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TABLE OF CONTENTS

Sr.No. Name. Page no.

1 Acknowledgement 1

2 Preface 2

3 Introduction 3

4 Company’s Profile 4

5 Advertisement Policy 12

5.1 Sales Promotion Stretegy 12

6 Production Infrastructure 13

6.1 Electrical Wiring Accessories. 14

6.2 Industrial Plugs And Sockets: 14

6.3 Pma–Ag Switzerland:A Safe And Universal

Electrical Wiring Protection System15

6.4 Wohner Technology 16

6.5 Environmental Management Systems (Ac): 17

6.6 Electrical Panels: 18

6.7 Enclosure Systems: 19

6.8 Mcb Distribution Boards 20

6.9 Switchgear 21

7 Main Departments 21

7.1 Sheet Metal Shop 22

7.1.a C.R.C.A (Cold Rolled Carbon Annealed) Sheet 22

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7.1.1 Machines Used 23

7.1.1.a Punching Machine 24

7.1.a.2 Features 25

7.1.1.b Bending Machine 26

7.1.1.b.2 Features 27

7.1.1.c Welding Machine 28

7.1.1.c2 Features 29

7.1.1.d Shearing Machine 29

7.2 Press Shop 31

7.3 Paint Shop 32

7.3.1 Appratus Set Up 32

7.3.2 Paint Process 34

7.3.3 Test After Paint 37

7.4 Electroplating Shop 37

7.4.1 Steps For Electroplating 37

7.4.2 Types Of Electroplating 38

7.4.3 Inspection 40

7.4.4 Treatment Methods 40

7.4.5 Storage And Safety 41

8 Switch Gear Divison 41

8.1 Product Manufactured 41

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8.1.a Rewirable Switch Fuse 41

8.1.b On Load Changeover Switch 42

8.1.c Double Break Fuse Switch 43

8.1.d Switch Disconnector Fuse 43

8.2 Distribution Boards 44

8.2.1 Features:- 44

8.2.2 Classification Of The Circuit Breaker 44

9 Testing List 49

10 Moulding Shop 59

10.1 Machine Used 59

10.2 Injection Molding Machines 59

10.3 Grainer Machine 64

11 Testing Labs 65

12 Technical Performance Of Switches 70

13 Panel Shop 72

13.1 Panel Types 72

13.2 Lt Power Panel For Ac Coach 73

13.3 Panel Parts 74

13.4 Panel Discription 75

14 Ac System(Cool Pack) 80

15 Product Range Of Ssk 81

16 Observation 100

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17 Conclusion 101

18 Appendix(Table & Fig) 102

1. ACKNOWLEDGEMENTWe 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.

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Last but not least I thank all the individuals who supported and criticized me in this period of

training semester.

SAVYASACHI

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.

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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.

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, non-

existence 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,

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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.

4. COMPANY’S PROFILE

1. Name ESS ESS KAY ENGG. Co. Ltd.

2. Status Private Limited Company

3. Date of Incorporation 1935 at Lahore (Pakistan)

4. Total Factory Area 45000 Sq. Yards.

5. Contact 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

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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

(f) Roof Mounted AC Package Units

(g) Enclosures

(h) Cable Protection System – PMA

(i) “Wohner” Bus Bar System

(j) “Pallazoli” Connectors and Industrial Plugs

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9. Vision

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

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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 company’s list of human resource is as follows.

Table 1

Type No

Qualified M.B.A. Engineer 140

Diploma holders 70

Sales staff 65

Workmen 450

Resident 35

Other 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

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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 company’s 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. AlliancesTo 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.

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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. Collaborationsa. PMA AG, Switzerland–Cable Protection System

b. Wohner Gmbh, Germany – Bus Bar system.

c. Pallazoli, Italy – Connectors & Industrial Plugs.

d. Aircotech, Switzerland – AC Package Units.

19. Our ClientsDomestic Clients Overseas Clients

Rail coach factory (RCF)

Larsen & Toubro

Indian Oil Corporation Ltd. (IOCL)

Tata

B.H.E.L.

