INDUSTRIAL INTERNSHIP

An INTERNSHIP REPORT

Submitted by

BHADELIYA JAYDEV HEMANTKUMAR

[190430109007]

ELECTRICAL ENGINEERING

SHANTILAL SHAH GOVERNMENT ENGINEERING COLLEGE

Gujarat Technological University, Ahmedabad

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 SHANTILAL SHAH GOVERNMENT ENGINEERING COLLEGE
Sidsar, Bhavnagar

CERTIFICATE

This is to certify that the internship report submitted along with the project
entitled Internship has been carried out by Jaydev Hemantkumar Bhadeliya
under my guidance in partial fulfilment for the Internship of Bachelor of
Engineering in Electrical Engineering, 7th Semester of Gujarat Technological
University, Ahmadabad during the academic year 2022-23.

Internal Guide Head of Department

Prof. M.U.Ghanchi Prof. B.N.Vaidya

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3
 Acknowledgement

I wish to express our sincere gratitude to our External guide Mr. Pradip Tripathi for
continuously guiding me at the company and answering all my doubts with patience. I would
also like to thank my Internal Guide Prof. M.U.Ghanchi for helping me through my internship
by giving me the necessary suggestions and advices along with their valuable co-ordination in
completing this internship.

I also thank my parents, friends and all the members of the family for their precious support
and encouragement which they had provided in completion of my work. In addition to that, I
would also like to mention the company personals who gave us the permission to use and
experience the valuable resources required for the internship.

Thus, in conclusion to the above said, I once again thank the staff members of Shree Patel
industries for their valuable support in completion of the project.

Thank You

Jaydev Hemantkumar Bhadeliya

[190430109007]
Electrical Engineering
SSGEC, Bhavnagar

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 Abstract

This is the summer internship report for year 2022-23 to represent my 15 days of experience
in the industry named Shree Patel Industry. Where I observed that how they are doing their
job. Many types of machines are in industry. All machines work properly.

The main purpose of research is to develop a control scheme for control panel maintenance. In
control panel many types of electrical equipments are used. In industry there are PLC also for
automatically process. In industry PF panel also. The PF panel maintain power factor.

In industry they are used different types of electrical and mechanical equipments for
measurement the instruments. Every machine has its own control panel.

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 Index

Institute Certificate……………………………………………….. 2

Industry Certificate……………………………………………….. 3

Acknowledgment………………………………………………… 4

Abstract…………………………………………………………... 5

Chapter 1: Introduction About Industry…………………………... 8

1.1 About Industry……………………………………………….. 8

1.2 All Branches…………………………………………………. 8

1.3 Aim & Objective & Achievements………………………….. 9

1.4 Customers of company………………………………………. 9

1.5 Machines in Industry………………………………….……… 9

Chapter 2: Power Distribution……………………………………... 11

2.1 Schematic Diagram of Power Distribution………………….. 11

2.2 Description about Power Distribution………………………. 12

2.3 PF panel and its components………………………………… 13

Chapter 3: Control Panel and its Component……………………… 15

3.1 Introduction control panel………………………..………...... 15

3.2 Components of control panel……………………………….... 16

Chapter 4: Machining plant and Plating plant…………………….. 25

4.1 Electrical parts in machining plants………………………….. 25

4.2 Electrical part in plating plant………………………………… 27

4.3 Tools and Equipments used in plants……………………….... 28

Conclusion……………………………………………………………. 31
Reference……………………………………………………………… 32

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 List of Figures

Fig. 2.1 Transformer ratings ……..………………………… 12

Fig. 2.2 MCCB……………………………………………... 13

Fig. 2.3 Capacitors………………………………………….. 14

Fig. 3.1 MCCB……………………………………………… 16

Fig. 3.2 MPCB……………………………………………… 17

Fig. 3.3 Contactors………………………………………….. 18

Fig. 3.4 SMPS………………………………………………. 19

Fig. 3.5 Relay……………………………………………….. 20

Fig. 3.6 VFD………………………………………………… 21

Fig. 3.7 Servo drive…………………………………………. 22

Fig. 3.8 PLC………………………………………………… 23

Fig. 3.9 Line reactor………………………………………… 24

Fig. 4.1 Induction motor…………………………………….. 25

Fig. 4.2 Servo motor………………………………………… 26

Fig. 4.3 Electroplating rectifier……………………………… 27

Fig. 4.4 Clamp meter………………………………………... 28

Fig. 4.5 Multimeter………………………………………….. 29

Fig. 4.6 Tachometer…………………………………………. 30

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 1. Introduction About Industry

