Six Months Industry Internship
Report
On
Electrical Maintenance
At
Asian Power Controls Pvt. Ltd.
Submitted by
Harsh J. Ganar
2021BELL023
Under the Guidance of
Dr. Manjusha Patil Mr. Rahul Bodre
Internal Mentor Industry Mentor
Department of Electrical Engineering
G H Raisoni Institute of Engineering & Technology, Wagholi, Pune
(An Autonomous Institute, Affiliated to SPPU, Pune)
June 2024
Academic Year 2023-24
Industry Institute Interaction Cell
Certificate
This is to certify that Mr. Harsh J. Ganar has satisfactorily completed the six
months industry internship entitled “Electrical Maintenance” at Asian Power
Controls Private Limited, from 1/01/2024 to 30/6/2024 During the academic year
2023-24 for the partial fulfillment of B. Tech. in Electrical Engineering of G H
Raisoni Institute of Engineering & Technology, Pune, an Autonomous Institute,
Affiliated to SPPU, Pune.
Dr. Manjusha Patil Mr. Rahul Bodre
(Internal Mentor) (Industry Mentor)
Dr. V. M. Panchade Prof. Girish Joshi
(HOD Electrical Department) Dean III
Internal Examiner External Examiner
Dr. N.U. Korde Dr. R. D. Kharadkar
Dean (Academics) Director
DECLARATION
I hereby declare that the six months internship report entitled “Electrical
Maintenance” conducted at Asian Power Controls Pvt. Ltd. from 1st January 2024 to
30th June 2024 during the academic year 2023-2024 submitted by me to G. H. Raisoni
Institute of Engineering and Technology, Wagholi, Pune in partial fulfillment of the
requirement for the award of degree of B. Tech (Electrical) is a record of internship work
carried out by me under the guidance of Dr. Manjusha Patil.
I further declare that the work reported in this report 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.
Place: Pune Name: Harsh J. Ganar
Date: / / 2023
ACKNOWLEDGEMENT
It is a great pleasure for me to present this report, which will vouch for prolific and
invaluable training. It would be considered an honor to have undergone INDUSTRY
INTERSHIP at “Asian Power Controls Pvt. Ltd.”, Pune.
I would like to express my deepest gratitude to Dr. V. M. Panchade, Head of
Department of Electrical, Internship coordinator and internal guide, Dr. Manjusha Patil,
G H Raisoni Institute of Engineering and Technology, Wagholi, Pune for granting the
permission to choose this undertaking.
I wish to thank Mr. Rahul Bodre for constant guidance, co-operation, inspiration,
and practical approach, which provided me with the much-needed impetus to work hard.
I also thank all other people who directly and indirectly contributed to the successful
completion of the In-plant training. This semester-long training has enriched me with
invaluable experience of the industrial culture of highest repute. It has provided me with
the best opportunity to put my engineering skills to practical use. The knowledge and
experience gained within the training will always be highly cherished by me and have a
lifelong influence on my career.
Also, I would like to thank each employee for their co-operation and thanking each
person in “Asian Power Controls Pvt. Ltd., Pune.”
About Internship
Internship work Title: Electrical Maintenance
Name: Harsh J. Ganar
Mobile No. 7796759676
Email: [email protected]
[email protected]
Branch: Electrical Engineering
Roll No.: 21
Registration No.: 2021BELL023
Year: 2023-24
Address: Tathagat Nivas, Lane no. 7D, Vidyanagar, Tingrenegar,
Pune - 411032
Internal Mentor: Dr. Manjusha Patil
Mobile No.: 8407944946
Name of Industry: Asian Power Controls Pvt. Ltd, Pune
Industry Address: Panchashil – Tech Park x, Viman Nagar, Pune
Industry Mentor: Mr. Rahul Bodre
Industry Mentor Mobile No.: 9623030143
Internship Duration: 01 January 2024 to 30 June 2024
INDEX
Chapter Content Page No.
No.
