A Project Report

On Industrial Training
In
Sudhir Power Ltd. ( Genset
Manufacturing Plant ),
IMT Manesar, Gurgaon
Submitted by-
Ayush Saraswat
13BME0399
VIT University, Vellore
 DECLARATION BY THE CANDIDATE

I hereby declare that the given industrial internship

project report is a record of bonafide project work
carried out by me under the supervision of Sudhir Power
Ltd., Manesar (Gurgaon). I further declare that the work
reported in this project has not been submitted and will
not be submitted, either in part or in full, for the award
of any other degree or diploma in this institute or any
other institute or university.

Signature of the Candidate

Name of the Candidate: Ayush Saraswat
 ACKNOWLEDGEMENT
I would like to thank all those who provided me with the
possibility to complete my industrial training. I would
convey my regards to Mr. Rohit Beniwal (HR) who
allowed me to complete the training. My thanks also
goes to internal faculty who made us aware of all the
processes happening.
Also to fellows completing their projects alongside with
me with their generous questions.
My sincere thanks to Sudhir Power Ltd., (Manesar plant)
for this wonderful opportunity.

Name of the Candidate: Ayush Saraswat

 CONTENTS

1. Sudhir Power Ltd. – An Overview………………….5

2. Bloksets………………………………………………………..7
3. Designing of Bloksets…………………………………….8
4. General Notes…………………………………………..…..9
5. Some Important Terminologies……………………..11
6. Important Notations and Codes…………………….13
7. Manufacturing of blokset………………………………14
8. Process………………………………………………………….17
9. Using CNC machine……………………………………….18
10. After Machining………………………………………19
11. Conclusion………………………………………………22
12. References………………………………………………23
 SUDHIR POWER LTD. – AN OVERVIEW

Sudhir Gensets Limited (SGL) is part of the Sudhir group

of companies, promoted by Mr. Sudhir Seth in 1973. The
company is an OEM of Cummins (India) Ltd & is primarily
engaged in the business of manufacturing of DG sets
based on the technology of Cummins India Limited. It is
one of the leading manufacturers of DG sets in the range
of 7.50 KVA to 3000 KVA and associate equipment such
as control panels and acoustics. The company is
controlled & managed by the Seth family with a
dominant presence in the northern & north-western
states of India. The client base of the company includes
companies like Reliance ADAG, BHEL, DLF Limited, GE
Power, IOCL, Unitech Limited, East India Hotels Ltd etc.
Sudhir group has three wholly owned subsidiaries,
namely, Sudhir Power Projects Limited, which is into EPC
business; and Sudhir Intravidyut Limited, which is into
the manufacture of transformers of up to 20 MVA MVA
and Sudhir Sales and Services Limited which is into
servicing of DG sets.
Strategic Alliances
1. Cummins
2. Schneider Electric
3. DU-PONT
4. Tesar

Products
1. LT Panels
2. HT Panels
3. Gensets
4. Transformers
5. PV Solar Modules
6. Bloksets
 BLOKSETS

Blokset is a modular offer for the production of LV

switchboards for electrical distribution up to 6 300A and
for motor control up to 250 kW.
Applications
 Modular Structure-Global Design, Local Implementation.
 Focus on Safety, Reliability & High-End Needs.
 Flexibility in Project Management.
 Intelligent System.
 High Performance.
 Cost Effective Installation, Up gradation or Modification
 DESIGNING OF BLOKSETS

The above is the 2D drawing of a new blokset that Sudhir

Power Ltd. Mechanical division has to design and
fabricate to give the desired new design to it’s one of the
client.
It is an assembly in which many parts are to be
assembled and they are highlighted with their product
code to cross-check the product parameters. Only few
parameters and design features were edited to meet the
demand of the organization which demanded the blokset
designs to be like that.
 GENERAL NOTES

1. All dimensions are in mm.

2. Degree of protection is very important factor which
varies from IP52 to maximum upto IP68.
3. Scale of the drawing should be accordingly.
4. Temperature compatibility for interior parts are to
be kept in mind.
5. Proper gaps between the interior parts are
necessary to avoid any damage to the blokset.
 MATERIALS USED