1.1 About Industry:

Shree Patel Industry established in 1961, to day SPI group is one of the major contributors to
the automotive industry which has carved out a niche for itself in providing unmatched
innovative solutions and products to the industry.

We, as an individual partner, to the engineering industry, as a whole, have joined the elite
group as solution providers to the products.

SPI’s growth is supported by continuous improvements and innovations to serve the high
standard set by engineering industry. SPI is equipped with latest computations, and
manufacturing technology to simulate, test and develop systems accurately to suit variety of
applications.

With vast experience of over 61 years with implementation of Quality System IATF 16949,
and over 600 experienced employees engaged in manufacturing & Turnover of Rs. 90 Crores.

1.2 All Branches:

➢ Shree Patel Industries (Gujarat)

➢ SPI Auto India Pvt. Ltd. (Gujarat)

➢ Vaishali Auto Industries (Gujarat)

➢ Shree Patel Industries (Uttaranchal)

1.3 Aim & Objective & Achievements:

➢ Achieve zero level defect.

➢ Increase productivity.

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 ➢ Reduce inventory levels, cost & production lead time.

➢ Achieve 100% customer satisfaction.

➢ Increase profitability of the organization.

➢ Reduce cost of poor quality.

1.4 Customers of company:

➢ Tenneco Automotive Ltd

➢ Ashok Leyland Ltd

➢ Endurance Technologies Ltd

➢ Gabriel India Ltd

➢ Sanjeev Auto Parts Manufacturers Pvt. Ltd

➢ Aurangabad Auto Eng. Pvt Ltd

➢ Tata Motors Ltd

➢ SKF India Ltd

1.5 Machines in Industry:

Machine Name Quantity

Straightening machine 1

Press cutting machine 2

CNC machine 28

Hex punching 2

Thread Rolling machine 9

Induction Hardening machine 2

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 Milling machine 3

Centreless Grinding machine 12

Drilling machine 5

Zinc plating machine 2

Etching machine 2

Blister machine 1

Coolant filtration plant 1

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 2. Power Distribution

2.1 Schematic Diagram of Power Distribution:

11 KV Distribution
Line

Industry Transformer

Power Factor (PF)

Panel

Main Panel

Distribution Panel

Various Machine’s
Control Panel

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2.2 Description about Power Distribution:

Fig. 2.1 Transformer Ratings

Transformer Ratings:

Power 315 KVA Windings Copper

Voltage in HV side 11000 V Frequency 50 Hz

Voltage in LV side 433 V Total Weight 1930 Kg

Current in HV side 16.53 A Oil Quantity 375 Litre

Current in LV side 420.01 A Temp. rise in Oil 45 oC

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 ➢ The supply from distribution line is 11 KV. The 11 KV line connected to industry step
down transformer that is 315 KVA. Transformer step down the voltage from 11 KV to
440 V. Transformer ratings are in fig 2.1.
➢ In transformer Primary side voltage is 11 KV and Secondary side voltage is 440 V.
The current in primary side is about 16 A and secondary side is about 420 A.
➢ The secondary side is connected with main panel board through HRC fuses.
➢ Then main panel board output connected with distribution panel.
➢ The PF panel is connected with main panel for control the power factor. And then the
supply is connected with distribution panel.
➢ The control panel of various machines like straightening machine, CNC machine,
thread rolling machine, grinding machine, induction hardening machine etc. is
connected with distribution panel.

2.3 PF panel and its Components:

1. MCCB (Moulded Case Circuit Breaker):

Fig. 2.2 MCCB

➢ MCCB is a protection device that is used to protect the whole circuitry from overload
current.

