6 MONTHS INDUSTRIAL TRAINING PPT EE BY KHUSHI RAM BHARDWAJ(DAVIET JALANDHAR)

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  • Foundedin 1981 by s. K. Sehgal and n. K. Sehgal for the die-casting purposes in jalandharkrishna laminations private ltd.
  • today kapsons is a multi-product, multi-advantage group with a combined turnover of about inr 500 CRORE. We serve globally various industry segments such as electrical, automobile, consumer durables and lighting by providing products and components of highest quality and reliability.
  • At kapsons every individual is committed to ensure complete customer satisfaction by supplying best quality products at competitive prices.These objects are achieved through dedicated teamwork and continuous training of each member of kapsons family.
  • Leaving above mention machinery same special welding machines are also used by kapsons industries ltd in pune and jalandhar plant.
  • . A gauge support for a machine tool having a tool engageable with a workpiece, comprising: an elongate arm pivotally connectable to the machine tool adjacent one end thereof and supporting a gauge at its opposite end for swingable movement toward and away from said workpiece, fluid pressure operated motor means to swing the arm toward the workpiece, said motor means including a cylinder and piston having a piston rod projecting into engagement with the arm to shift the same upon extension of the piston rod, and spring means coupled with the arm.
  • 6 MONTHS INDUSTRIAL TRAINING PPT EE BY KHUSHI RAM BHARDWAJ(DAVIET JALANDHAR)

