us how it works on which principle

It is based on the principle of production of dynamically (or motionally)

induced e.m.f (Electromotive Force). Whenever a conductor cuts magnetic
flux, dynamically induced e.m.f. is produced in it according to Faraday's Laws
of Electromagnetic Induction. This e.m.f. causes a current to flow if the
conductor circuit is closed.

Hence, the basic essential parts of an electric generator are :

A magnetic field and

A conductor or conductors which can so move as to cut the flux.

Construction :

A single-turn rectangular copper coil abcd moving about its own axis in a
magnetic field provided by either permanent magnets or electromagnets.
The two ends of the coil are joined to two split-rings which are insulated
from each other and from the central shaft. Two collecting brushes (of
carbon or copper) press against the slip rings.

Working of an AC Generator

When the armature rotates between the poles of the magnet upon an axis
perpendicular to the magnetic field, the flux which links with the armature
changes continuously. Due to this, an emf is induced in the armature. This
produces an electric current through the galvanometer and the slip rings and
brushes.

The galvanometer swings between the positive and negative values. This
indicates that there is an alternating current flowing through the
galvanometer.

Fleming’s right-hand rule states that, stretch the forefinger, the middle finger
and the thumb of the right hand such that they are manually perpendicular to
each other. If the forefinger indicates the direction of the magnetic field,
thumb indicates the direction of the motion of the conductor. The middle
finger indicates the direction of the induced current in the conductor.

At the end of second day we learned how alternator works on which principle.

Day 3 :- ( 29/11/2018 )

On the beginning of day 3 we continued to study about the electronic

circuit used in alternator called voltage controller AVR ( Automatic voltage
controller )

An AVR or automatic voltage regulator is a device used to give the

regulated voltage to the exciter field of a generator, depending on terminal
voltage variations(load variations). It compares the rectified output of a
voltage transformer, proportional to the terminal voltage of the
generator,(compounding transformer-to step down the voltage) with the
reference voltage and generates an error signal equal to their difference
and give it to the exciter field. Hence in this way we can regulate the
terminal voltage of the generator.

AVR is an abbreviation of Automatic Voltage Regulator.

The basic function is:

 Stabilizing the voltage as load varies

Additional functions may be be built in, model by model

 Controlling output frequency by adjusting prime mover speed

(acting as a governor)
 Accommodating paralleling of generators (e.g. voltage droop
 Responding to overloads (e.g. fold back voltage reduction)
 Drive various indicators

An automatic voltage regulator (AVR) is an electronic device for

automatically maintaining generator output terminal voltage at a set value
under varying load and operating temperature. It controls output by
sensing the voltage Vout at a power-generating coil and comparing it to a
stable reference. The error signal is then used to adjust an average value of
the field current.

automatic voltage regulation helps provide energy to your generator

system’s exciters. The AVR component of your Genset’s main function is to
assert and sustain the appropriate voltage level range for your generator
system’s alternating current. Your automatic voltage regulator is an
important factor in the determination of your generator system’s
performance and longevity as well as the technology that it is powering.
Because all appliances and electrical machinery have varying ranges of
voltage would be considered specifically quintessential, the automatic
voltage regulator serves a very important function by modifying improper
voltage input and output.

At the end of the 3rd day we fully understood this AVR (automatic voltage
controller ) and why it is necessary in alternators .

Day 4 :- 30/11/2018

On the beginning of day 4 we started to studying working of stator used in

generator. Instructor help us to disassebles the stator from its rotor. And
they taught us very well.

stator is the stationary part of a rotary system, found in electric

generators, electric motors, sirens, mud motors or biological rotors. Energy
flows through a stator to or from the rotating component of the system. In
an electric motor, the stator provides a rotating magnetic field that drives
the rotating armature; in a generator, the stator converts the rotating
magnetic field to electric current. In fluid powered devices, the stator
guides the flow of fluid to or from the rotating part of the system.