Escorts

Jaypee Group

Jindal Stainless Steel, among others

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

Jordan Electric Power Supply Co.,

Jordan

20.1 Housing / Commercial Projects:1. DLF 24. Cotton City, Coimbatore

2. UNITECH 25. South Indian Shelters, Chennai

3. ESSEL Tower, Gurgaon 26. Shreenath Tower, Rajkot

4. Raheja Builders 27. Alaap, Rajkot

5. NIHO 28. NRI City , Jaipur

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6. ELDECO 29. Royal En Sign , Jaipur

7. Parsvnath 30. Sand Dune, Jaipur

8. HEWO 31. Paradise Group, Jaipur

9. AWHO 32. Suncity, Delhi

10. Ansals 33. Unique builders Jaipur,

11. Akashganga, Jaipur, 34. Index One, Jaipur

12. Brahma Majestic. Pune 35. Brahma Builders, Pune

13. Nike Nore & Associates, Pune 36. Parmar Builder, Pune

14. Sanghvi Builder / OM Builders, Pune 37. Goyal Ganga, Pune

15. Esha Realators, Pune 38. Kolte Patil Builders, Pune

16. Pharande Developers, Pune 39. Rohitin Mehta Associates, Pune

17. Beharay Rathi Builders, Pune 40. K.D Builders, Pune

18. Landscape Construction, Pajim Goa 41. Kamat Construction, Panjim Goa

19. Models Construction, Panjim Goa 42. Richmont Builders, Goa

20. Omaxe-Green City Faridabad 43. Krishna Residency, Mumbai

21. Safal Twins, Mumbai 44. Aggarwal Residency, Mumbai

22. Royal Chambers, Mumbai 45. Ramoji Film City, Hyderabad

23. Ansal City, Jodhpur, 46. Rajtilak, Surat and many more

……………..

20.2 Hospitals1. Escorts, Amritsar 5. Sir Ganga Ram Hospital, Delhi

2. Apollo, Delhi 6. Batra Hospital, Delhi

3. DMC, Ludhiana 7. Fortis, Mohali

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

20.3 Government / Public Sector / Private Sector / Others1. Parliament House 16. Rail Coach Factory, Kapurthala

2. THDC 17. NTPC

3. PSEB 18. MPEB

4. Chattisgarh Electricity Board 19. LIC

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5. United Bank of India 20. ICICI Bank

6. UTI Bank 21. BHEL

7. PWD, Punjab,UP,Haryana,Rajasthan,Assam 22. IOCL

8. AECL 23. HCL

9. ITI Rai Bareilly 24. GNVF Ltd.

10. HAL 25. BEL

11. CPWD 26. NFL

12. Kalpataru Power Transmission Ltd. 27. Biocon , Bangalore

13. National Institute of Oceanography, Goa 28. Krishi Bhawan, Panjim Goa

14. Office of GSIDC, Panjim Goa 29. Ordnance Factory, Khamaria M.P

15. Airport Authority of India 30. SBI and many more ……………..

20.4 Religious InstitutionsSwaminarayan 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

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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 equipment’s 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

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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 dealer’s

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 company’s 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:

Today’s 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:

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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 COMPANY’s 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

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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

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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 MCB’s.

7. Matching accessories like support plates aluminum alloy flanges and cable glands are

readily available to suit different applications.

6.3. PMA–AG 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 self-

extinguishing 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

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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

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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, MCCB’s 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

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TR, rugged and antirust stain less frames. Equipped with air cooled condensers, requirement

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

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Feeder Pillars

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.

P a g e | 24

Constructional features:

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 customer’s 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 MCB’s

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

P a g e | 25

through use of high conductivity ETP copper tin plated Bus Bars. Suitable knockouts are

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 DEPARTMENTSThe standard electrical limited is divided into 11 departments: -

Sheet metal shop

Press shop

Paint shop

P a g e | 26

Research & development department

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 | 27

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 | 28

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 multi-

station 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 | 29

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 | 30

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.

P a g e | 31

CNC system are used for feeding of size and co-ordinates.

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 | 32

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 | 33

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 | 34

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 | 35

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 dep’t. 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 dep’t. 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 | 36

7.3 PAINT SHOPIn 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) Powder coating guns (electrostatic application)

2) Powder baking oven

3) Thermic fluid heater

4) Spray booth

5) 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 | 37

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 | 38

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 | 39

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. Degreasing Tank 10 75-85 10

2. Water Rinsing Tank --- Normal 1

3. Derusting

Tank

1 50-60 5

4. Water Rinsing Tank ----- Normal 1

5. Water Rinsing Tank ----- Normal 1

6. Activation Tank 8.5 – 9.5 Normal 1

7. Phosphating Tank 1 30-35

8. Water Rinsing Tank ----- Normal 1

9. Sealing 3-4 75 - 80

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 | 40

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 | 41

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 SHOPElectroplating 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 | 42

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

Cathode: - copper, brass

P a g e | 43

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 | 44

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 | 45

5) At ph= 10-11, the heavy metal & trivalent chrome gets precipitated.