1 Introduction of Industry & Organization Structure 1
2 Introduction of Product/Service/Software 3
3 Introduction of work assigned 6
4 Detailed Study 8
5 Outcome 13
6 Schematic Diagram and Explanation 15
7 Test Report 17
8 Participation of External and Internal Guide 18
9 Any other information 19
10 Relevant Photos during Internships 20
11 Internship Completion Certificate 24
References 26
Chapter 1
INTRODUCTION OF INDUSTRY & ORGANIZATION
STRUCTURE
______________________________________________________________
Asian Power is a leading company in Power Generation, Distribution, Automation,
and Management, with over 10 years of experience providing customized solutions for
industrial applications. With a strong focus on customer needs and technological innovation.
Asian Power offers a wide range of products and services, including Electrical
Systems, HVAC, Plumbing, Fire Fighting, Fire Alarm, Security Systems, Structured Data
Cabling, Integrated Building Management Systems, EPC, and Diesel Generator & Control
Panels manufacturing.
With an unwavering commitment to excellence, Asian Power stands out as the
premier choice for clients seeking unparalleled Electrical & Power Management services.
1.1 Operation & Maintenance:
Asian Power Pvt. Ltd operates a 24-hour a day, 365 days a year maintenance
service for contracted clients, to ensure that any breakdown or problem is resolved
rapidly and cost-effectively.
Services include an emergency service 24 hours a day, 365 days a year. A
dedicated reactive maintenance help desk.
National maintenance coverage by skilled, specialist engineers and approved subcontractors
1
Industry:
Appliances, Electrical, and Electronics Manufacturing
Company size:
51-200 employees
Headquarters:
Pune, Maharashtra
Founded:
2004
Website:
https://www.asianpower.co.in
Specialties:
Power Quality Solutions, Facility Management Services, DG Synchronization & Load
Sharing Panels, Co-Generation, Power Import / Export controls, and Turbine Speed Control
& Protection System
Address:
Asian Power Controls Pvt. Ltd
Gat No 1497, Pawar Mala, Pune Saswad Road, Wadki, Pune, Pune, Maharashtra 412308, IN
2
Chapter 2
INTRODUCTION OF PRODUCT/SERVICE/SOFTWARE
______________________________________________________________
2.1 Services & Maintenance:
Asian Power is Providing MEP Services to various sector like Information Technology,
Hospital, and Process Industries & Sugar Co-Generation Plant since 2007. Asian Power
Controls offers the best power management solutions like Power Generation, Power Control &
Protections, Power Quality Solutions, UPS & Back Up System, Co-Generation, Control Panel
Manufacturer, Facility Management to optimize and improve the performance of each
industrial application, providing. In addition to its products, provide expert advice, synergy and
partnership to our customers.
Our technologies and services enhance energy conversion of renewable and fossil fuels,
energy extraction and distribution, and electric power generation and distribution. Power
generation OEMs throughout the world use Woodward engine management systems and genset
controls, as well as our solar inverters and wind converters.
Our power management controls meet the diverse needs of the electrical power generation
industry from base load or process control, to peak shaving and emergency power or
communications-intensive distributed power generation requirements. Through the ability to
provide control over the generator and the prime mover, our controls and systems help power
generators deliver consistently reliable power and coordinate a variety of distributed
resources. Backed by decades of experience with generator controls, load sharing,
synchronization, and power protection technologies, Woodward’s power generation control
solutions set standards worldwide.
3
2.2 Process Industries/ Plant
Fig. 2.2 Industry plant
In Critical Plant Applications Asian Power have supplied system to the Process plants.
Due to power interruption they had faced huge loses and production got hampered. To run the
plant without interruption, Asian Power Team visited their plants, understood their work
process & provided them cost effective solution. Few of the process plants are M/s Zuari Agro
Ltd, M/s Enkei Wheels India Ltd, M/s Maharashtra Enviro Ltd and many more have used our
systems.
2.3 Server System
Fig. 2.3 Server Plant
Asian Power Controls Pvt. Ltd. are Authorized system Integrator for Woodward in Power
Generation products supplying Synchronizer, Load Sharer & Protection system for Panel
Industries. Since 2007 many of our esteemed customers are regularly taking Woodward
products from us.