Depending on the configuration of a spinning electromotive device the

stator may act as the field magnet, interacting with the armature to create
motion, or it may act as the armature, receiving its influence from moving
field coils on the rotor. The first DC generators (known as dynamos) and DC
motors put the field coils on the stator, and the power generation or
motive reaction coils on the rotor. This is necessary because a continuously
moving power switch known as the commutator is needed to keep the field
correctly aligned across the spinning rotor. The commutator must become
larger and more robust as the current increases.

The stator of these devices may be either a permanent magnet or

an electromagnet. Where the stator is an electromagnet, the coil which
energizes it is known as the field coil or field winding.
The coil can be either iron core or aluminum. To reduce loading losses in
motors, manufacturers invariably use copper as the conducting material in
windings. Aluminum, because of its lower electrical conductivity, may be an
alternate material in fractional horsepower motors, especially when the
motors are used for very short durations.
An AC alternator is able to produce power across multiple high-current
power generation coils connected in parallel, eliminating the need for the
commutator. Placing the field coils on the rotor allows for an
inexpensive slip ring mechanism to transfer high-voltage, low current
power to the rotating field coil.

It consists of a steel frame enclosing a hollow cylindrical core (made up of

laminations of silicon steel). The laminations are to
reduce hysteresis and eddy current losses.

DAY 5 : - ( 01/12/2018 )

On the beginning of the day 5 we continued study about main part of the
generator that is rotor shaft. we learned principle of rotar and its structure.

The rotor is a moving component of an electromagnetic system in

the electric motor, electric generator, or alternator. Its rotation is due to
the interaction between the windings and magnetic fields which produces
a torque around the rotor's axis.

Operating principle
In a three-phase induction machine, alternating current supplied to the
stator windings energizes it to create a rotating magnetic flux. The flux
generates a magnetic field in the air gap between the stator and the rotor
and induces a voltage which produces current through the rotor bars. The
rotor circuit is shorted and current flows in the rotor conductors. The
action of the rotating flux and the current produces a force that generates a
torque to start the motor.

An alternator rotor is made up of a wire coil enveloped around an iron

core.[11] The magnetic component of the rotor is made from steel
laminations to aid stamping conductor slots to specific shapes and sizes. As
currents travel through the wire coil a magnetic field is created around the
core, which is referred to as field current. The field current strength
controls the power level of the magnetic field. Direct current (DC) drives
the field current in one direction, and is delivered to the wire coil by a set of
brushes and slip rings. Like any magnet, the magnetic field produced has a
north and a south pole. The normal clockwise direction of the motor that
the rotor is powering can be manipulated by using the magnets and
magnetic fields installed in the design of the rotor, allowing the motor to
run in reverse or counterclockwise.

Day 6 :- ( 02/12/2018 )

On the 6th day of the inplant training we studied about introduction and
working of excitation field

An electric generator or electric motor consists of a rotor spinning in

a magnetic field. The magnetic field may be produced by permanent
magnets or by field coils. In the case of a machine with field coils, a current
must flow in the coils to generate the field, otherwise no power is
transferred to or from the rotor. The process of generating a magnetic field
by means of an electric current is called excitation. Field coils yield the
most flexible form of magnetic flux regulation and de-regulation, but at the
expense of a flow of electric current. Hybrid topologies exists, which
encorporate both permanent magnets and field coils in the same
configuration. The flexible excitation of a rotating electrical machine is
employed by either brushless excitation techniques or by the injection of
current by carbon brushes (static excitation).

Excitation in generators
For a machine using field coils, as is the case in most large generators, the
field must be established by a current in order for the generator to produce
electricity. Although some of the generator's own output can be used to
maintain the field once it starts up, an external source of current is needed
for starting the generator. In any case, it is important to be able to control
the field since this will maintain the system voltage.

Separate excitation

For large, or older, generators, it is usual for a separate exciter dynamo to

be powered in parallel with the main power generator. This is a small
permanent-magnet or battery-excited dynamo that produces the field
current for the larger generator.

