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Project ID: 416373
INTERNSHIP AT JAKSON LTD

INTERNSHIP REPORT
Submitted by
SAINI BHASKAR SHANKAR LAL
200190109045
In fulfillment for the award of the degree of
BACHELOR OF ENGINEERING
in
Electrical
Department
Government Engineering College, Valsad
Gujarat Technological University, Ahmedabad
May, 2024
Gujarat Technological University i Government Engineering College,Valsad

Project ID: 416373
Near Sanskar Kendra, Behind B.K.M. Science
College, Tithal Road, Valsad – 396001
CERTIFICATE
This is to certify that the internship report submitted along with the entitled
INTERNSHIP AT JAKSON has been carried out by SAINI BHASKAR
SHANKAR LAL under my guidance in fulfillment for the degree of Bachelor
of Engineering in Electrical Department, 8th Semester of Gujarat
Technological University, Ahmedabad during the academic year 2022-23.
Prof. N. I. Patel Prof. K. L. Mokariya
Internal Guide Head of the Department
Gujarat Technological University ii Government Engineering College,Valsad

Project ID: 416373
Gujarat Technological University iii Government Engineering College,Valsad

Project ID: 416373
Gujarat Technological University iv Government Engineering College,Valsad

Project ID: 416373
Near Sanskar Kendra, Behind B.K.M. Science
College, Tithal Road, Valsad – 396001
DECLARATION
I hereby declare that the Internship report submitted along with the entitled
INTERNSHIP AT JAKSON submitted in partial fulfillment for the degree of
Bachelor of Engineering in Electrical Department to Gujarat Technological
University, Ahmedabad is a bonafide record of original project work carried out
by me at Jakson Limited, Kalsar under the supervision of Mr. Ajaykumar M.
Contractor and that no part of this report has directly been copied from any
students’ reports or taken from any other source, without providing due
reference.
Name of the student Sign of Student

SAINI BHASKAR SHANKAR LAL
Gujarat Technological University v Government Engineering College,Valsad

Project ID: 416373
Acknowledgement
The successful completion of an internship depends upon the way the students
studied each and every aspect in the industry and also how they were taught by
the industry people. For me I had a very well balance indeed in both these aspects.
So, I can say that my internship has been successful due to my Industry guide
Mr. Ajaykumar M. Contractor .
I would like to thank H. R. Viral Dodia sir for giving me the support for internship
in the workshop. It has been a wonderful and knowledgeable 3 months there.
Hence, I take this opportunity to express my sincere gratitude to all the staff
members of Jakson Limited, Kalsar who gave their precious time in explaining
the fundamentals of genset. Even if they had work, they came forward and cleared
all the concepts which was related to their respective sections.
I would also like to thank all the section heads who gave their support in my
internship by introducing me with the knowledgeable persons of their sections
and also gave proper guidance.
I would also like to thank my internal guide Prof. N. I. Patel who also helped in
clearing some concepts and shared his knowledge of genset.
Last but not the least I would also like to thank my parents without whom I
would not have been able to grab this golden opportunity.
Gujarat Technological University vi Government Engineering College,Valsad

Project ID: 416373
Abstract
In this internship report, I have mentioned all of my learnings and experiences I
have gained at Jakson Limited.
Jakson Limited has 75 years of expertise in Gensets and is the leading

manufacturers in India.
Throughout my tenure at Jakson Limited during my internship, I had the invaluable

opportunity to immerse myself in the intricate workings of gensets and explore a
diverse array of panel types, enriching my understanding and expertise in these
crucial aspects of the industry.
During my internship at Jakson Limited, the focus extended beyond mere technical
knowledge; it delved into the intricate workings of the industry itself. I had the
privilege to witness the entire lifecycle of a genset, from the manufacturing process
of the canopy to the meticulous final assembly, encompassing every intricate part
required to complete it. Moreover, I gained firsthand insight into the stringent
quality procedures and adherence to IS standards, thus broadening my
understanding of the meticulous standards upheld in the industry.
I was involved in range of tasks like testing of Panels and making of Bill Of
Material which is necessary to make a DG genset, by collaborating with engineers
and technicians in the company. I also gained practical skills in manufacturing
techniques and processes. Understood the importance of quality assurance and
control in Panel Production. Also learnt about industrial standards and regulations.
Gujarat Technological University vii Government Engineering College,Valsad

Project ID: 416373
List of Figures
Figure 1-1: Jakson Headquarters................................................................................................2
Figure 1-2: Acoustic enclosure..................................................................................................3
Figure 1-3: Base frame ..............................................................................................................4
Figure 2-1: Organisation Chart..................................................................................................6
Figure 3-1: Flow of Manufacturing Process............................................................................10
Figure 3-2: HRCA Sheet..........................................................................................................11
Figure 3-3: CRCA Sheet..........................................................................................................11
Figure 4-1: CNC Punching Machine........................................................................................15
Figure 4-2: Bending Machine .................................................................................................16
Figure 5-1: Pre-treatment.........................................................................................................20
Figure 6-1: Electron Gun ........................................................................................................23
Figure 6-2: Curing....................................................................................................................23
Figure 7-1: MAG welding & TIG welding..............................................................................26
Figure 8-1: AMF panel.............................................................................................................28
Figure 8-2: Manual panel.........................................................................................................29
Figure 8-3: Control panel.........................................................................................................30
Figure 8-4: Power panel...........................................................................................................31
Figure 8-5.1: Battery charger panel.........................................................................................34
Figure 8-5.2: Battery charger panel.........................................................................................34
Figure 8-6: Auto start stop panel..............................................................................................35
Figure 8-7 Sync panel..............................................................................................................36
Figure 9-1: SAP logo...............................................................................................................39
Gujarat Technological University viii Government Engineering College,Valsad

Project ID: 416373
List of Tables
Table 3-1: Sheet Comparison...................................................................................................12

Table 3-2: Sheet IS Standards..................................................................................................13
Gujarat Technological University ix Government Engineering College,Valsad

Project ID: 416373
List of Abbreviations
SAARC South Asian Association for Regional Coordination
HRCA Hot Rolled Close Annealed
CRCA Cold Rolled Close Annealed
CNC Computerized Numerical Control
MWp Mega Watt-peak
GW Gigawatt
NTPC National Thermal Power Corporation
EPC Engineering Procurement & Construction
CPCB Central Pollution Control Board
DG Diesel Generator
IS Indian Standard
HRSPO Hot Rolled Pickled and Oiled or Hot-Rolled, Pickled, Skin passed and Oiled
GI Galvanized Iron
CE "Conformité Européenne," which means "European Conformity”
WDO Water Drying Oven
PH Potential of Hydrogen
UV Ultra Violet
VOCs Volatile Organic Compounds
TIG Tungsten Inert Gas
MIG Metal Inert Gas
MAG Metal Active Gas
DC Direct Current
CO2 Carbon Dioxide
Gujarat Technological University x Government Engineering College,Valsad

Project ID: 416373
HR Human Resources
LKVA Low Kilo-volt Ampere
KVA Kilo-volt Ampere
LHP Low Horse Power
MHP Medium Horse Power
HHP High Horse Power
AVM Anti Vibration Mounts
PDI Pre-Dispatch Inspection
EOT Electrical Overhead Travelling Crane
PPC Production Planning and Control
Gujarat Technological University xi Government Engineering College,Valsad

Project ID: 416373
Table of Contents
Acknowledgement..................................................................................................................................vi
Abstract..................................................................................................................................................vii
List of Figures.......................................................................................................................................viii
List of Tables..........................................................................................................................................ix
List of Abbreviations...............................................................................................................................x
Table of Contents...................................................................................................................................xii
CHAPTER 1 OVERVIEW OF JAKSON GROUP.................................................................................1
1.1 : HISTORY OF JAKSON GROUP...............................................................................................1