4
2.4 IT System
Fig. 2.3 IT System
Information Technology (IT) to run their business & Maintain Server, HVAC system,
lighting load they need electricity. They do not rely on Grid power, during Load Shedding
period DG back up is required. Also for short duration they used UPS power source. Asian
Power have successfully installed our system which is: M/s Wipro Ltd, M/s Cognizant, M/s
TCS, M/s Tech Mahindra, M/s Accenture, and many more.
2.5 Hospitals
Fig. 2.4 Hospital Applications
For Hospital Critical Applications Asian Power have supplied DG Synchronization &
Load Sharing System. UPS system for their critical ICU & OPD & CT Scan Machines. Due
to power interruption they have faced huge losses and OPD, Trauma get hampered. To run
Hospital working without interruptions, Asian Power Team visited their plant understood
their work process & provided them cost effective solutions. Few of the Hospitals are: M/s
KLE Hospitals Belgaon, M/s KEM Hospital, M/s Sahydari Hospital & M/s Deenanath
Mageshkar Hospital in Pune and many more have used our system.
5
Chapter 3
INTRODUCTION OF WORK ASSIGNED
______________________________________________________________
During internship at Asian Power Controls Pvt. Ltd, my primary work
assignment was centred on ensuring uninterrupted power supply to consumers 24 hours
a day, 365 days a year. My role involved promptly addressing any electrical
abnormalities at the consumer's end to restore normal conditions and maintain
continuous power delivery.
I had the privilege of working with Asian Power Controls Pvt. Ltd, a leading
company in the industry, for a specified duration from [01/01/2024] to [01/07/2024].
This internship provided me with a valuable opportunity to apply my skills in a practical
setting and gain hands-on experience.
Throughout my internship, I assumed various roles, including that of an operator,
electrician, and technician. As an operator, I was responsible for the effective and
efficient operation of machinery and equipment within the company. In my capacity as
an electrician, I tackled tasks related to electrical systems, such as troubleshooting issues,
conducting repairs, and ensuring overall system functionality.
This experience at Asian Power Controls Pvt. Ltd. not only broadened my
understanding of the industry but also allowed me to contribute to the vital task of
maintaining a seamless power supply for consumers.
v January 2024: Introduction and training
§ First week Introduced to the company
§ Second week starting to Explore HT panel
§ Third week I Explored LT panel
§ Fourth week learnt about 1000KVA transformer (air cooled)
6
v February 2024: Work at DG [Diesel Generator] room
§ First week I learned about the DG gensets.
§ Second week I explored the 3X500 KVA DG synchronizing panel
§ Third week I took readings of all panels and DG runtime.
§ Fourth week I learnt how to refuel the DG fuel tanks with diesel tanker.
v March 2024: Work at HT [High Tension] panel
§ First week I took readings from HT meter Kiosk.
§ Second week I Explore circuit breakers, VCB panel.
§ Third week I took readings of all panels and Sub energy meters.
§ Fourth week I learned all maintenance process and all places.
v April 2024: Work at main LT [Low Tension] Panel
§ First week I learnt the working of main LT panel and Bus bars.
§ Second week I Explore circuit breakers used for low tension.
§ Third week I took readings of all panels.
§ Fourth week I Explored transformers and learned about step down process.
v May 2024: Introduction to Active Harmonic Filter Panel
§ First week I learned all maintenance process of AHFP.
§ Second week I took readings of the AHFP Thdi.
§ Third week I learned some site work
7
Chapter 4
DETAILED STUDY
______________________________________________________________
4.1 INTRODUCTION
Our works to protect built assets by managing and executing maintenance works in
a safe and efficient manner with extensive planned preventive maintenance regimes enabling
responsiveness when defects occur and reactive when repair services are needed. This
company believes in carrying out services with minimum disruption to achieve high
standards of performance, quality with convenience for building tenants and visitors.
With experience ranging from corporate, commercial, and residential work including
maintenance and installation work within units and buildings. The ability to perform and
self-deliver all tasks with modern planning, scheduling and maintenance techniques enables
us to provide a flexible, cost effective and responsive service to the smallest or the most
complex of buildings.
4.2 Objectives:
• Reliable reactive & predictive maintenance.
• Ensuring proper planned preventive maintenance.
• Maintaining safe and productive environments.