6) After this the water of both the stream is fed into the sludge-setting tank.

7) Sludge setting tank water is allowed to stand for 8-10 hours. As a result sludge settles

down.

8) The clean water is then brought to ph adjustment tank through the clarifier.

9) 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 air-

conditions, refrigerators, geysers and other house-hold electrical appliances. Extensively used

as industrial main control switch.

P a g e | 46

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 | 47

housed in a polyester reinforced moulded frame having high dielectric strength and thermal

with stand capacity.

Range 63 – 1000A

No. of poles four

Rated voltage 415A.C

Insulation voltage 660V

Utilization category 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 63-400A

No. of poles TP TPN & FP

Rating insulation voltage 415V

Utilization category 660V

Specification 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.

2) These switches are compact in size and front operated and thus ideal for power

panels.

P a g e | 48

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 décor 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 DB’s painted in epoxy polyester powder coating

. Earth bar fitted on upper end plate, having same number of holes as number of

MCB’S.

Neutral has same number of outgoing holes as number of MCB’S.

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

Four pole circuit breaker with three pole protected

Four pole circuit breaker with four pole protected.

P a g e | 49

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

f) According to the I2T characteristics

MCB RATING CHAT FOR DOMESTIC APPLICATIONS

P a g e | 50

SR.NO APPLIANCES CAPACITY MCB RATING

01

02

03

04

05

REFRIGERATOR 165LT/350LT

T.V. V.C.R MUSIC SYSTEM

VACCUME CLEANER WASHING

MACHINE

WASHING MACHINE WITH HEATER

IRON

400W/750W

400W

400W

1300W

750W

4A-6A

4A

4A

10A

6A

06

07

08

09

10

11

12

13

GEYSER

HOT PLATE

AIR CONDITIONING

PHOTOCOPIES

WATER COOLER

POWER PLUG

ONE LIGHTING CIRCUIT

ONE POWER CIRCUIT

1000,

2000,

3000W

1000W

1TON

1.5TON

2TON

1500W

700W

1000W

10 PTS

1000W

2 PTS

3000W

6A10A16A

10A

10A

16A

25A

16A

6A

10A

10A

20A

P a g e | 51

Table 3

MCB RATING FOR MOTOR APPLICATIONS

MOTOR

H.P

KW MCB RATING (AMPRS)

STAR - DELTA D.O.L

1.0

1.5

2.0

3.0

4.0

5.0

6.0

7.5

10.0

12.5

15.0

17.5

20.0

0.75

1.10

1.5

2.25

3.00

3.75

4.50

5.50

7.50

9.30

11.00

13.00

15.00

-

-

-

-

-

10A

10A

16A

16A

20A

25A

25A

32A

2A

3A

4A

6A

6A

10A

10A

16A

16A

20A

25A

32A

40A

P a g e | 52

25.0

18.50 40A 50A

Table 4

Construction:-

9. TESTING LIST

For certification purposes, Type test are carried out in sequences

P a g e | 53

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 designed for

installation in an individual enclosure are tested in the 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,

2m for cross section larger than 10 mm2.

P a g e | 54

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 Values of the rated current In A

1

1.5

2.5

4

6

10

16

25

35

50

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.

9.2.1 Test of indelibility of Marking

P a g e | 55

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.

Nominal diameter of thread mm Torque Nm

P a g e | 56

1 2 3

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

-

0.4

0.5

0.6

0.8

1.2

1.8

2.0

2.5

3.5

4.0

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 | 57

Fig.17

These last test are made by means of a suitable screwdriver or spanner applying a torque as

shown

Cross section of conductor

accepted by the terminal (mm2)

Up to 4 Up to 6 Up to 10 Up to 16 Up to 50

Pull(N) 50 60 80 90 100

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.

Insulation resistance of the main circuit.

Dielectric strength of the main circuit.

Dielectric strength of the auxiliary circuit.

Value of test voltage.

P a g e | 58

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

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

P a g e | 59

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 Circuit breaker to be tested

Test at reduced short circuit current All circuit breaker

Test at 1500 A

Test at service short circuit capacity I cn > 1500 A

Test at rated short circuit capacity

Table 8

P a g e | 60

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

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.

