NATIONAL DIPLOMA IN ENGINEERING SCIENCES

ACKNOWLEDGEMENT
I am writing this report preface for my first industrial training report according to the basic
training schedule. I had to undergo training at Loadstar (pvt) Ltd, Kotugoda from 21st
August 2006 from a period of nine months.

Fist of all I take this opportunity to thank the N.I.T.A. and Institute of Engineering
Technology I.E.T the principle, head of the industrial training and the training officer and
the staff of academic to gave me a fully equipped industry. Special thank for head of the
Electrical Training department to give essential information writing about this report.

It’s my duty to thanks the Loadstar (pvt) ltd for providing great industrial training. First, I
would like to deeply appreciate and thanks to Mr Sameera, Electrical Engineer for his
supervision, instructions and suggestions. I’m grateful and indebted to him. At this instant I
wish to express my sincere thanks to the General Manager, Engineering Manager,
Engineers, Engineering Assistants, Electricians, All workers and office staff in the
Engineering & Manufacturing Division at K.T.D. for their help and guidance which made
my self easier to complete this training program successfully.

Finally I extend my thanks to the people, whose names are not mentioned here, but helped
me in numerous ways to complete the training program, and prepare this report in time.

………………..
M.S.G. Fonseka
EP / 05 / 6045

BASIC INDUSTRIAL TRAINING

 NATIONAL DIPLOMA IN ENGINEERING SCIENCES

CONTENTS TABLE
Page No.

1. Introduction of Loadstar 01

2. Cables 06
2.1 How to Identify the Cables 07
2.2 Types of Cables 08
2.3 Construction of a Cable 08
2.4 Accessories of Cables 10
2.5 How to decide wire to a motor 12
2.5.1 Deciding wire to DC motor 13
2.5.2 Deciding wire to AC motor 13
2.5.3 Deciding wire to 3 phase motor 14
2.6 Cables types use in this factory 15

3. Current Devices 17
3.1 Residual Current Device 18
3.1.1 Purpose & Operation 18
3.1.2 Use & Placement 21
3.1.3 Testing 23
3.1.4 Limitation 23
3.1.5 History & Nomenclature 24
3.1.6 Types 25
3.2 Residual Current Circuit Breaker 26
3.2.1 Protection 26
3.2.2 Selection 28

4. Motors & Motor Controlling 30

4.1 Principle of the motor 31
4.1.1 Induced Current 31
4.1.2 Slip 32
4.2 DC motors 33
4.3 AC motors 34
4.4 Three phase motors 35
4.5 Squirrel-Cage motors 48
4.6 Capacitor start/Capacitor run motor 42
4.7 Motor control method 45

4.7.1 Reduced voltage method 46

4.8 VSD 49

5 PLC 54
5.1 Programmable Logic Controllers 55
5.2 Basic Ladder Logic 57
5.3 Connecting PLC to process 58
5.4 Processing System 59
BASIC INDUSTRIAL TRAINING
 NATIONAL DIPLOMA IN ENGINEERING SCIENCES
5.5 PLC Operation 60
5.6 System of EM-II PLC 62
5.7 Ladder Logic 63
5.8 Ladder Logic Input 64
5.9 Ladder Logic Output 64
5.10 Ladder Diagram 65
5.11 Ladder Logic Design 65
5.12 Assignment of I/O Numbers 66
5.13 Timers/Counters/Latches 67
5.14 Design & Safety 74
5.15 Input/Output Block 76
5.16 Instructions Type 78
5.17 Basic Instructions of EM-II PLC 79
5.18 Functions Instructions 84
5.19 Implementation 87
5.20 The PLC Environment 91

6 Maintenance Management 97
6.1 Introduction 98
6.2 Organization maintenance 98
6.3 Types of maintenance 99
6.3.1 Improvement maintenance 99
6.3.2 Corrective maintenance 99
6.3.3 Preventive 99
6.4 Plan layout 101
6.4.1 Objectives of layout 101

7 Waste present in production System & Remedies 102

BASIC INDUSTRIAL TRAINING

 NATIONAL DIPLOMA IN ENGINEERING SCIENCES

Approval of the Engineer

Remarks:

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Designation Signature

BASIC INDUSTRIAL TRAINING