• Operate 24 hour a day, 365 days a year maintenance service for contracted clients,
to ensure that any breakdown or problem is resolved rapidly and cost-effectively.
• Services include an emergency service 24 hours a day, 365 days a year.
• Maintenance coverage by skilled, specialist engineers and approved subcontractors.
• A team of supervisors and account managers who conduct quality and compliance
audits to ensure high and compliant standards.
8
4.3 Air Circuit Breaker
For the industries operating at high voltage or power supply, it becomes inevitable
to protect the machinery especially motor protection from overflow of current. Sudden
high voltage surges cause immense damage to the overall throughput of the plant.
Schneider Electric India offers a range of high threshold Air Circuit
Breakers (ACBs) that save the system from overcurrent and short-circuit. The primary
functionality of Air Circuit Breaker is the protection for electric circuits over 800 to
6300A. It has redefined the solution to over voltage or surges that can cause harm to the
system and is equivalent to various Surge Protection Devices. The range of products are
benchmark standard in enhancing security and reliability in industrial operations.
There are several types of circuit breakers like oil circuit breakers, standard circuit
breakers, vacuum circuit breakers, etc. An air circuit breaker is used for protecting low
voltage circuits by effectively cutting the high flow of current.
4.3.1 Air Circuit Breaker Working:
Air circuit breakers come with a high resistance capacity which aids in increasing
the resistance of the arc. In addition, it provides short circuit and overcurrent protection
up to 15kV. Air circuit breakers utilize pressure from compressed air to blow out the arc.
4.3.2 Applications of Air Circuit Breakers:
Air Circuit Breakers (ACBs) are essential electrical devices used in industries to
protect against overloads and short circuits. They also manage power in buildings and
ensure a stable electricity supply. In critical facilities like hospitals, they provide precise
protection while maintaining uninterrupted power.
Fig. 4.1 Air Circuit Breaker
9
4.4 Air cooled/Dry Type Transformers:
In view of the requirement of Indian Industry, Asian Power have introduced
VOLTAMP Cast Resin (Dry Type) Transformers. This introduction supplements our
existing product viz. Vacuum Resin Impregnated Dry Type Transformers. Dry Type
Transformers of both the above varieties are in use.
The Company has Resin Impregnated Dry Type Transformers up to 1000 KVA, 11
KV Class (In Technical collaboration with a leading GERMAN Company) and Cast Resin
Dry Type Transformers up to 12.5 MVA, 33 KV Class (In Technical collaboration with a
leading GERMAN Company).
To offer time proven designs substantiated by reliable field experience, we have
entered Technical Collaboration with M/s. HTT, Hann Munden, GERMANY.
In view of the requirement of Indian Industry, we have introduced VOLTAMP Cast
Resin (Dry Type) Transformers. This introduction will supplement our existing product viz.
Vacuum Resin Impregnated Dry Type Transformers. Dry Type Transformers of both the
above varieties are in use in the Indian Industry. To offer time proven designs substantiated
by reliable field experience we have entered Technical Collaboration with M/s. HTT, Hann
Munden, Germany.
.
Fig. 4.2 Air cooled/Dry type Transformer
10
4.5 Automatic Power Factor Control Panel [APFC]:
The Automatic Power Factor Correction (APFC) system is a key component in
electrical systems designed to maintain and optimize the power factor. Symbolized by its
distinctive representation in schematic diagrams, the APFC system actively monitors the
power factor of the electrical load and employs capacitor banks to automatically adjust and
correct the power factor as needed. The system typically includes capacitor banks, a
controller, and switching devices. The capacitor banks are strategically switched on or off by
the controller, which continuously assesses the power factor of the load. This dynamic
adjustment helps achieve a power factor close to unity (1.0), enhancing energy efficiency and
minimizing reactive power losses in the distribution network.
Fig.4.3 APFC Panel
4.6 MCB MCCB ELCB RCCB [Circuit Breakers]:
Circuit breakers are vital components in electrical systems, each serving specific
safety functions. Miniature Circuit Breakers (MCBs) are compact and ideal for low-voltage
applications, tripping to interrupt circuits during overcurrent conditions. Molded Case Circuit
Breakers (MCCBs) cater to higher voltage and current levels, providing robust protection
against overloads and short circuits in industrial settings.