P a g e | 61

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 | 62

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 | 63

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 | 64

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 | 65

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 | 66

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 | 67

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 | 68

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 machineThe 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

P a g e | 69

Fig 32

11. TESTING LABS11.1 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

P a g e | 70

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

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 starts revolving and then the

strength of the connection is to be tested out .

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 | 71

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 | 72

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 | 73

Fig 41

P a g e | 74

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

(rms) for one minute

It withstood 3KV (rms) for

2 minutes

Temperature rise Should not exceed 45

degree Celsius ,about

40,000 operations on load

It did not increase 14

degree Celsius after 50,000

operations in 6amp

accessories and 18degree

Celsius after

50,000operations in 16 amp

accessories.

Milli volt drop Should not exceed 20mV

(in 6 Amp & 16 Amp

accessories) after 40,000

operations on load .

Not exceeded 7mv

after1,20,000 operations in

6 amp and 9 mv in 16 amp .

Insulation resistance Should not be less than

100M ohms (before

humidity treatment)

Found more than 500 M

ohms ( after humidity

treatment )

Electrical endurance test

(ON-OFF) test

Switches should be tested

at 40,000 operations(ON-

We tested our switches at

120,000 operations on load.

P a g e | 75

OFF) on load ( even after this switches

worked properly).

Mechanical strength Specified only at 0.4Nm

impact energy

Tested at maximum impact

energy 1 nm for all rating

designs .(hammer stroke

test from a distance of 270

mm)

Making &breaking

capacity

The switches and sockets

are required to be tested at

130% of the rated current

and 110% of the rated

voltage for 500 continues

operations, with an interval

of 30 seconds

Our switches and sockets

were tested at 130% of the

rated current and 110% of

the rated voltage for 1500

operations and were found

to be in good working

conditions.

Resistance to heat at

125degree celcius

The outer body of the

molding should be heated

to the temperature of 125

degree Celsius for 60

minutes. Thereafter the ball

pressure test should not

make an impression deeper

than 2mm

Was not affected by

abnormal heat and fire at

850 degree Celsius

Resistance to abnormal

heat & to fire (glow wire

test)

The test is performed on

parts of insulating material

which might be exposed to

thermal stress due to

electric effects and

decoration shall not unduly

P a g e | 76

be affected by abnormal

heat and by fire at a

temperature of 650 degree

Celsius

Table 8

13. PANEL SHOPPanel 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

P a g e | 77

PLC PANEL

MCC  PANEL (MOTOR CONTROL CENTRE)

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)

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Fig 42

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

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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)

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 mm² but electrical

substations may use metal tubes of 50 mm in diameter (1,963 mm²) or more as busbars

Comparision between Woehner Bus Bar system and Traditional Bus Bar system

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Panel with Woehner Bus Bar Panel with Traditional Bus Bar system

This system is space saving. There is no need ofseparate

bus bar chamber. Switchgear can be mounted directly on

bus bar with base material of Woehner

In this system separate bus bar chamber is required

which increase the size of the panel even the cost

There is no need of bus bar drilling to take connections

for switchgear with this there is no need of using extra

X-section of bus bar & there are no heat losses. With this

one can save time for fitting switchgear very low costs of

wire and lugs & hardware for taking input on switchgear

as compared to traditional

In this one has to use extra X-section area of bus bar,

extra wires, lugs, hardware is required to take input

tappings. Drilling is required in bus bar which produces

heat where wires are tight with nut and bolts.

Any make of switchgear can be replaced with each other

in panel without going for any changes & time

consumption is vey less.

Where as In this if you have to replace switchgear of

another make lots of mechanical alterations like

drilling etc.

This system helps to bring panel almost maintenance free

Less than half of area remains where tightening is

required. If there is no losing the life of switchgear will

automatically increases.

In this more time is require for maintenance which results

more production loss.