1.2 : ABOUT THE COMPANY..........................................................................................................2
CHAPTER 2 KALSAR PLANT.............................................................................................................5
2.1 : UNIT – 1......................................................................................................................................7
2.2 : UNIT – 2......................................................................................................................................8
2.3 : UNIT – 3......................................................................................................................................8
2.4 : UNIT – 4......................................................................................................................................9
CHAPTER 3 MANUFACTURING PROCESS OF AE.......................................................................10
3.1 : HRCA SHEETS........................................................................................................................10

3.2 : CRCA SHEETS.........................................................................................................................11
3.3 : DIFFERNCE BETWEEN CRCA AND HRCA SHEETS........................................................12
3.4 : LIST OF HRCA AND CRCA SHEETS USED IN INDUSTRY.............................................13
CHAPTER 4 CNC PUNCHING MACHINE........................................................................................14
4.1 : BENDING MACHINE...............................................................................................................15

4.2 : METAL SHEET BENDING MACHINE..................................................................................16
4.3 : HYDRAULIC PRESS BRAKE MACHINE..............................................................................17
4.4 : ADVANTAGES OF HYDRAULIC PRESS BRAKE MACHINE...........................................17
CHAPTER 5 PRE-TREATMENT........................................................................................................18
CHAPTER 6 POWDER COATING.....................................................................................................22
CHAPTER 7 FABRICATION..............................................................................................................25
7.1 : TIG WELDING.........................................................................................................................25

7.2 : MIG WELDING........................................................................................................................25
CHAPTER 8 DIFFERENT PANELS FOR DG....................................................................................27

8.1 : AMF PANEL.............................................................................................................................27
8.2 : MANUAL PANEL....................................................................................................................29
Gujarat Technological University xii Government Engineering College,Valsad

Project ID: 416373
8.2.1 : CONTROL PANEL...........................................................................................................29
8.2.2 : POWER PANEL...............................................................................................................31
8.3 : BATTERY CHARGER PANEL...............................................................................................34
8.4 : AUTO START STOP PANEL.................................................................................................35
8.5 : SYNC PANEL...........................................................................................................................36
CHAPTER 9 DESIGN DEPARTMENT...............................................................................................39
CHAPTER 10 FUTURES SCOPE........................................................................................................41
CHAPTER 11 CONCLUSION..............................................................................................................42
CHAPTER 12 REFERENCES..............................................................................................................43
Gujarat Technological University xiii Government Engineering College,Valsad

Project ID: 416373 OVERVIEW OF JAKSON GROUP
CHAPTER 1 OVERVIEW OF JAKSON GROUP
Jakson Group is a Noida based company which was established in the year 1947. The
company has 75 years of expertise in gensets and is the leading manufacturers in India. Also,
with its green project it has become one of the top 10 manufacturers of solar panels in India.
It has also done projects for the government like setting up solar plants at President’s office,
Airports. With such hard work and dedication to do something for the nation the company
has also collaborated with Indian army to make extreme level gensets for them and also make
engines for their tanks and big guns. Jakson has also contributed in the electrification of some
villages and has also partnered with Government to complete the metro project in Kolkata.
Jakson Green which is the new green energy platform of Jakson Group has bagged a 121
MWp solar EPC order from Amplus Solar which is India’s leading distributed solar energy
provider. Jakson Green has also got the opportunity to build the world’s first Methanol
production plant in partnership with NTPC. On the top of that the company has secured over
1 GW of renewable EPC orders across India, Africa and the middle east region and has
achieved a major milestone record in a short span. Recently the company also announced to
build India’s first urban-centric green hydrogen fueling station at Badarpur, New Delhi which
will contribute in minimizing pollution.
1.1 : HISTORY OF JAKSON GROUP
Jakson Group was established in the year 1947 in Delhi by Satish Gupta who is the owner of
the company. The company started and installed its first genset manufacturing plant in the
year 1979. Till then it was an electrical equipment selling company. In the year 1982, the
company collaborated with Cummins Inc. for genset manufacturing and has since then been a
successful manufacturer of gensets in India. In the year 2005 the company became India’s
leading genset manufacturing company. It has established dedicated plants for genset
manufacturing in Kathua, Jammu & Kashmir and Daman in the year 1979 and 2000
respectively. In Kathua plant high rating gensets are manufactured whereas in Daman plant
Low, medium and certain high rating gensets are manufactured. With its growing market
value and as a responsible company Jakson group took its step forward in green energy by
announcing solar manufacturing dedicated plant in the year 2012. In the year 2011, the
Daman plant was shifted at Kalsar where it is now currently making its DG sets with great
efficiency. The Kalsar plant is 17 acres and the largest plant in the whole company. The
headquarters of Jakson group is established in
Gujarat Technological University 1 Government Engineering College,Valsad
Noida, Uttar Pradesh where also two plants were completed in the year 2014 as announced
for solar energy for the betterment of society. The two plants manufacture solar panels and
battery based energy systems respectively. Also the company makes kits and inverters related
to solar panels and also its supporting structure and battery management system. Jakson has
expanded their work globally in different branches such as Eletrcial transmission, EPC, Solar,
Battery systems, etc. The company is also a part of SAARC which has Asian country
members and has done project across the countries like in South Africa. The Kathua Plant is
soon to be shifted at Phaltan,Maharashtra near Pune whose work is going on with great
enthusiasm.
Figure 1-1: Jakson Headquarters
1.2 : ABOUT THE COMPANY
Jakson manufacturing plant in Kalsar, Gujarat was established in the year 2011 and serves as
an integrated plant for manufacturing acoustic enclosures and DG Sets. The plant has an
installed capacity of 14,000 DGs and 20,000 enclosures annually. It has a total manufacturing
space of 3.5 lakh square feet and is spread across 17 acres.
The Jakson Kalsar plant comprises of 4 units where vivid different work is been carried out
in each of the unit. The manufacturing begins from the production of the base frame which is
required to be of good quality as it has to be endured all the weather conditions around the
world. According to the ratings of the gensets the canopy is manufactured in different units.
The Plant manufacture DGs from lower ratings to high power ratings. They can be broadly
classified in four sections:
1.LKVA from 7.5 -62.5
2.LHP from 82.5-160
3. MHP from 180-500
4.HHP from 500-1500
The Acoustic enclosures manufactured can be broadly classified in four ways:
1. Standardize A. Es
2. CPCB A. Es
3. Defense Special A. Es
4. Customized A. Es
Figure 1.2: Acoustic enclosure
The manufacture of canopy is a step-by-step systematic process which includes quite advance
machineries and technology along with a quite good work force. It starts from the incoming
raw materials such as different types of sheets followed by the fabrication process. Once the
fabrication and cutting part is completed these materials is passed on for further process I.e.
pre-treatment which is a very essential process in all the industry as every industry wants
their product to be of good quality to sustain and compete in market.

After the Pre-treatment process the parts are processed for painting to get aesthetic and eye-
catching look which is a major point as the product should look good. After those different
parts of the canopy are assembled and stuffing of foam is done with adhesive.
Figure 1.3: Base frame

At last, after all this rigorous work process a canopy is ready and handed to production and
assembly unit to assemble the engine (Cummins) and alternator (Stamford) on base frame
and the acoustic enclosure is fitted from top and bolted properly.
Along with the production of canopy jakson also design control panels inhouse of high
standard and automated for controlling and synchronizing of the DG set with the mains.
Some of the specials remote control panel are also designed for special application gensets.
This control panel consist of HMI and microprocessor-based relay which are programmed
with suitable data to function and sense as accurately as possible.
Jakson group also emphasis on reducing pollution as low as possible so for that they also
manufacture CPCB gensets which has a very low carbon emission and going forward can be
a great asset keeping in mind about the environment.
The Jakson group also serve gensets to the ones who serves our country to the defense. They
are special application gensets which are designed to operate in every possible worst weather
condition whether it be rajasthan hot climate or jammu & kashmir cold climate.
As this gensets are used by the defense of our country efforts are made to eliminate all the
possibilities of non-functioning of gensets and due to it all the things used in this gensets are
double so that failure of operations is as low as possible.