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➢ It provides protection against overload and short circuit faults. Also used for switching
the circuits.
➢ MCCB shut down the system whenever there is an overload current flowing through it.
➢ There are 3-phase MCCB and its rated current is 40 A.
➢ MCCB uses a temperature sensitive device (the thermal element) with a current
sensitive electromagnetic device (the magnetic element) to provide the trip mechanism
for protection.

2. Capacitor Bank:

Fig. 2.3 Capacitors

➢ A capacitor bank is to provide desired reactive power to the inductive loads and raise
the voltage according to the required system strength and capacitor bank size.
➢ Thus, due to the capacitor bank there is improving the power factor.
➢ A Capacitor bank provide leading reactive power that cancel out the lagging reactive
power.
➢ Therefore, the power factor is improving which range is between 0.93 to 0.98.
➢ A capacitor bank installed parallel to the load provides this reactive power. It reduces
the phase difference between the voltage and current.

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 3. Control Panel and its Components

3.1 Introduction to control panel:

➢ An electrical control panel is a combination of electrical devices which use electrical

power to control the various mechanical functions of industrial equipment or
machinery. An electrical control panel includes two main categories: panel structure
and electrical components.
➢ The panel structure of an electrical control panel is a metal box with a back panel that
looks similar to a breaker box. There is an enclosure with one or two doors, depending
on its size, made of metals like steel or aluminium. it also has a panel mounted at the
back of the metal box, which supports the wire ducts.
➢ In control panel so many electrical and electronic equipments are used like contactors,
MCCB, MPCB, PLC, Relay, VFD (Variable Frequency Drive), Servo drive.
➢ There can be multiple electrical components present in an industrial control panel,
depending on the functions it has to perform.
➢ An electrical control panel is an enclosure, typically a metal box or plastic moulding
which contains important electrical components that control and monitor a number of
mechanical processes.
➢ Operators will interact with the controls of the panel to operate and control the plant
and process.
➢ Control panel is a cabinet which contains electrical components to control the motors
and equipments.

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3.2 Components of Control Panel:

1. MCCB (Moulded Case Circuit breaker):

Fig. 3.1 MCCB

➢ MCCB is a protection device that is used to protect the whole circuitry from overload
current.
➢ It provides protection against overload and short circuit faults. Also used for switching
the circuits.
➢ MCCB shut down the system whenever there is an overload current flowing through it.
➢ There are 3-phase MCCB and its rated current is 40 A.
➢ MCCB uses a temperature sensitive device (the thermal element) with a current
sensitive electromagnetic device (the magnetic element) to provide the trip mechanism
for protection.

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2. MPCB (Motor Protection Circuit Breaker):

Fig. 3.2 MPCB

➢ A motor protection circuit breaker is an electromagnetic device.

➢ A MPCB is using for motor protection against overload current and short circuit
current.
➢ It has internal contacts that connect the power supply line to the load.
➢ In event of overload or short circuit, the MPCB automatically disconnect the circuit.
➢ When an internal coil detects the short circuit current or overload current, the coil
determines the opening contact.
➢ It can be used for both frequency 50 Hz and 60 Hz.
➢ The MPCB can interrupt any electrical fault that is below its breaking capacity.

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3. Contactors:

Fig. 3.3 Contactors

➢ The contactor is an electrical component that serves to connect or disconnect the AC

power.
➢ A contactor is an electrically controlled switch used for switching an electrical power
circuit.
➢ Electric current flows through one contact and into the device in which the contactor is
embedded. Therefore, the function of contactor is to switch an electrical circuit on or
off. Overloading of the circuit can be prevented by adding thermal overload relay.
➢ Generally, the magnetic coil of a contactor is designed to operate at a low voltage such
as 230V AC, 110V AC, 24V DC, etc. So, provide the power supply to the magnetic
coil as per requirement.