11
Earth Leakage Circuit Breakers (ELCBs) focus on preventing electric shocks by
detecting ground leakage and automatically disconnecting the circuit. This is especially
crucial in areas where electrical equipment is in proximity to the ground, such as bathrooms
or outdoor installations.
Residual Current Circuit Breakers (RCCBs) monitor current imbalances, tripping
when detecting leakage to the ground and enhancing protection against electric shock
hazards. RCCBs are often used in conjunction with MCBs to provide comprehensive safety
in various electrical installations.
Residual Current Circuit Breakers (RCCBs) monitor current imbalances, tripping
when detecting leakage to the ground and enhancing protection against electric shock
hazards. RCCBs are often used in conjunction with MCBs to provide comprehensive safety
in various electrical installations.
Fig.4.3 MCB, MCCB, ELCB, RCCB [Circuit Breakers]
12
Chapter 5
OUTCOME
______________________________________________________________
Outcomes of my Internship at Asian Power Controls Pvt. Ltd:
• Skill Development Opportunity: My internship at Asian Power Controls Pvt. Ltd has been
instrumental in providing me with an invaluable opportunity to cultivate and enhance a
diverse set of skills pertinent to the roles of an operator, electrician, and technician.
• Operator Role:
Machinery and Equipment Operation: I refined my skills in operating a variety of
machinery and equipment, gaining a deeper understanding of operational processes.
Performance Monitoring: Effectively monitored and maintained performance
indicators, contributing to the efficient functioning of the equipment.
• Electrician Role:
Troubleshooting Proficiency: Acquired hands-on experience in troubleshooting
electrical issues, markedly improving my problem-solving abilities.
Fault Analysis and Repair: Developed the ability to analyze and diagnose faults,
apply appropriate repair techniques, and ensure adherence to electrical safety
protocols.
• Maintenance Skills:
Routine Inspections: Developed strong maintenance skills by conducting routine
inspections to ensure optimal equipment performance.
Preventive Maintenance: Executed preventive maintenance tasks and maintained
meticulous records of maintenance activities.
• Technician Role:
Technical Expertise Enhancement: Strengthened technical expertise through
involvement in equipment installations, gaining practical knowledge in configuring,
setting up machinery, and troubleshooting technical malfunctions.
13
• Soft Skills Development:
Effective Communication: Improved essential soft skills, including effective
communication, through collaboration with experienced professionals.
Teamwork: Enhanced teamwork skills by being an integral part of a dynamic work
environment.
Adaptability: Developed adaptability skills, allowing me to thrive in changing
circumstances.
• Understanding of Responsibility:
Importance of Responsibility: Gained insight into the significance of responsibility
in the workplace, understanding its crucial role in ensuring task efficiency and
success.
• Teamwork and Discipline:
Working in a Team: Acquired practical knowledge on how to effectively work in a
team, fostering collaboration and synergy.
Maintaining Discipline: Learned the importance of maintaining discipline within a
company for a smooth and productive work environment.
• Cultural Understanding:
Company Culture: Developed an understanding of the culture at Asian Power
Controls Pvt. Ltd, recognizing its values and norms, and aligning my work
approach accordingly.
14
Chapter 6
SCHEMATIC DIAGRAM & EXPLANATION
______________________________________________________________
Fig. 6.1 PCC & Synch. Panel Single Line Diagram
Power flow is indicated by lines representing the 11 KV grid connections. Grounding
symbols are appropriately included in the diagram to highlight the grounding points within
the system. Labels and annotations play a crucial role in providing clarity, ensuring that all
components and connections are clearly labeled. Additionally, a legend is included to clarify
symbols and abbreviations used in the schematic diagram. The overall design aims to present
a clear and organized representation of the substation layout, making it easily
comprehensible for the audience.
The schematic diagram of the Main HT Panel encompasses various critical
components aimed at efficient power distribution. A dry-type transformer is featured
prominently, symbolized with the appropriate graphical representation, with its
15
specifications and ratings indicated for clarity. Connected downstream are essential
protective devices such as the Air Circuit Breaker (ACB), symbolized by the standard ACB
symbol, and Miniature Circuit Breakers (MCBs) represented using their respective symbols.