Project ID: 416373 KALSAR PLANT
CHAPTER 2 KALSAR PLANT
The Kalsar Plant was started in the year 2011 which is a village in the Valsad district of
Gujarat. This plant is of 17 acres and is widespread on a very green area where there are
plants and pure air everywhere thus making it a nature friendly industrial plant. In this plant
in house manufacturing of acoustic enclosures and base frame are done for the Cummins
generator to make it a silent powered genset according to the CPCB standards. As you enter
the company there is an Admin building/Main building where the HR, management staff and
Plant head’s office are located. There is total 4 Manufacturing units in this plant namely Unit
– 1,2,3,4 respectively and 2 stores namely Main store and LKVA store along with a
maintenance department workshop. In Unit – 1 small rating DG canopy are manufactured
from 7.5 KVA to 180 KVA. In Unit – 2 medium and high rating DG canopy are
manufactured from 200 KVA to 1500 KVA. Also, in Electrical Panels are manufactured for
different customer requirements namely Manual Panel, AMF Panel, Isolating Panel,
Capacitor Panel, Synchronizing Panel. In Unit – 3 Assembly of all DG parts are done
including base frame and canopy after which the load test is done for the genset to check
whether it is proper functioning or not. In Unit – 4 base frames are manufactured. Special
projects like the Dhanush gun engine and genset for army base camp are also made and
assembled here which is a real honour. To be perfect in these products extra testing is done.
The genset is run for 24 hours and then transport test is done with full fuel to check leakage.
Weather test is also done as army camps are located at harsh weather locations.

ORGANISATIONAL CHART:
Figure 2-1: Organisation Chart
SUBSTATION:
The substation consists of 750 KVA transformer and an electrical panel with capacitor bank
and Automatic Power Factor controller to keep the power factor leading.
Transformer data:
KVA = 750
KW = 705
11 KV / 415 V
Maximum Ampere = 65.6 A / 1000 .05 A
Capacitor Bank = 25, 15, 10, 7, 5, 2 KVAR respectively

Load Data of plant:
Demand contract = 450 KVAH
Actual maximum demand = 383 KVAH
85% of contact demand can be used = 383
KVAH Last month KWH = 116058
Last month KVAH = 123303
Average power factor = 0.94
Net bill payment = 963456 Rs.
Motors Used in Plant:
EOT Crane: 3, 5, 10, 15 HP Motors Total 20 in number with KW Ratings 2.23, 3.73, 7.46,
11.19 KW respectively.
Compressor: 30 KW Total 2 in number.
Backup DG used in Plant:
500 and 125 KVA used for plant purpose
40 KVA used for Admin Building
2.1 : UNIT – 1
In this unit the canopy of 7.5 to 180 KVA and the canopy of special project URJA are made.
The colour used in this unit for powder coating is cummins green. The CNC punching
machine used is AMADA EM2510 NT 220 ton machine. The bending machine used are of
AMADA company of 125 and 130 ton respectively. There are six fabrication stations where
two are of TIG welding and four are of MAG welding. Then there are the 9 tanks of 17000
litres each for the pretreatment process. The whole pretreatment process takes a time of 57
mins. After this the powder coating area is there which is suspended on 32 load bars on
econveyor.

2.2 : UNIT – 2
In this unit the canopy of 200 to 1500 KVA are manufactured. The colour used in this unit for
powder coating is harmony green. The CNC punching machine used is EM 2510 NT 125 ton
machine. Th ebending machine used are of AMADA company 125 and 130 ton respectively.
There are six fabrication stations where two are of TIG welding and four are of MAG
welding. Then there are the 9 tanks of 17000 litres each for the pretreatment process. The
whole pretreatment process takes a time of 57 mins. After this the powder coating area is
there which is suspended on 32 load bars on th econveyor. The whole powder coatin process
tkes a time of 85 mins 10 secs. The canopy made are also then assembled and stuffing is
applied over it.
2.3 : UNIT – 3
In this unit assembly of all the DG’s are done and their load testing and Pre Dispatch
Inspection are done here. The assembly is done in four stages:
1. The base frame comes from unit – 4 and AVM are bolted to the places where the engine
and alternator are to be placed.
2. The engine, alternator and radiator are the mounted in the base frame and bolted accordingly.
3. The extra support items such as pipes radiator guard are attached to the required parts.
4. the canopy is places in top of the assembly and bolts are attached and finally the genset is
ready.
After the genset is ready load test is done using load bank of required rating as per the genset
rating. There are two types of load bank available which are resistive heat load bank and
inductive load bank. In the resistive head load bank water is added to increase the load on the
genset whereas in inductive load bank direct switching is done using buttons and resistance
and inductance is varied automatically inside the circuit. After the load test is done the genset
is placed in the PDI area where it waits for the Pre dispatch inspection. In PDI the quality
teamchecks the parameters of the genset such as proper connections, mountings and all other
specifications as per the PDI check list and then only the product is certified ok by quality
assurance team.

2.4 : UNIT – 4
In this unit the base frame for all the gensets are manufactured. For the base frame 3 to 4 mm
HRCA sheets are used and they are painted black in colour as the base frame is at the bottom
and it has to face many foreign particles on the ground so it has to be a durable colour. The
sheets are bended and welded as per the requirement and for proper shape fixtures are already
made aa per the design parameters. The sheets are to be placed into these fixtures for proper
making of the base frame. In 7.5 to 500 KVA genset the tank is made in the base frame itself,
whereas for the 125 and above 500 KVA gensets the tank is provided separately. As for small
DG sets the tank is provided in the base frame the leak test is also done to check whether the
fuel won’t leak from the tank after supply.

Project ID: 416373 MANUFACTURING PROCESS OF AE
CHAPTER 3 MANUFACTURING PROCESS OF AE
The company jakson limited manufactures two major components of DG set that is the
acoustic enclosure and base frame. The enclosure is used to give mechanical and physical
protection to the DG and reduce the noise level of the machine and the role of base frame is
to provide a strong base to support the engine and alternator, so to produce a better-quality
enclosure and base frame we require suitable sheets.
Figure 3-1: Flow of Manufacturing Process
The sheets used are: CRCA and HRCA sheets for acoustic enclosure(canopy) and base
frame production respectively
3.1 : HRCA SHEETS:
Hot rolled close annealed sheets are rolled above its recrystallization temperature which is
usually 1000 degrees Celsius. During heating, the metal goes through different stages. Due to
this, the properties of the metal are also get altered.
Dimensional accuracy and surface finish are poor in hot rolled steel. Hot rolled steel is
usually softer compare to cold rolled steel due to heating. Due to poor surface finish, HRCA
sheets are not used in precision parts.
One more issue with the HRCA sheet is that, when it is cooled after heating, it changes the
size and shape due to shrinking. This is one more reason HRCA sheet is not used in
applications where higher dimensional accuracy is expected.
Due to above reasons the HRCA sheets are used in manufacturing of base frame. The
company uses standardize HRCA sheets of D IS 2062 standard and uses different dimension
sheets from 3mm to 4mm thickness.