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4. SMPS (Switched Mode Power Supply):

Fig. 3.4 SMPS

➢ The SMPS power supply transfers power from a source usually an AC outlet to a
DC device.
➢ The SMPS is an electronic power supply that incorporates a switching regulator
to convert electrical power efficiency.
➢ It is mainly used for obtaining a controlled DC power supply as output. The
SMPS is provide a constant DC output at all time.
➢ It can increase or decrease the output voltage to maintain a constant output
regardless of changes in load.
➢ The purpose of SMPS is to gain the most efficient conversion process.
➢ SMPS is operated by switching and hence the voltages vary continuously. The
switching device is operated in saturation or cut off mode.
➢ The output voltage is controlled by the switching time of feedback circuitry. Switching
time is adjusted by adjusting the duty cycle.

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5. Relay:

Fig. 3.5 Relay

➢ Relays are normally used in the control panels, manufacturing and building
automation to control the power along with switching the smaller current values in a
control circuit.
➢ Relays are switches that open and close circuits electromechanically or electronically.
Relays control one electrical circuit by opening and closing contacts in another circuit.
➢ when a relay contact is normally open (NO), there is an open contact when the relay is
not energized. When a relay contact is Normally Closed (NC), there is a closed contact
when the relay is not energized.
➢ However, the supply of amplifying effect can help control the large amperes and
voltages because if low voltage is applied to the relay coil, a large voltage can be
switched by the contacts.
➢ Protective relays can prevent equipment damage by detecting electrical abnormalities,
including overcurrent, undercurrent, overloads and reverse currents.

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6. VFD (Variable Frequency Drive):

Fig. 3.6 VFD

➢ A variable frequency drive, is a type of a motor control electrical device for starting
and controlling an AC inductive motor and its speed with varying frequency (Hz) and
voltage.
➢ A VFDs manipulate the frequency of their output by rectifying an incoming AC
current into DC, and then using voltage pulse width modulation to recreate an AC
current.
➢ VFDs save energy by enabling electric motors to operate at less than full speed.
➢ A VFD transforms the input mains of constant frequency into a frequency range that
can be varied to control motor speed.
➢ This Drive is for speed control of Induction motor.

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7. Servo Drive:

Fig. 3.7 Servo Drive

➢ This is a device that is used with servo motor. The servo drive controls the servo motor
according to instruction from PLC or another controller.
➢ A servo drive receives command signal from a control system, amplifies the signal,
and transmits electric current to servo motor in order to produce motion proportional to
the command signal.
➢ Servo drive is to translate low power command signals from the controller into high
power voltage and current to the motor.
➢ The servo drive can regulate and properly coordinate the motor’s desired position,
speed, torque etc.
➢ Servo drive is only for speed control of servo motor.

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8. PLC (Programmable Logic Controller):

Fig. 3.8 PLC

➢ PLCs are small industrial computers with modular components designed to automate
customized control processes.
➢ PLC used in many industries to control the production process.
➢ PLCs are often used in factories and industrial plants to control motors, pumps and
other machinery.
➢ There is main three components of PLC are:
1. Processor (CPU) 2. Inputs 3. Outputs
➢ PLCs are fast, easy to operate and are considered easy to program.

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9. Line Reactor:

Fig.3.9 Line Reactor

➢ A line reactor is a variable frequency drive (VFD) accessory that consists of a coil of
wire that forms a magnetic field as current flows through it.
➢ This magnetic field limits the rate of rising of the current, thus reducing harmonics and
protecting the drive from power system surges and transients.
➢ The additional reactance added in series with the system for protection, are called
reactors.
➢ A reactor is a coil which has large number of turns and whose ohmic resistance value
is much greater.
➢ Reactors may be tapped so that the voltage across them can be changed to compensate
for a change in the load that the motor is starting.

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 4. Machining plant and Plating Plant

4.1 Electrical parts in machining plants:

1. Induction Motor:

Fig. 4.1 Induction Motor

➢ Three phase induction motors are widely used in different types of industry because
they are self-starting, reliable and economical.
➢ Working principle of three phase induction motor is faraday’s law of electromagnetic
induction.
➢ When the motor is excited with a three-phase supply, three-phase stator winding
produces a rotating magnetic field.
➢ This changing magnetic field cuts the rotor conductors and induces a current in them
and rotor starts rotating.
➢ For the speed control of 3-phase induction motor they are used variable frequency
drive (VFD).