Additionally, a Molded Case Circuit Breaker (MCCB) is strategically placed within the
diagram, with its rating specified to showcase its role in safeguarding larger loads or critical
systems.
Energy meters are strategically integrated, symbolized appropriately to
highlight their placement for measuring the consumption of specific circuits or equipment.
Furthermore, an Automatic Power Factor Correction (APFC) panel, symbolized distinctly,
is included to emphasize its role in maintaining power factor and enhancing overall system
efficiency. The interconnected components are illustrated using lines to showcase the
electrical connections, with a clear indication of the power flow direction from the
transformer through the protective breakers, energy meters, and the APFC panel. To enhance
clarity, all components, breakers, meters, and panels are meticulously labeled, and arrows or
annotations are employed to elucidate the direction of electricity flow and convey critical
information. The inclusion of a legend is paramount, serving to clarify symbols and
abbreviations utilized in the schematic diagram, ensuring that the audience can readily
decipher the layout and connections within the High Tension Panel.
16
Chapter 7
TEST REPORT
The below report shows the monthly consumption of diesel generator and MSEB
consumption:
Fig. 7.1 Diesel consumption per floor and shops
Fig. 7.2 Kiosk Meter and Sub Meter Consumption per floor
17
Chapter 8
PARTICIPATION OF INTERNAL GUIDE
______________________________________________________________
Internal Guide
They guided me as below.
1. Clearly define the scope and objectives of the internship, including any
specific goals or deliverables that need to be achieved.
2. Establish clear roles and responsibilities for team members, including the
intern,and other stakeholders.
3. Set up regular meetings or check-ins to track progress and address any issues
that arise.
4. Provide the intern with training and support to help them understand their
responsibilities.
5. Encourage the intern to ask questions and seek guidance as needed.
6.
Encourage the intern to take on increasing levels of responsibility as they
progress through the internship.
7. Monitor to ensure that it is on track and make any necessary adjustments
to the plan as needed.
8. Communicate regularly with the intern and other team members to keep them
informed of the training progress.
9. Provide feedback and guidance to the intern on their work and overall
performance.
18
Chapter 9
ANY OTHER INFORMATION
______________________________________________________________
On behalf of our team, I would like to extend our heartfelt gratitude for our internship
at your esteemed company. Your support has been invaluable, enabling us to make
significant strides towards our objectives. We are honored to have your company as a
partner and eagerly anticipate our continued collaboration to drive success in our
industry. Thank you once again for your generous contribution.
I would also like to personally express my sincere appreciation for the opportunity to
participate in this internship. The guidance and support from Dr. Manjusha Patil and
Mr. Rahul Sir have been immensely beneficial, and I am deeply grateful for the chance
to gain valuable experience and enhance my skills in my field.
Thank you for believing in me and providing this opportunity. I am confident that this
internship will be both valuable and rewarding, and I am excited about the prospects it
holds for the future.
Once again, thank you for your support and guidance. I look forward to working with
and learning from you throughout this internship.
19
Chapter 9
Relevant Photos
______________________________________________________________
v Hadapsar, Panel manufacturing plant
20
v Panchashil Tech Park, Viman nagar
21
Internship Diary First Page
______________________________________________________________
22
Joining Letter
______________________________________________________________
23
Certificate
______________________________________________________________
24
Feedback Form
______________________________________________________________
25
REFERENCES
______________________________________________________
• Asian Power Controls (2024). Applications/power-back-up-system/
Accessed on: 15th May 2024, [Online]. Available: https://asianpower.co.in
• Asian Power Controls (2024). Applications/services and maintainance
Accessed on: 15th May 2024, [Online]. Available: https://asianpower.co.in
• Asian Power Controls (2024). Services/Integrated facility management
Accessed on: 15th May 2024, [Online]. Available: https://asianpower.co.in
• Asian Power Controls (2024). Services/ Expert Specialized Services
Accessed on: 15th May 2024, [Online]. Available: https://asianpower.co.in
26