    1. 1. KHUSHI RAM BHARDWAJ<br />D.A.V.I.E.T(JALANDHAR)<br />JUNE 2011<br />KAPSONS INDUSTRIES LTD.<br />
    2. 2. Established in 1981<br />ESTABLISHED AS KRISHNA LAMINATIONS PRIVATE LTD. JALANDHAR<br />
    3. 3. KAPSONS TODAY<br />KAPSONS INDUSTRIES TODAY SPREADING IN 4 MAJOR PLANTS IN JALANDHAR AND PUNE.<br />
    4. 4. Quality<br />ISO 16949:2000, ISO 14001:1996, is/ISO 9001:2000, ISO 9001-2000 certified.<br />
    5. 5. Infrastructure<br />Covered Area-::<br /> Unit I 62,568 Sq. Ft.<br /> Unit-II & III 72732 Sq. Ft.<br /> Unit IV 85000 Sq Ft(pune)<br />
    6. 6. Safety and Attendance<br />ATT/TO Data<br />2010<br /><ul><li>Absenteeism Rate 0.04%</li></ul>2011- YTD 5thjune<br /><ul><li>Absenteeism Rate 0.016%</li></ul>Safety Data<br />2010<br />Total Hours Worked<br /> 4018 hours<br />Minor First-Aid Cases 27<br />Cases Days Away 3<br />2011 YTD 5thjune<br />Total Hours Worked 1668<br />Minor First-Aid Cases 13<br />Cases Days Away 0<br />
    7. 7. Annual turnover<br />2007 rs. 350 crore<br />2008 rs. 395 crore<br />2009 rs. 432 crore<br />2010 rs. 500 crore<br />
    8. 8. Equipment List<br />Presses<br />(1) Gauging Machine<br /> (2) Sorting Machine<br /> (3) Lapping Machine<br /> (4) Roll Forming Machine<br /> (5) Steel Ball Plant<br /> (5) Wire Forming Machine<br /> (6) Double Disk Grinding Machine<br /> (7) Blade Grinding Machine<br /> (8) Rough Grinding Machine<br /> (9) Surface Grinding Machine<br />
    9. 9. Gauging & Sorting Machine <br />
    10. 10. Lapping Machine<br />
    11. 11. Rolling machine<br />
    12. 12. Products and services<br />
    13. 13. Clientele<br />M/S. Asea Brown Boveri Ltd. Faridabad.<br /> M/S. Bharat Bijlee Ltd. , Thane.<br /> M/S. Alstom Ltd. (AEI Works), Calcutta.<br />M/S. Crompton Greaves Ltd M/S. Alstom Ltd. (Paharpur Works), Calcutta.<br />
    14. 14. GENERATORS MAINTENANCE <br />
    15. 15. Typical Generator Maintenance <br />
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    17. 17. Generators <br />
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    19. 19. System controls <br />
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    33. 33. REASONS WHY GENERATORS FAIL<br />FOREIGN OBJECT DAMAGE<br />Problem: Objects can come from external sources or<br />failure of internal components, they can pick up energy<br />from the spinning rotor and do extensive damage<br />Prevention: Inspect on a regular basis all internal parts<br />that are prone to failure or can be dislodged.<br />Inspection tests can be a combination of visual<br />inspection along with ultrasonic or magnetic particle<br />tests on rotating components<br />
    34. 34. STATOR WINDING VIBRATION<br />Problem: Primarily a design related problem that<br />affects large (>300Mw) generators which have<br />insufficient end winding bracing to limit the<br />movement of end turns.<br />Prevention: Proper bracing of the end winding is<br />required to limit motion caused by steady state and<br />transient electromagnetic forces.<br />
    35. 35. ROTOR WINDING DISTORTION<br />Problem: Rotor winding distortion caused by poor end<br />turn blocking support design or by foreshortening of<br />the rotor coils. Foreshortening is caused by thermal<br />forces which compress rotor coils.<br />Prevention: Proper design of rotor coils and bracing to<br />support the coils under axial load is essential.<br />Rotors should be tested for turn to turn shorts at<br />operating speed.<br />
    36. 36. STATOR WINDING VIBRATION<br />Problem: Primarily a design related problem that<br />affects large (>300Mw) generators which have<br />insufficient end winding bracing to limit the<br />movement of end turns.<br />Prevention: Proper bracing of the end winding is<br />required to limit motion caused by steady state and<br />transient electromagnetic forces.<br />
    37. 37. OVERHEATING<br />Problem: Overheating of the rotor or stator can lead to<br />insulation failure, shorting of turns and ground<br />faults. Overheating can result from blocked<br />ventilation passages caused by shifting insulation<br />components or slot wedges.<br />Prevention: Inspect on a regular basis to ensure all rotor<br />wedges are "locked" in place preventing migration<br />and thus blocking of cooling passages.<br />
    38. 38. CONTAMINATION<br />Problem: For air cooled machines, dirt and dust cause<br />tracking which can lead to electrical ground faults.<br />Prevention: Inspect air filterson a regular basis , the<br />filters must be checked and cleaned regularly.<br />Polarization index (PI) tests give a good indication of<br />overall cleanliness of the rotor winding.<br />
    39. 39. ROTOR VIBRATION<br />Problem: There are many causes, turn-to-turn shorts,<br />rotor coil foreshortening, electrical grounds,<br />mechanical imbalances, overheating, etc.<br />Prevention: Comprehensive vibration measuring is effective<br />combined with a regular maintenance program.<br />
    40. 40. STATOR WEDGE LOOSENESS<br />Problem: When stator wedges become loose, coils can<br />vibrate causing insulation wear leading to ground<br />faults or turn-to-turn shorts.<br />Prevention: Inspect on a regular basis tightness of<br />wedge blocks.<br />
    41. 41. STATOR CORE DAMAGE<br />Problem: Stator core looseness can occur over time as<br />pre-tensioned through bolts relax. A loose core<br />results in insulation wear to coils and laminations<br />resulting in hot spots and core-to-coil failures.<br />Prevention: Inspect bolt tightness on a regular basis.<br />
    42. 42. GENERATOR MAINTENANCE<br />The following tests which should be carried out annually in addition to vendor recommended maintenance.<br />
    43. 43. A) INITIAL GENERATOR TEST<br />• “Megger” rotor winding<br />• “Megger” exciter armature winding<br />• “Megger” exciter field winding<br />• Complete polarization index (pi) on main stator<br />• Check bearing insulation<br />
    44. 44. B) INSPECTION ON STATIC EXCITER<br />• Remove exciter end cover<br />• Examine condition of diode carrier<br />• Examine exciter armature/stator for contamination<br />• Examine exciter armature/stator for winding wear<br />• Check pmg magnets for contamination<br />
    45. 45. C) ELECTRICAL CONTROL/PROTECTION PANEL<br />• Visually inspect external surfaces of panel<br />• Complete insulation resistance checks of panel wiring<br />• Check function of all relays<br />• Check all fuses<br />• Check all lamps<br />• Check operation of all switches<br />• Check operation of panel heaters<br />• Run generator; recalibrate avr<br />• Secondary inject all protective relays<br />
    46. 46. E) ROTOR EARTH FAULT PROTECTOR<br />• Carry out static checks to confirm operation of<br />detector<br />• Carry out functional check to confirm operation of<br />detector<br />
    47. 47. F) SLIP-RINGS AND BRUSH-GEAR (IF FITTED)<br />• Check all brushes for grade and length<br />• Check condition of brush holders/mountings<br />• Check that spring tensions are correct<br />• Check conditions of slip-rings<br />• Check mechanical run-out of slip-rings<br />• Check cooler and leakage alarms<br />

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