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2. Servo Motor:

Fig. 4.2 Servo motor

➢ A servo motor is an electromechanical device that produces torque and velocity based
on the supplied current and voltage.
➢ Servo motors are available in an extensive variety of types, shapes and sizes.
➢ A servo motor works as part of a closed loop system providing torque and velocity as
commanded from a servo controller utilizing a feedback device to close the loop.
➢ A servo motor converts electrical energy into rotational motion.
➢ The function of the servo motor is to convert the control signal of the controller into
the rotational angular displacement or angular velocity of the motor output shaft.
➢ Generally, it is used for high starting torque for the industrial application.
➢ For the speed control of servo motor, they are used servo drive.

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4.2 Electrical part in plating plant:

1. Electroplating Rectifier:

Fig. 4.3 Electroplating Rectifier

➢ Rectifier is a rectifying device. It is high frequency switching power supply unit which
can convert AC (alternating current) to DC (direct current).
➢ Electroplating rectifiers is an equipment that converts AC into DC supply.
➢ Electroplating rectifier has two main components: Transformer and Diodes.
➢ The diodes are mounted on heat sinks. Heat sink absorbs the heat that is produced by
diode when its works.
➢ Whole circuit (Transformer and Diodes) are dipped in oil tank. The oil provides
cooling and insulation.
➢ The input voltage of rectifier is 400-440 V. It is three phase AC supply with 50 Hz
frequency.

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 ➢ The output voltage is variable DC from zero to maximum rated voltage.
➢ The output current is maximum rated DC current.

4.3 Tools and Equipments used in Plants

1. Clamp Meter:

Fig. 4.4 Clamp meter

➢ A clamp meter is an electrical test tool that combines a basic digital multimeter with a
current sensor.
➢ It is one type of multimeter that measure current, voltage both AC and DC, resistance
etc.
➢ A clamp meter is an instrument that can be clamped around a live wire in order to
measure the current it’s carrying.
➢ Clamp meter detect the magnetic field emitted by current flowing in a wire in
order to measure the current value.
➢ This design has the advantage of being able to measure current without requiring
that the circuit under measurement be cut.

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2. Multimeter:

Fig. 4.5 Multimeter

➢ A multimeter is a measuring instrument that can measure multiple electrical properties.

➢ A typical multimeter can measure voltage, resistance, and current, in which case it is
also known as a volt-ohm-milliammeter (VOM), as the unit is equipped
with voltmeter, ammeter, and ohmmeter functionality.
➢ A digital multimeter is a test tool used to measure two or more electrical values.
➢ It features a large backlight LCD, auto power off and an audible buzzer system.
➢ The multimeter also can perform the continuity and diode test.

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2. Tachometer:

Fig. 4.6 Tachometer

➢ It is digital device that measures the speed of the rotating object.

➢ The tachometer is a measuring instrument that is used to measure the operating speed
of a motor in revolutions per minute.
➢ It is measure the rotation speed of a shaft or disc, as in a motor or other machine.
➢ The device can measure the rotational speed of the shaft or disc when the motor is in
motion.
➢ It also indicates the angular speed of a rotating shaft.

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 Conclusion

It was a wonderful learning experience at SHREE PATEL INDUSTRIES for two weeks
internship. I gained a lot of insight regarding almost every aspect of plant. I gained more
information and knowledge related to my branch. I was given exposure in almost all the
departments at the plant. All the employees are appreciating, sharing their experience and
giving their peace of wisdom which, they have gained in long journey of work. I am very
much thankful for the wonderful facility from SPI. I hope this experience will surely help me
in my future and also in shaping my career.

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 Reference

➢ https://www.inductiveautomation.com/resources/article/what-is-a-PLC
➢ https://www.arrow.com/en/research-and-events/articles/switch-mode-power-
supply#:~:text=Like%20other%20types%20of%20power,regardless%20of%20change
s%20in%20load.
➢ https://www.shakedeal.com/blog/what-is-tachometer-and-its-
uses/#:~:text=An%20Electric%20Tachometer%20works%20on,crankshaft%20is%20
making%20per%20minute.
➢ https://www.powerengineers-india.com/electroplating-rectifiers.html

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