Figure 3-2: HRCA Sheet
3.2 : CRCA SHEETS:
A cold rolled close annealed sheet is cold-rolled sheet metal. These cold rolled sheets are
rolled under recrystallization temperature which is usually 50-degree Celcius. The carbon
content is usually low in the CRCA sheet as the composition is not altered by heating. Cold-
rolled sheets are much harder and finishes are much better than hot rolled steel.
Also, the achieved dimensional accuracy is good since there is no heating of the material.
The surface of the cold-rolled close annealed sheet is of smooth blue-gray finish with square
corners. Since there is no heating, dimensional accuracy is very high, and that is why you
may get sheets of less than .01 inch thickness also.
Due to above reasons the CRCA sheets are used in manufacturing of canopy. The company
uses standardize CRCA sheets of D IS 513 standard and uses different dimension sheets
having 1.2mm,1.5mm,1.9mm,2mm,2.5mm,3mm of thickness.
Figure 3-3: CRCA Sheet

3.3 : DIFFERNCE BETWEEN CRCA AND HRCA SHEETS:
CRCA SHEET HRCA SHEET
COLD ROLLED CLOSED ANNEALED SHEET HOT ROLLED CLOSED ANEALLED SHEET
ROLLED BELOW RECRYSTALLIZATION ROLLED ABOVE RECRYSTALLIZATION

TEMPERATURE TEMPERATURE
SMOOTH SURFACE FINISH ROUGH SURFACE FINISH

GOOD DIMENSION ACCURACY POOR DIMENSION ACCURACY
NO CHANGES IN CHEMICAL COMPOSITION CHEMICAL COMPOSITION MAY CHANGE
SUITABLE IN PRECISION PARTS NOT SUITABLE IN PRECISION PARTS
COSTLY CHEAP
LESS CARBON CONTENT MORE CARBON CONTENT
USED IN CANOPY USED IN BASE FRAME
Table 3-1: Sheet Comparison

3.4 : LIST OF HRCA AND CRCA SHEETS USED IN INDUSTRY:
Mostly HRCA and CRCA sheets are used of different dimensions, and the sheets are
inspected and check and then used for further processes. The HRSPO sheets mentioned in the
list are used for special customer orders and similarly GI sheets are used in making electric
panels for DG set. A short list of sheets used in industry is shown in the below table.
TYPES OF SHEETS DIMENSIONS(MM) IS STANDARDS
CRCA 1.2X1250X2500 D IS 513

CRCA 1.5X1250X2000/2500/ D IS 513
2900/3000
CRCA 1.9X1250X2500/3000 D IS 513
CRCA 2X1250X2900 D IS 513
CRCA 2.5X1250X1700/2500 D IS 513
CRCA 3X1250X2500/2700 D IS 513
HRCA 3X1250X2500/2700 D IS 2062
HRCA 3X1510X2310/2700 D IS 2062
HRCA 4X1250X2800/3000/3860/ D IS 2062
4000/4200
HRSPO 3X1250X2400 D IS 2062
GI 2X1250X2500 STD MS
Table 3-2: Sheet IS Standards

Project ID: 416373 CNC PUNCHING MACHINE
CHAPTER 4 CNC PUNCHING MACHINE

Computer numerically controlled (CNC) punching is a sheet metal manufacturing process
that is carried out by CNC punch presses. These machines can be either a single head and
tool rail design or multi-tool turret design. The CNC punching machine is basically
programmed to move a sheet of metal in an x and y direction so as to accurately position the
sheet under the machine’s punching ram ready to punch a hole or form.
The processing range for most CNC punch presses is 0.5mm to 6.0mm thick in a range of
materials including steel, zintec, galv, stainless steel and aluminium.
In Jakson limited company, the CRCA (Cold Rolled Close Annealed) OR HRCA (Hot Rolled
Close Annealed) sheets with 1.5 mm, 2mm, 2.5mm & 3 mm thickness are taken as per design
and then they are placed in CNC Punching Machine where the machine is computer
programmed and has 45 tools for cutting different shapes.
The choice of hole punched can be as simple as a circle or rectangle right through to special
shapes to suit a specific cut out design. By using a combination of single hits and overlapping
geometries, complex sheet metal component shapes can be produced.
Standard features:
• High speed servo-controlled punching head
• 4 Repositioning cylinders (2 upper, 2 lower)
• 3 Hydraulic sheet clamps
• 4 Vibration dampers
• 45 tools stations complete with tool holders
• Slug suction device
• Part chute door 300x470mm
• Quick tool set for tool alignment
• CE optical safety light
• Automatic oil spray machine

Figure 4-1: CNC Punching Machine
4.1 : BENDING MACHINE: -
A bending machine is referred to as a primarily used machine which is mainly used to form a
bend on any required work piece. The machine is used to make use of the bending tool which
is present in it and is responsible for the process.
In Jakson limited company, 125 tonne and 130 tonne Hydraulic Press Brake Machine is used
for bending process. In which the different size of V shape dye and punch is used.
- For 1.5 mm sheets- 14 mm V Shape die and 20 mm Punch is used.
- For 2.0 mm sheets- 14 mm or 16 mm V Shape die and 20 mm Punch is used.

Figure 4-2: Bending Machine
4.2 : METAL SHEET BENDING MACHINE
The sheet bending machine is mainly selected for the purpose of creating a bend in the metal
sheets. The metal pieces are initially fixed on the clamping device which is known to hold
them during the complete operating process. The nature of this bending machine is found due
to an unknown fact which is that they are manufactured by using a very high-grade raw
material.
A sheet folding machine is referred to as an instrument which is used to bend the objects at
any particular angle. This profile of bending machine is referred to as a pipe bending machine
as it is used mainly with an aim to bend the pipe objects. Mainly this type of machine is
found suitable to be used whenever it comes to any bending objects like a pipe, tube, etc. The
profile bending machines are the ones which are used due to their highly accurate quality and
is preferred amongst most of the users.

4.3 : HYDRAULIC PRESS BRAKE MACHINE
All the technically superior and perfectly engineered instruments are found to consume less
electricity and are even found having minimum maintenance. Mostly due to the rear
cylinders, the system is responsible for consuming lower pressure along with the compact
cylinders. The machines with these types of superior quality are found having power to fight
against fatigue failure and the machines have a capacity of better rigidity as well as load
carrying capacity.
These are the tools which are mostly found including features like accuracy, high speed,
minimum wear and tear etc. The tougher will be the hydraulic brake the more it will last
hydraulic. These are found to be simple to operate and are even noise and vibration free.
There are many models of such machines available in the market, which are specifically
designed to set the requirements of the client.
4.4 : ADVANTAGES OF HYDRAULIC PRESS BRAKE MACHINE
There are various advantages of using hydraulic press brake machine one amongst which is
that it offers the machine a huge pressure supplies in almost all the directions. This is done in
order to maintain a good quality of the final product.
One more advantage which is commonly known about the hydraulic press brake is that it is
preferred by the industries as the machine is found to be adaptive and easy to operate. There
are various roles which a machine follows like cutting, bending and spreading of the sheets
that can be easily executed by the usage of the machine.
Other advantage is that the design of the machinery seems to be along with a simple structure
which can bend and cut down a mass number of materials like metals at a particular time.