Table 9

Fig 43

Contactor (ABB Company)

Rating:- 300A , 600V AC

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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

Fuse size

Wire GaugeRecommended

Maximum Fuse Size

00 awg 400 amps

0 awg 325 amps

1 awg 250 amps

2 awg 200 amps

4 awg 125 amps

6 awg 80 amps

8 awg 50 amps

10 awg 30 amps

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12 awg 20 amps

14 awg 15 amps

16 awg 7.5 amps

Table 11

Voltmeter:-range 0-800V

MCB:- 240/415V ac & 60/220V

MPCB

MCCB:- MOULDED CASE CIRCUIT BREAKER

Range : 25A to 1600A

Rated Voltage : 240/415V AC. DC Mccb’s also available

Execution : SP, TP&FP with switched neutral

Breaking Capacity : up to 50KA

Fig 44

RCCB/ELCB

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

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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 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. Disconnector with HRC Fuse MCCB

1. The breaking capacity is >80KA Not more than 20KA

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2. Cost of HRC Fuse less More expensive

3. It must be repairable Not repairable

4. Not affected by ambient Fully depend on ambient

5. Fusing – 1.6 time

Non Fusing – 1.2 time

Tripping time not controlled on

overload

6. After heavy short circuit only HRC Fuse to be

replaced

After heavy short circuit

MCCB is totally damaged

7. The incoming, outgoing terminals are suitable

as per cable size

Fixed terminals

8. Not defected by vibrations Due to electromechanical design, more

affected by vibrations

9. Less temperature rise High temperature rise

10. Not affected by weather Affected by weather

11. Un-interrupted duty Interrupted duty

12. Less weight Heavy weight

13. Unbreakable Breakable

14. Dielectric strength is more after short

circuit/overloading

Dielectric strength is less after short

circuit/over loading

15. Insulation resistance is more after

overload/short circuit

Insulation resistance is less after

overload/short circuit

Table 10

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.

P a g e | 85

Refrigeration cycle

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

Fig 45In 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 = 6.022×1023 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

15. DIFFERENT PRODUCT RANGE OF SSK

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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

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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) .

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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

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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

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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

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HCF-701,HCF-708,HCF-752 (Rs.3135.00)

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 .

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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

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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

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BELL PUSH 6A 230V AC

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.

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LX-243

SWITCH SOCKET COMBINED 5 PIN (6A 250V AC)

FITTED WITH POWDER COATED STEEL PLATE & COVER FRAME

(SUITABLE FOR 4”X3” BOX)

LX-135

ENERGY SWITCH 30A WITH KEY TAG HORIZONTAL

Signature EL Series

EL-243

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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

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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

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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

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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

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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

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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

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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

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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

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SWITCH SOCKET COMBINED UNIVERSAL 6A

250V AC ISI 2/3 PIN

Cat No. N-125

SWITCH SP WITH INDICATOR 16A 250V AC ISI

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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.

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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 | 107

18. APPENDIX

I

Fig no:- Discription Page. No.

1 Company motto 5

2 Mig Welding 23

3 CNC punching machiine 26

4 Punching press 26

5 HH bending machine, CNC 27

6 Amada bending machine 27

7 Spot welding machine 28

8 Shearing machine(front & Back)

30

9 Powder coating gun 32

10 Cabinet & Supply for gun 34

11 Painting process 36

12 Baking of paint 36

13 Rewireable switch fuse 41

14 Short circuit testing device of change over switches

49

15 Thread forming tapping screw 51

16 Thread cutting tapping screw 51

17 Reliability test 53

18 Dielectric property test 54

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19 Short Circuit test diagram 55

20 Abbreviations 56

21 Second diagram test 56

22 Test of resistance to shock 57

23 Mechanical impact test 57

24 Test figures 58

25 Moulding machine 60

26 Dye of moulding machime 61

27 Preheater system for polycarbonate resin

61

28 Moulds 62

29 View of machine 63

30 Different frames 63

31 Waste polycarbonate & Grainer machine

64

32 Switch internal part 64

33 Heating oven for switch 65

34 Mechanical strength test 65

35 Tumbling barrel test 66

36 Circuit diagram 66

37 Mechanical impact test 67

38 Endurance test device 67

39 Milli volt drop test 68

40 Ampere test 68

41 Components used to manufacture modular switches

69

42 Outer look of panel 73

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43 Bus bar 76

44 Mccb 77

45 Refrigeration cycle 80

II

Table no Description Page no

1 Human resource in company 6

2 Phosphating process 35

3 MCB rating chart for domestic application

46

4 MCB rating for motor application.

47

5 Cross sectional area of copper 50

6 Screw parameters 52

7 Cross sectional 53

8 Test kind 55

9 Technical performance of ssk switch

70

10 Comparison of different bus bar 75

11 Fuse size 77

12 Comparison b/w fuse & Mcb 79

13