Self excitation

Modern generators with field coils are usually self-excited; i.e., some of the
power output from the rotor is used to power the field coils. The rotor iron
retains a degree of residual magnetism when the generator is turned off.
The generator is started with no load connected; the initial weak field
induces a weak current in the rotor coils, which in turn creates an initial
field current, increasing the field strength, thus increasing the induced
current in the rotor, and so on in a feedback process until the machine
"builds up" to full voltage.
Brushless excitation

Brushless excitation creates the magnetic flux on the rotor of electrical

machines without the need of carbon brushes. It is typically used for
reducing the regular maintenance costs and to reduce the risk of brush-fire.
It was developed in the 1950s, as a result of the advances in high-
power semiconductor devices. The concept was using a rotating diode
rectifier on the shaft of the synchronous machine to harvest induced
alternating voltages and rectify them to feed the generator field winding.
Brushless excitation has been historically lacking the fast flux de-regulation,
which has been a major drawback. However, new solutions have emerged.
Modern rotating circuitry incorporates active de-excitation components on
the shaft, extending the passive diode bridge. Moreover, their recent
developments in high-performance wireless communication have realized
fully controlled topologies on the shaft, such as the thyristor rectifiers and
chopper interfaces.

Day 7 :- ( 03/12/2018 )

Step-up Transformer
A transformer in which the output (secondary) voltage is greater than its
input (primary) voltage is called a step-up transformer. The step-up
transformer decreases the output current for keeping the input and output
power of the system equal.

Considered a step-up transformer shown in the figure below. The E1 and

E2 are the voltages, and T1 and T2 are the number of turns on the primary
and secondary winding of the transformer.
The number of turns on the secondary of the transformer is greater than
that of the primary, i.e., T2> T1.Thus the voltage turn ratio of the step-up
transformer is 1:2. The primary winding of the step-up transformer is made
up of thick insulated copper wire because the low magnitude current flows
through it.

Applications – Step-up transformer is used in transmission lines for

transforming the high voltage produced by the alternator.The power loss of
the transmission line is directly proportional to the square of the current
flows through it.

Power = I2R

The output current of the step-up transformer is less, and hence it is used
for reducing the power loss. The step-up transformer is also used for
starting the electrical motor, in the microwave oven, X-rays machines, etc.

Step-down Transformer
A transformer in which the output (secondary) voltage is less than its input
(primary) voltage is called a step-down transformer. The number of turns
on the primary of the transformer is greater than the turn on the secondary
of the transformer, i.e., T2 < T1. The step-down transformer is shown in the
figure below.

The voltage turn ratio of the step-down transformer is 2:1. The voltage turn
ratio determines the magnitude of voltage transforms from primary to
secondary windings of the transformer.

Step-down transformer is made up of two or more coil wound on the iron

core of the transformer. It works on the principle of magnetic induction
between the coils. The voltage applied to the primary of the coil magnetise
the iron core which induces the secondary windings of the transformer.
Thus the voltage transforms from primary to the secondary winding of the
transformer.

Applications – It is used for electrical isolation, in a power distribution

network, for controlling the home appliances, in a doorbell, etc.

Working Principle of a Transformer

The basic principle on which the transformer works is Faraday’s Law of
Electromagnetic Induction or mutual induction between the two coils. The
working of the transformer is explained below. The transformer consists
of two separate windings placed over the laminated silicon steel core.

The winding to which AC supply is connected is called primary winding and

to which load is connected is called secondary winding as shown in the
figure below. It works on the alternating current only because an
alternating flux is required for mutual induction between the two windings.

DAY 8 :- ( 04/12/2018 )

Detailed structure and working of P-N junction diode used in generators

On the beginning of 8th day we started studying about working of p n

junction diodes

There are three possible biasing conditions and two operating regions for
the typical PN-Junction Diode, they are: zero bias, forward bias and reverse
bias.

When no voltage is applied across the PN junction diode then the electrons
will diffuse to P-side and holes will diffuse to N-side through the junction
and they combine with each other. Therefore, the acceptor atom close to
the P-type and donor atom near to the N-side are left unutilized. An
electronic field is generated by these charge carriers. This opposes further
diffusion of charge carriers. Thus, no movement of the region is known as
depletion region or space charge.