Project ID: 416373 PRE-TREATMENT
CHAPTER 5 PRE-TREATMENT
Pre-treatment means surface preparation. Here by pre-treatment, we mean metal pre-
treatment as the powder coating is predominantly applied to metals.
Surface preparation includes: Cleaning – mechanical or chemical
Mechanical cleaning includes methods like scratch brushing and sand blasting. This by
abrasive action not only removes the surface impurities but also eliminates scratches and
surface irregularities. Cleaning is very good; however, coating must be done immediately
because the cleaned surface is in a highly reactive state and corrosion occurs very soon.
Chemical cleaning includes removal of dirt, oil and grease, and the oxidation products
present on the surface by means of chemicals. The chemicals may be applied by wiping,
spraying or dipping.
Purpose Of Pre-treatment:
1. To help paint adhere to the metal
2. Make a painted surface last longer
3. Enhance rust and corrosion resistance of metal
4. Metal needs to be clean to allow good paint adhesion
5. Properly applied pre-treatment increases the shelf life of the product
Key Processes (9 Tank Process):

• Degreasing 1
• Degreasing 2
• Rinse 1
• Rinse 2
• Activation
• Phosphating
• Rinse 3
• Passivation
• WDO (Water Drying Oven)

Degreasing 1:
 Remove dust, grease and oil from the surface of components
 Chemical Used: DELUBE-RT
 Process To Be Conduct: Total Alkalinity/Free Alkalinity
 Time:8 min
 Operating Temp: Ambient
Degreasing 2:
 Remove dust, grease and oil from the surface of components
 Chemical Used: DELUBE-RT
 Time:15 min
Rinse 1:
 The primary purpose of a rinse is the removal of solution that adhere to a metal
surface from degreasing bath (Alkaline) Chemical Used: Fresh Water
 Process To Be Conduct: Titration
 Time: 2 min
Rinse 2:
 The primary purpose of a rinse is the removal of solution that adhere to a metal
surface from degreasing bath (Alkaline) Chemical Used: Fresh Water
 Time: 2 min
Activation:
 The purpose of activation is to prepare for a uniform crystalline structure. In the
phosphating stage, the metal surface is treated with a solution of phosphoric acid with
other chemicals. The purpose is to get a layer or coating which is primarily phosphate.
Phosphating:
 The phosphating process relies on the basic pickling reaction that occurs on the metal
substrate when the process solution comes in contact with the metal. The benefit of
phosphating is that it provides strong adhesion and corrosion protection.
 Chemical Used: KRISBOND-RT
 Process To Be Conduct: Accelerator Test
 Time: 16 min
Rinse 3:
 The primary purpose of a rinse is the removal of solution that adheres to a metal surface.
 Chemical Used: Fresh Water
 Time: 2 min
Passivation:
 Promoting the formation of passive chromium/nickel oxide layer to act as a barrier to

further corrosion.
 Chemical Used: KRISPASS-NC
 Process To Be Conduct: PH Check
 Time: 2 min
WDO:
 To dry off the components before powder coating process.

 Temp: 80 °C – 110 °C
 Time: 10 min
Figure 5-1: Pre-treatment

PROBLEMS BECAUSE OF IMPROPER PRETREATMENT:
Pre-treatment is the base for powder coating. It is said that you cannot make good coating
work with poor pre-treatment. Hence utmost care should be taken to ensure proper pre-
treatment is applied before powder coating. Proper pre-treatment means application of the
right process and proper maintenance of the chemicals.
PROBLEMS BECAUSE OF IMPROPER CLEANING: -
1. Appearance of oily patches.

2. Appearance of pin holes.
3.Appearance of rusty surface beneath powder coating film.
PROBLEMS BECAUSE OF IMPROPER CONVERSION COATING: -

1. Reduced resistance to weather.
2. Reduced mechanical resistance.
3.Poor finish of the powder coating
film.
PROBLEMS BECAUSE OF IMPROPER DRYING: -

1. Appearance of pin holes.
2. Poor bonding of the powder coating film. These problems can be avoided by the choice of
the right process – right chemicals and proper maintenance of the chemicals.

Project ID: 416373 POWDER COATING
CHAPTER 6 POWDER COATING
Powder coating is a process, in which powder consisting fine particles of pigment and resin
are electrically charged and sprayed onto the parts. This adds thin layer of powder on the
surface of the part. The part that is being coated is grounded so that the charged particles that
are being sprayed adhere to the part until melted and fused into solid coating in a curing
oven.
There is main three category of powder coating
1. Thermostat
2. Thermoplastic
3. UV curable powder
Powder coating is used in a wide range of industries and applications, from automotive and
aerospace to architecture and furniture. It can be applied to a variety of materials, including
metal. Power coating is a known for being durable, corrosion resistant, and cost-efficient
finish. colours in powder coating are combination of chemical pigment mixed with the base
formulation. The pigment itself isn’t enough to describe the colour of a coating as variable
like gloss and texture, influence the apparency as well.
WORKING
The powder coating process consist of three step-
1. Pre-treatment
2. Powder application
3. Curing
The most common way of applying the powder coating to metal objects is to spray the powder using
an electrostatic gun. The gun imparts a negative charge to the powder, which is then sprayed towards
the grounded object by mechanical or compressed air spraying and then accelerated toward the
workpiece by the powerful electrostatic charge.

Figure 6-1: Electron Gun
Curing:
After the parts have been sprayed, they are cured in a curing oven. the oven will reach
temperature of between 150 to 200 degrees Celsius resulting in the melting of powder
particles into a uniform film. Then the parts are cooled to create a hard coating.
Figure 6-2: Curing

Advantages
 Durability: Powder coating is highly durable and can withstand harsh weather
conditions, chemical exposure, and abrasion. This makes it a popular choice for
industrial and outdoor applications.
 Environmentally friendly: Powder coating is an environmentally friendly coating
option because it does not contain any solvents or VOCs (volatile organic
compounds). This means that it is better for the environment and for the health of
those applying it.
 Uniform finish: Powder coating creates a uniform and consistent finish, without any
drips or sags. This means that it provides a high-quality finish that looks professional
and lasts longer.
 Cost-effective: Powder coating is cost-effective because it does not require any
special equipment or solvents. This means that it is easier and cheaper to apply,
making it a popular choice for both large and small-scale projects.
 Versatility: Powder coating can be used on a variety of different surfaces, including
metal, plastic, and wood. It can also be used to create a range of different finishes,
including gloss, matte, and metallic.
Overall, powder coating offers a range of benefits that make it an attractive option for many
different applications

Project ID: 416373 FABRICATION
CHAPTER 7 FABRICATION
Fabrication is the process of making something from semi-finished or raw materials rather
than from readymade components. It is the process of making something from scratch rather
than assembling it. In this industry the welding process is done inside fabrication part of the
manufacturing process. The TIG and MIG welding are the two welding methods used for
fabrication of CRCA and HRCA sheets, the sheets are welded using TIG and MIG welding
process and then are further sent for different processes. Welding is a fabrication process that
joins materials, here sheets. So, the fabrication part of manufacturing process includes two
processes: TIG welding and MIG welding and the welding is done according to the
design(drawing) of the product.
7.1 : TIG WELDING:
Tungsten inert gas welding is an arc welding process that uses a non-consumable tungsten
electrode to produce the weld. The weld area and electrode are protected from oxidation or
other atmospheric contamination by an inert shielding gas (argon).
The components of TIG welding are Tungsten electrode, argon gas cylinder, DC supply,
workpiece, electrode holder, torch handle, filler rod etc.
The tungsten electrode melting point is 3422 degrees Celsius. Negative charge is given to
electrode and positive to workpiece (ground) so arc produced between electrode and
workpiece, so this arc melts base metal. Power shielding gas(argon) is used along with
tungsten electrode, the gas creates a protective shield and stops the oxygen and protects from
oxidation. Filler rod is used to insert extra material inside. When electrode moves on work
piece molten pool fuses and melts so after sometime after cooling the welding joint takes
place.
TIG welding has high initial cost and is used only where look of DG is important because it
gives better finishing, it is used in door handles, edges and the outer side of enclosure. As
tungsten is non consumable, it does not have sputters and it used to give an aesthetic look to
the enclosure as it is clean form of welding due to less spark and oxidation.
7.2 : MIG WELDING:
Metal inert gas welding is an arc welding process that uses a continuous solid wire electrode
heated and fed into the weld pool from a welding gun. The gun feeds a shielding gas
alongside the electrode helping protect the weld pool from airborne contaminations.
Project ID: 416373 FABRICATION
The components of MIG welding are Gas cylinder, electrode, electrode holder, torch handle,
insulating sheath, filler rode, DC supply, workpiece, wire reel, drive roll etc.
The solid wire acts as both filler material and electrode. The wire used is bare wire means no
flux on the wire. It uses consumable electrode. For carbon steel CO 2 is used so here there are
HRCA and CRCA carbon content sheets used so instead of argon or helium, CO 2 gas is used
and it is an active gas not inert gas, so the welding is actually called MAG welding.
DC supply is given the electrode is fed with positive charge and workpiece is fed with
negative charge. The drive roll draws wire from wire reel continuously from wire reel, due to
contact between electrode and workpiece arc is created and heat is produced which melts the
bare wire and the same time carbon dioxide gas is supplied from cylinder which creates a
shield around the welding zone it acts as a flux. When electrode moves on work piece it
creates a molten pool fuses and welding joint is created between two pieces.
The MIG/MAG welding is mostly used in canopy and base frame sheets, it is used for large
and thick materials and it is a fast-welding process, but the process includes spark and the
welding looks little bit dirty due to spark slag is created so it is only used at the place which is
not directly visible, like inside view of DG enclosure and mostly used in base frame.
Figure 7-1: MAG welding & TIG welding