1. CRCA – Cold Rolled Cold Annealed

Properties
a) Thickness – 1.5mm, 2mm, 3mm
b) Usage – Structures, Frame parts

2. HR – Hot Rolled
Properties
a) Thickness – 3mm
b) Usage – Base Structures, Transformer

3. SS – Stainless Steel
Properties
a) Thickness – less than 2mm
b) Usage – Tanks

4. Al - Aluminium
Properties
a) Thickness – 3mm, 5mm
b) Usage – Gland Plates
 5. GI – Galvanized
Properties
a) Thickness – 2mm
b) Usage – Outer Enclosure

SOME IMPORTANT TERMINOLOGIES

1. ISMC – Indian Standard Medium Channel

Material Dimension @ weight/ length

For eg.
ST0030027 ISMC 200X75 @130kg/6mm

2. MS Angle
 3. MS Flat

Specific weight for rectangular and square bar

= Length X Breadth X Thickness X 7.85
= 74800 – 8000 (kg/m3)

Above range is for regular and ordinary steel

4. % Scrap-Ratio

The % scrap ratio which was observed in the organization

that was around 10.49 % as an average.
 IMPORTANT NOTATIONS AND CODES

1. Important notation of the designs

SGX – E / 12 – 21 / M + CCT2

a) SGX – RMU Model

b) E – Extensible type
c) 12 – Rated Voltage
d) 21 – Short circuit current
e) M – Metering Panel
f) C – Load break switch – 1
g) C – Load break switch – 2
h) T2 – Breaker

2. Degree Of Protection

IP52
a) 5 – For dust
b) 2 – For water

In industry mechanical engineers used varying

fromIP23 upto IP53.
 MANUFACTURING OF BLOCKSET

1. OUTER BODY PARTS

For this, the industry used 2 CNC machines –
a) AMADA 2510NT – For Punching

Size of metal sheet = 2500 X 1250 mm

AE2510NT
X-axis: –10 mm to 2510 mm
Y-axis: +30 mm to 1340 mm (inner track)
–10 mm to 1300 mm (center track)
–50 mm to 1260 mm (outer track)
Punching Range

G92: ESTABLISHING COORDINATE SYSTEM

2. AMADA AIII 1253 – For Bending

For bending of
600 and 900
And upto 4mm bending

Force
Force upto the 80 ton for was applied using these
CNC machines.

All these CNC machines were FANUC based CNC

Machines.
 PROCESS
The sheet metal was loaded on the CNC machine
using the automatic sheet changer machine which
was used. There was a detector which was there in
the machine.
 USING CNC MACHINE

1. The drawing prepared was called GA drawing and

then the nesting was prepared (DWG file format)
with the help of AUTOCAD 2013.

2. Then the drawing was transferred to AMADA

AP100 software which deal with CAD/CAM
processes which had 7 stages of it’s working like
follows –

a) Unfold drawing
b) Parts processing
c) Sheet pressing
d) Simulation
e) Data manager
f) Parameter Manager
g) Maintenance

The afterward process was done itself as AMADA AP100

creates the GM CODE programming using drawing
parameters and the sheet metal operation was
successfully done with these processes.
 AFTER MACHINING
1. Welding
MIG welding used to be carried out to join the folded
edges which were previously bended using AMADA
1253NT CNC machine.
Properties
CO2 gas used in MIG welding with 0.8mm wire coiled.

2. Grinding
Grinding was done using different grinders to remove
the extra deposition of splatter.

3. Smoothening of surface
After all these again grinding was done with grinding
sheet of 80 grain size.

4. Assembly
Then the finally assembly took place and the blokset
was ready to transfer in the Electrical department.
For joining the parts, workers used lock nuts to ensure
better grip with more stability and rigidity.
 CONCLUSION

The whole training at Sudhir Power Ltd. (Manesar

plant) improved my understanding to use sheet metal
feature in SolidWorks and what other stages are
required for the sheet metal to be finally worked upon.
Designing and fabrication of blockset require skills
which can be developed by working with such skilled
mechanical engineers in industry. The learning
procedure of CNC machine and it’s working was really
useful and it improved my technical knowledge along
with practical use.
Finally, it was observed that Sudhir Power is working
efficiently to deliver the promises to it’s client and
have been successfully manufacturing around 5 crores
of gensets making it a large competition in today’s
world.
 REFERENCES

1. sudhirpower.com
2. Google Images
3. Scribd.com
4. Internet