If we apply forward bias to the PN-junction diode, that means negative

terminal is connected to the P-type material and the positive terminal is
connected to the N-type material across the diode which has the effect of
decreasing the width of the PN junction diode.

If we apply reverse bias to the PN-junction diode, that means positive

terminal is connected to the P-type material and the negative terminal is
connected to the N-type material across the diode which has the effect of
increasing the width of the PN junction diode and no charge can flow across
the junction

Zero Biased PN Junction Diode

In the zero bias junction, potential provides higher potential energy to the
holes on the P and N side terminals. When the terminals of the junction
diode are shorted, few majority charge carriers in the P-side with plenty
energy to overcome the potential barrier to travel across the depletion
region. Therefore, with the help of majority charge carriers, the current
starts to flow in the diode and it is denoted to as forward current. In the
same way, minority charge carriers in the N-side move across the depletion
region in reverse direction and it is referred to as reverse current.

Potential barrier opposes the movement of electrons & holes across the
junction and permits the minority charge carriers to drift across the PN
junction. However, the potential barrier helps minority charge carriers in P-
type and N-type to drift across the PN-junction, then an equilibrium will be
established when the majority charge carriers are equal and both moving in
reverse directions, so that the net result is zero current flowing in the
circuit. This junction is said to be in a state of dynamic equilibrium.

When the temperature of the semiconductor is increased, minority charge

carriers have been endlessly generated and thus leakage current starts to
rise. But, electric current cannot flow since no external source has been
connected to the PN-junction.

Day : - 9 ( 05/12/2018 )

On the day of 9th we continued our study to control panels used in

generators different types of control panels and how its operates.

the heart of a generator control panel is its ability to automatically start and
stop a generators engine. This is accomplished by sensing when the
Automatic Transfer Switch needs the generator to run. The Generator
Control Panel, turns on the fuel or ignition, and engages the starter. It
senses that the engine has started, disengages the starter, and waits for the
Automatic Transfer Switch to request that the generator be shut down.

Another critical function that the generator control panel can perform is
protecting your generators engine. The Generator control Panel can
monitor critical engine functions such as oil pressure, and coolant
temperature, and shut down the generator engine to protect it from harm.

The more advanced the Generator Control Panel, the more things it can
monitor. The monitoring of generator functions such as voltage, current,
frequency, are all possible. Some Generator Control panels have built in
displays so that an operator can visually check on the generators function.
Some have remote communication capability to alert personnel of a
problem.
Some simple Generator Control Panels can be programmed from the front
panel with parameters unique to a specific installation. Most will require
that a computer be connected to perform the setup functions.

A generator’s control panel connects to several sensors throughout the unit

to bring you vital information regarding system efficiency, voltage and run
hours; triggering alarms and display warnings if something is wrong. Used
in conjunction with an Automatic Transfer Switch (ATS); the control
panel can start the generator the instant that a power outage is detected.
Fully utilizing your control panel helps to protect your generator engine
from low oil pressure, high oil temperatures, coolant level fluctuations and
dangerous engine speed variants. It also helps to protect the alternator
from circuit breaker failure and system overloads. With the addition of
upgradable aftermarket control panels, users can pinpoint the parameters
to be monitored as well as customize automation requirements and alerts;
fine-tuning the information provided to best fit your application.
When choosing the right generator for your application, it is wise to
consider the level of control and quality of information you will need to
effectively operate your unit. Mission critical applications will most likely
require advanced control panel functions and precise automation. Limited
use, emergency power backup systems for smaller or less intensive
applications will require less from their control panels. Basic information on
voltage and amperage as well as warning lights and alarms in case of
pending failure are standard for even simple control panels.