Project ID: 416373 DIFFERENT PANELS FOR DG
CHAPTER 8 DIFFERENT PANELS FOR DG
8.1 : AMF PANEL
An Alternator AMF (Automatic Mains Failure) Panel is an electrical control panel designed
to ensure uninterrupted power supply in the event of a mains power failure. It is commonly
used in applications where a backup generator, typically driven by an alternator, is employed
to provide continuous electricity.
Functionality
The primary function of an Alternator AMF Panel is to monitor the availability of the mains
power supply and automatically initiate the startup of a backup generator when a mains
power failure occurs. Key functionalities include:
a. Automatic Mains Monitoring: The AMF panel continuously monitors the incoming mains
power supply. It detects the presence or absence of the mains power and initiates appropriate
actions accordingly.
b. Mains Failure Detection: When a mains power failure is detected, the AMF panel sends a
signal to the backup generator to start.
c. Generator Startup: The AMF panel activates the backup generator, ensuring a smooth and
timely transfer of electrical load from the mains to the generator.
d. Load Transfer: Once the backup generator is operational, the AMF panel transfers the
electrical load from the mains to the generator, providing uninterrupted power supply.
e. Mains Restoration: When the mains power is restored, the AMF panel automatically
switches the electrical load back to the mains and initiates the shutdown sequence for the
generator.

Figure 8-1: AMF panel
An Alternator AMF Panel typically consists of the following components:

a. Controller: The central control unit responsible for monitoring the mains power supply,
initiating generator startup, load transfer, and managing the entire process.
b. Sensors and Detectors: These devices detect the presence or absence of mains power and
provide input to the controller for decision-making.
c. Switchgear: Includes contactors, relays, and circuit breakers that control the switching
between mains and generator power sources.
d. Generator Start/Stop Mechanism: Controls the startup and shutdown of the backup
generator as directed by the controller.
e. Indicators and Displays: Provide real-time status updates, fault indications, and system
diagnostics for monitoring and troubleshooting.

8.2 : MANUAL PANEL

DG genset is operated and monitored manually with the help of manual panel. Manual panel has
PSO which is used for the purpose of controlling and monitoring of different parameters of DG
genset.
Manual panel consists of two panels which are as follows: -
i. Control Panel
ii. Power Panel
Figure 8-2: Manual panel
8.2.1 : CONTROL PANEL

An alternator control panel is an electrical control system designed to monitor and regulate
the operation of an alternator, which is a device that converts mechanical energy into
electrical energy. The control panel provides the necessary controls, monitoring, and
protection features to ensure the reliable and efficient operation of the alternator.
Functionality
The primary functions of an alternator control panel include:
a. Voltage and Frequency Regulation: The control panel monitors and regulates the output
voltage and frequency of the alternator to maintain stable and consistent electrical power.

b. Load Management: It ensures that the alternator can handle the connected electrical load
without overloading and provides the necessary control mechanisms to manage the
distribution of power.
c. Start/Stop Control: The control panel enables the operator to start or stop the alternator as
needed, based on power requirements or operational conditions.
d. Protection Mechanisms: It incorporates various protective features to safeguard the

alternator and connected electrical systems against potential faults, such as overvoltage,
overcurrent, and overheating.
e. Monitoring and Diagnostics: The control panel provides real-time monitoring of crucial
parameters such as voltage, current, frequency, and temperature. It may also include
diagnostic functions for troubleshooting and fault identification.
Figure 8-3: Control panel
Components of an Alternator Control Panel
An alternator control panel typically consists of the following components:
a. Controller Unit: The central control module that receives input signals, monitors
parameters, and regulates the alternator's operation based on predefined settings and control
algorithms.
b. Instrumentation and Displays: Digital or analog meters and indicators that display critical
Parameters such as voltage, current, frequency, and operational status.
c. Control Switches and Buttons: Allow the operator to start or stop the alternator, adjust
voltage and frequency settings, and activate various control functions.
d. Protection Devices: Circuit breakers, fuses, relays, and other protective components that
prevent damage to the alternator and connected electrical systems in case of faults or
overloads.
e. Sensors and Transducers: These devices measure parameters such as voltage, current,
frequency, and temperature, providing input to the controller for monitoring and control
purposes.
f. Communication Interfaces: Optional interfaces that allow the control panel to communicate
with external systems, such as remote monitoring systems or building management systems.
8.2.2 : POWER PANEL

Power panel consists of MCCB and Power Cables/Bus bar which is responsible for supplying
power to the load. The electrical output of alternator is sent to the load by either cables or bus bars.
But to provide protection between DG and load when any fault occurs the DG gets isolated from
the load hence the power panel is used to protect the DG from any fault or future damage. Hence
power panel is used between alternator and load.
Figure 8-4: Power panel

Calculation for MCCB: -

The MCCB is selected such that it can handle atleast 110% of full load of DG genset. To
understand the selection of MCCB rating, lets take an example.
Suppose we have a DG of 3 phase with 400 KVA rating.
Hence to find rating of MCCB rating, first we have to find the rated current. We can find the rated
current using following formula: -
KVA = (√3) V I cos Ø

400 = (√3) (415) I (0.8)
I = 400 ÷ ((√3) (415) (0.8))
I = 556.48 A
Hence 10 % of 556.48 A will be 55.648 A so we have to select such that it can withstand atleast
556.48 + 55.648 = 612.13 A
Hence, we will use the MCCB of 630 A rating.
Calculation for Cables: -

Cables supply the electricity produced by DG genset to the load so we select the cables such that it
can carry the rated current. Suppose we have a DG of 400 KVA of 3 phase. Hence the rated current
is 556.48 A.
We select the cable as per the formula of current density.
J=I÷A
I=JA

Let we have a copper cable of 95 mm^2,
J = 2 A mm^-2 (for copper)

I=JA
I = 2 × 95
I = 190 A
Hence one cable can carry 190 A.

To carry 556.48 A we will need such three cable so that they can carry
12 × 190 = 570 A
Per phase we will need 3 copper cables of 95 mm^2.

As for neutral cable we select number of neutral cables such they can carry atleast half of rated
current. Hence number of cables of neutral will be half of number of cables per phase. That’s why
we will need 2 copper cables of 95 mm^2 for neutral.

8.3 : BATTERY CHARGER PANEL

The battery charger panel of a DG (Diesel Generator) set is a specialized electrical panel
responsible for charging the batteries that power essential systems and controls of the generator.
Battery charger panel is used to charge the battery of the DG set. It mainly consists of Battery
charger. It takes AC input and give DC output. Battery charger is selected by voltage rating of
Battery.
It should remain active only when the supply is sourced from mains and not from the DG,
automatically turning off when the supply switches to the DG.
Figure 8-5.1: Battery charger panel Figure 8-5.2: Battery charger panel
The primary function of the battery charger panel is to charge the batteries connected to the DG set
ensuring they are adequately charged to start the generator and power essential systems during
operation.
The battery Charger that is used here in Jakson ltd. are of Mahamai and Neutech. Mahamai used in
CPCB – 2 and Neutech is used in CPCB – 4. The battery Charger that is used in CPCB -2 will
operate whether the load is connected to it or not.

8.4 : AUTO START STOP PANEL

In these busy times, everyone wants to get their work done automatically to save time and energy.
Generally DG has manual panel which is used to switch the DG on or off when the supply from the
grid cuts off.
To make it automatic, AMF panel is used with the manual panel. To reduce the number of panels,
Auto start stop panel is used to automatically switch the DG on or off.
Figure 8-6: Auto start stop panel
DG will switch on when the grid supply cuts off and it will switch back off. When the grid supply
comes back. We can say that Auto Start Stop panel is the combination of manual panel and AMF
panel.

8.5 : SYNC PANEL

In places where the load is not constant and can changed eventually we need multiple DG sets at
those places. Hence when load increased a certain point, another DG should start and load should
be distributed between those DG sets such that none of those DG run on overload.
Hence life cycle of DG set will increase and efficiency of DG set will increase as well.
But these DG sets should be synchronized when they connected to load otherwise this will lead to
phase to phase fault and damage of DG and load. Hence the synchronization of multiple DG sets is
done by the use of sync panel. And when they got synchronized the sync panel connect those DG
sets to load.
Figure 8-7: Sync panel
Synchronization of DG Set has always been a hot topic for the Electrical engineers. Complicated
logic and complex circuitry has made the system difficult for majority of engineers to fully digest
the subject.
As you know, synchronization is simply the parallel operation of two or more generators sets
sharing the load according to their ratings. Synchronization requires Voltage, Frequency, Phase
angle and Phase rotation of all the alternators to be same.
With the advancement of technology, the synchronization process is made easier now. Now a
days, synchronising including monitoring, controlling and protection could be easily achieved with
the help of a DG synchronsing controller without any manual intervention.

This topic explains only the basic requirements and logic of operation of DG synchronization in
isolated parallel mode or island mode.
To familiarize with the topic, let us start with some of the terminologies involved and devices
required to accomplish the task of synchronization.
 Line Voltage Monitor (LVM): LVM is a special kind of monitoring relay used for detecting the
supply availability in the bus. Some LVM also have added functionalities like reverse phase
sequence checking, Under Voltage/Over Voltage settings etc. LVM will give its feedback through
the normally open (NO) or normally closed (NC) contacts.
 Auto Mains Failure (AMF) : Auto mains failure means disconnecting the load from the utility
mains when the supply fails, Automatic powering up of the DG set and feeding the load from the
DGs and vice-versa.
 Load Dependent Start/Stop : Load depended Start/Stop is a functionality available in the DG
Controller, wherein the controller will decide the number of DGs to be continued in service based
on the present load in the system. If the load on the bus decreases below the set value in the
controller, the controller issues stop command to highest run hour DG and vice-versa.
 DG Synchronization Controller : It is a multi-functional programmable controller used to control,
monitor, and synchronize DGs. It also has functions for the protection of engine and alternator.
Each DG requires one controller for its operation. DG Sync. Controller will have input terminals
for accepting the voltage, current inputs from the alternator and bus. Programmable discrete inputs
of the DG Sync. Controller will be provided with the feedback from generator circuit breaker,
feedback from protective relays, neutral isolating contactor, DG instrumentation sensors etc. for
logical functioning. Programmable output relays of the controller will be used for DG Start/Stop,
GCB Open/Close and Emergency Stop etc. Also, the controller will have analog output ports for
voltage/speed bias signals etc. Leading controllers available in the market are from Woodward,
DIEF, Deep Sea, Cummins PCC, SICES etc.
 CAN Bus : Controller Area Network is a widely used network communication protocol used for
the communication of machines and controllers. All the DG Sync. Controllers in a system are
communicating with each other through CAN bus, which is typically a two-wire communication
network. Now a days, most of the diesel engines have electronic control circuitry with a CAN
communication interface, allows the DG Sync. Controller to communicate with engine as well.
 Voltage Bias : Voltage bias signal is the voltage signal given to the alternator’s automatic voltage
regulator (AVR) for adjusting the terminal voltage in order to match it with the other DG’s voltage
during synchronization process. It normally varies between +/-3 V depending on the manufacturer.

 Speed Bias : Speed bias signal is the voltage signal given to the engine speed governor for
adjusting the speed of the engine in order to match the frequency with the other DG’s frequency. It
normally varies between +/-5 V depending on the manufacturer. Now a days, the electronic DGs
come with CAN communication port through which the DG controller can communicate with the
engine, which eliminate the need of separate speed bias signal, Start/Stop command and
instrumentation cables from individual sensors, safety switches etc. to run from DG to the DG
Sync. Controller
 Neutral Isolating Contactor (NIC) : Contactor used in the neutral circuit of DG to isolate/connect
the neutral during the synchronization process
Following devices are very much essential for establishing synchronism:
1. Electrically Operated ACBs for the Utility and DG Incomer feeders with under volt coil, closing coil
and shunt coil
2. Line Voltage Monitor
3. DG Sync. Controller
4. Current transformers in the alternator circuit and voltage inputs from alternator and bus circuits
5. Basic electrical protective relays for the protection of alternator like Reverse/Reverse reactive power
relay, Earth fault relay, Restricted earth fault relay/Differential protection relay etc.
6. Temperature scanner for monitoring winding and bearing temperatures of the DG (Optional based
on the size of the rating of DG)
7. Battery charger circuit for DG battery
8. Instrumentation circuitry from DG to DG control panel for voltage bias, speed bias, DG Start/Stop,
RTD & BTD connection, High lube oil pressure, Oil temperature, Fuel levels, Coolant temperature
sensor, DC supply from battery charger to battery.

Project ID: 416373 DESIGN DEPARTMENT
CHAPTER 9 DESIGN DEPARTMENT
Design department play a very important in the production of DG set. The Design Department at
the plant design base frame of the DG set, Canopy of the DG set and Make the BOM (Bill Of
Material) which is list of all the material used in complete production of the DG sets. They use the
SAP to make BOM. And for 2D design purposes they use Autocad and Inventor for 3D design.
Design Department at Kalsar plant also manage all the above task of Palthan plant which is
situated in Pune.
My task at kalsar Design team was to make the BOM as per the requirement of the customer. I did
this task by using SAP software.
Figure 9-1: SAP logo
Traditional business models often decentralise data management, with each business function
storing its own operational data in a separate database. This makes it difficult for employees
from different business functions to access each other’s information. Furthermore, duplication
of data across multiple departments increases IT storage costs and the risk of data errors.
By centralising data management, SAP software provides multiple business functions with a
single view of the truth. This helps companies better manage complex business processes by
giving employees of different departments easy access to real-time insights across the
enterprise. As a result, businesses can accelerate workflows, improve operational efficiency,
raise productivity, enhance customer experiences and ultimately increase profits.