Day 10 :- (06/12/2018 )

On the beginning of the day 10 we studied about governor system used in

alternators. This is the most important part of generator it uses software to
control over generator speed, pressure, temperature, automatic on-off and
related things
The governor is a device which varies the amount of fuel delivered to the
engine in order to maintain a constant speed. Without a governor the
engine would slow down and probably stall when a significant load was
added. Of course you could just manually increase the fuel to the engine
but then when the load is removed the engine will be spinning too fast. This
can be acceptable if the generator only powers a single load which is always
connected. For other situations where the loads may vary then a governor
is needed to automatically control the fuel and thus speed.

The speed of the engine determines the speed of the alternator, which
determines the frequency of the alternating current produced. For many
types of electrical motors the speed is determined by the frequency of the
alternating current.

Most cheap generators use a simple proportional control. That is, the speed
of the engine is inversely proportional to the load on the engine. At no load
the speed might be 3% higher than the target speed and it full load and
maybe % lower. This means that the generator set only runs at its Target
speed 41 precise load.

A more advanced governor will use a PID (Proportional Integral Derivative)

controller. Without getting into the math, this type of controller can hunt
around until it finds the exact right fuel setting for a load which results in
the target speed.

On the electrical side of the generator set there are two sets of windings,
the armature winding and the field winding. The armature winding
produces the electricity that runs through whatever loads the generator is
powering. In order for the armature winding to produce any current in has
to be rotating with respect to a magnetic field. It doesn't matter whether
the winding rotates or the magnetic field rotates so long as they are
rotating with respect to each other. The strength of the magnetic field in
combination with the load determines the voltage produced by the
armature winding. The magnetic field can be created by permanent
magnets but since these are not adjustable we have no control over the
voltage. Therefore we use an electromagnet to generate the electric field,
this is produced by the field winding.

The field winding uses some of the electricity made by the generator to
create a magnetic field. The purpose of the AVR (Automatic Voltage
Regulator) is to control the amount of power going to the field winding to
adjust the magnetic field strength to adjust the voltage produced by the
armature winding.

In short, the governor maintains the desired engine speed and AC

frequency. The AVR maintains the desired output voltage

Day – 11 ( 07/12/2018 )

At the end of the day of our inplant training we studied about

specification and cost of different generators and listed some
important generator models.

1) Kirloskar 5 Kva To 625 Kva Industrial Generator, 230 To 415 V

Rs 1.8 Lakh

Product Specification

Fuel Type Diesel

Voltage 230 to 415 V

Brand Kirloskar

Power 5 kVA to 625 kVA

Material of Stainless steel

Construction
 Finish Paint Coate

2) Kirlosker Diesel Portable Generator (230 V, 3000 rpm)

Rs. 167,000

DESCRIPTION

Powered with single cylinder 418 c heavy duty engine

· Rated with rotational speed of engine is around 3000 rpm
· Rated power output capacity of 5.5kW/7.48 hp
· Fuel tank storage capacity of 12.5 l
· Employs insulation of H type

SPECIFICATION

 Frequency50 Hz
 Rotational speed3000 rpm
 Output Capacity5.5 kW/7.48 hp
 Fuel Tank (Ltr)12.5 L

 Voltage230 V

3) 45kva Kirloskar KOEL iGREEN Diesel Generator, for Power

Rs 3.85 Lakh

Product Specification
Application Power
 Cooling System Oil Cooling

Fuel Type Diesel

Brand Kirloskar

Noise Level Silent or Soundproof

Power 45kVA

Number of Cylinder 3

Warranty 24 months

Genset Rating KVA 45

Output Type AC Single Phase

4) Koel KG1 750WS 750 KVA Generator

Product Specification

 ✔ Fuel Type: Diesel

 ✔ Cylinders: 12
 ✔ Phase: 0
 ✔ Warranty: 0
 ✔ Power Rating Range: 750
 ✔ Fuel Tank Capacity Range: 990 Litres

CONCLUTION

I CONCLUDE THAT I HAVE DONE MY INPLANT TRAINING IN

“GOKUL POWER SERVICES” AND HAS GOT FULL KNOWLEDGE
ABOUT WHAT WE HAVE DONE IN THE GOKUL POWER SERVICES
AND GOT THE CERTIFICATE.