Project ID: 416373 DESIGN DEPARTMENT
Founded in 1972, the company was initially called System Analysis Program Development
(Systemanalyse Programmentwicklung), later abbreviated to SAP. Since then, it has grown from a
small, five-person endeavor to a multinational enterprise headquartered in Walldorf, Germany,
with more than 105,000 employees worldwide.
With the introduction of its original SAP R/2 and SAP R/3 software, SAP established the global
standard for enterprise resource planning (ERP) software. Now, SAP S/4HANA takes ERP to the
next level by using the power of in-memory computing to process vast amounts of data, and to
support advanced technologies such as artificial intelligence (AI) and machine learning.
The company’s integrated applications connect all parts of a business into an intelligent suite on a
fully digital platform, thereby replacing the process-driven, legacy platform. Today, SAP has more
than 230 million cloud users, more than 100 solutions covering all business functions, and the
largest cloud portfolio of any provider.
Christian Klein leads the company, heads up the Executive Board of SAP SE, and, at 42, is the
youngest CEO of any major enterprise on Germany’s DAX blue chip market index.
The company develops software solutions that are used by small businesses, midsize companies,
and large corporations. With standard applications, industry solutions, platforms, and
technologies, every business process can be mapped and designed. The software collects and
processes data on one platform, from raw material purchasing to production and customer
satisfaction. SAP solutions can be installed “on premise” at a user’s location(s) or used from the
cloud, helping companies analyse and efficiently design the entire value chain. SAP solutions can
also be used to create forecasts, such as when a machine needs to be repaired or how revenue will
develop in the next half year.
In addition, SAP helps customers seamlessly link operational data on business processes with
experience data on emotional factors such as purchase experience and customer feedback. This
enables companies to better understand and respond to their customers.

Project ID: 416373 FUTURES SCOPE
CHAPTER 10 FUTURES SCOPE
The future scope of diesel generators will largely depend on several factors, including
advancements in technology, changing energy demands, and environmental regulations.
While diesel generators have been widely used for their reliability and power generation
capabilities, there are some emerging trends and considerations that may shape their future
scope:
Energy Transition: The global push towards renewable energy sources, such as solar and
wind power, may impact the future scope of diesel generators. As the adoption of clean
energy increases, the demand for diesel generators may decline in certain sectors. However,
diesel generators could still play a role in providing backup power or supporting hybrid
energy systems where renewable sources are intermittent.
Efficiency and Emissions: Stricter environmental regulations aimed at reducing emissions are
likely to influence the future of diesel generators. Manufacturers are continuously working on
improving the efficiency of diesel engines and reducing emissions through advancements in
technology, such as better combustion systems, after-treatment systems, and the use of
alternative fuels. Compliance with emission standards will be crucial for the sustained use of
diesel generators.
Hybridization and Microgrids: Diesel generators can be integrated into hybrid systems that
combine multiple energy sources, such as solar, wind, or energy storage, to optimize
efficiency and reduce fuel consumption. Microgrids, which are localized power grids that can
operate independently or in connection with the main grid, may incorporate diesel generators
as a backup or as part of a diversified energy mix.
Sustainable Fuels: The development and utilization of sustainable fuels, such as biodiesel or
synthetic diesel, could positively impact the future scope of diesel generators. These fuels
have the potential to reduce greenhouse gas emissions and improve the environmental
footprint of diesel generators. Continued research and development in alternative fuels may
enhance the long-term viability of diesel generators.
It is important to note that the future of diesel generators may also be influenced by regional
factors, government policies, and economic considerations. As technology advances and
energy demands evolve, the scope of diesel generators may shift towards more efficient,
cleaner, and integrated solutions to meet the changing needs of various sectors.

Project ID: 416373 CONCLUSION
CHAPTER 11 CONCLUSION
During my three-month internship at Jakson Limited, a leading manufacturer of diesel

generators, I gained valuable insights into the industry and witnessed the significance of
diesel generators in various sectors. Through my experiences and observations, I can
conclude that the future scope of diesel generators is dynamic and evolving, influenced by
factors such as energy transitions, efficiency improvements, emissions regulations,
hybridization trends, remote power generation needs, sustainable fuels, and industrial and
commercial applications.
My internship at Jakson Limited has allowed me to witness the commitment of the company
towards innovation, quality, and sustainability. It has also provided me with practical
experience in various aspects of diesel generator manufacturing, including production
processes, quality control, and customer engagement.
In conclusion, while the future of diesel generators may witness shifts due to changing energy
dynamics and environmental concerns, their importance in backup power, hybrid systems,
remote power generation, and specific industries remains significant. As the industry
continues to adapt and embrace advancements in technology and environmental practices,
diesel generators will continue to play a crucial role in meeting diverse energy needs across
sectors.

Project ID: 416373 REFERENCES
CHAPTER 12 REFERENCES
1 https://www.jakson.com/
2 https://www.cummins.com/generators
3 https://www.pfonline.com/articles/
4 https://www.realpars.com/
5 https://www.linkedin.com/pulse/dg-synchronization-basics-simply-explained-c-eng-i-igbc-ap-
6 https://www.sap.com/india/about/what-is-sap.html

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Project ID: 416373

INTERNSHIP AT JAKSON LTD

SAINI BHASKAR SHANKAR LAL

In fulfillment for the award of the degree of

Government Engineering College, Valsad

Gujarat Technological University, Ahmedabad

Gujarat Technological University i Government Engineering College,Valsad

Government Engineering College, Valsad

Near Sanskar Kendra, Behind B.K.M. Science

College, Tithal Road, Valsad – 396001

Prof. N. I. Patel Prof. K. L. Mokariya

Internal Guide Head of the Department

Gujarat Technological University ii Government Engineering College,Valsad

Gujarat Technological University iii Government Engineering College,Valsad

Gujarat Technological University iv Government Engineering College,Valsad

Government Engineering College, Valsad

Near Sanskar Kendra, Behind B.K.M. Science

College, Tithal Road, Valsad – 396001

Name of the student Sign of Student

Gujarat Technological University v Government Engineering College,Valsad

Gujarat Technological University vi Government Engineering College,Valsad

Jakson Limited has 75 years of expertise in Gensets and is the leading

Throughout my tenure at Jakson Limited during my internship, I had the invaluable

Gujarat Technological University vii Government Engineering College,Valsad

Gujarat Technological University viii Government Engineering College,Valsad

Table 3-1: Sheet Comparison...................................................................................................12

Gujarat Technological University ix Government Engineering College,Valsad

HRCA Hot Rolled Close Annealed

CRCA Cold Rolled Close Annealed

CNC Computerized Numerical Control

MWp Mega Watt-peak

NTPC National Thermal Power Corporation

EPC Engineering Procurement & Construction

CPCB Central Pollution Control Board

CE "Conformité Européenne," which means "European Conformity”

WDO Water Drying Oven

VOCs Volatile Organic Compounds

TIG Tungsten Inert Gas

MIG Metal Inert Gas

MAG Metal Active Gas

CO2 Carbon Dioxide

Gujarat Technological University x Government Engineering College,Valsad

LKVA Low Kilo-volt Ampere

KVA Kilo-volt Ampere

LHP Low Horse Power

MHP Medium Horse Power

HHP High Horse Power

AVM Anti Vibration Mounts

PDI Pre-Dispatch Inspection

EOT Electrical Overhead Travelling Crane

PPC Production Planning and Control

Gujarat Technological University xi Government Engineering College,Valsad

1.1 : HISTORY OF JAKSON GROUP...............................................................................................1

3.1 : HRCA SHEETS........................................................................................................................10

4.1 : BENDING MACHINE...............................................................................................................15

CHAPTER 6 POWDER COATING.....................................................................................................22

7.1 : TIG WELDING.........................................................................................................................25

CHAPTER 8 DIFFERENT PANELS FOR DG....................................................................................27

Gujarat Technological University xii Government Engineering College,Valsad

Gujarat Technological University xiii Government Engineering College,Valsad

CHAPTER 1 OVERVIEW OF JAKSON GROUP

1.1 : HISTORY OF JAKSON GROUP

Figure 1-1: Jakson Headquarters