To Study the power supply of the Assembly Shop
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Transcript of To Study the power supply of the Assembly Shop
FIAT INDIA AUTOMOBILES PVT LTD
To Study the overall power Supply in the assembly shop
Project Report on
Project HeadMr. Anant Kulkarni
ByAbhishek Roy
Acknowledgement
I have taken efforts in this project. However, it would not have been possible without the kind support and help of many individuals and organizations. I would like to extend my sincere thanks to all of them. I am highly indebted to Anant Kulkarni sir, prasanna Sir, Ranti Sir, Arun Ghosh Sir for their guidance and constant supervision as well as for providing necessary information regarding the project & also for their support in completing the project. I would like to express my gratitude towards member of Assembly Shop of FIAl (Fiat india automobiles limited.) for their kind co-operation and encouragement which help me in completion of this project. I would like to express my special gratitude and thanks to industry persons for giving me such attention and time.
107 106 105 104 103 102 101 100 99 98 97 96 95 94 93 93 92 91 90 89
Body getting down to trim
lineBody lifted
1 2 3 4Wheel
Alignment
Roll and brake test
WheelAlignment
Roll and brake test
21 3 4
Expansion Area
Engine line
Vibration Bench
Door line
1- 13
Dash board preparation Area
Glass Glazing
From
Pai
nt S
hop
40 39 38 37 36 35 34 33 32 31 30 29 28 27 26
41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
71 70 69 68 67 66 65 64 63 62 61 60 59 58 57
Sho
wer
Tes
t
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
From
Tr
ack
72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88
PF-1
PF-2
PF-3
PF-4
To track
To sales yard
Final line
End of Line
Trim Line
FinishingBolleno Verde
Body Storage Area
5
[Layout (Assembly line)]
SINGLE LINE DIAGRAM -FIAL ASSEMBLY SHOP SUB STATION
Transformer #1 2.5 MVA22 / 0.430KV
22Kv Section
Transformer #2 2.5 MVA22 / 0.430KV
2F2
(125
0A A
CB)
TieB
etwe
en P
CC
1 &
23F
2(12
50AAC
B)
To F
ixed
Cap
acito
r 75
KVAR
1F
3 (4
00A
MCC
B)
TieB
etw
een
PCC
1 &
22F
2(12
50AAC
B)
To F
ixed
Cap
acito
r 12
5 KV
AR 1F3 (
400A
MCC
B)1F
2 (40
00A A
CB)
1F2
(400
0A A
CB)
MLDB-1 1F1 400A. MCCB
To U
PS 6
KVA
2F4
(63A
M
CCB)
SPAR
E 2
F 5
(63A
MCC
B)
SPAR
E 2F
6 (6
3A M
CCB)
To L
DB-8
1F2
(63
A M
CCB)
MLDB-21F6 400A.
MCCB
To L
DB-9
1F3 (6
3A M
CCB)
To L
DB-10
1F4
(63
A M
CCB)
To L
DB-1
1 1F
5 (6
3A
MCC
B)
To L
DB-1
2 2F
2 (6
3A
MCC
B)
To A
S LD
B-1 2
F3 (
63A
M
CCB)
To L
DB-1
3 2F
4 (6
3A
MCC
B)
To S
HOP
SOCK
ET
2F5
(63A
MCC
B)
To S
HOP
SFU
2F
6 (63
A
MCC
B)
To S
tree
t Lig
hting
DB
2F7
(63A
MCC
B)
To L
DB-1
1F2
(63A
MCC
B)
PCC # 1PCC # 2
MLDB # 1&2
Y Y
1250Amp SF6
(1250Amp SF6)
Y
Y
X
Incomer from MRS # 2
Panel No.: 09
Y
Y
X 1250Amp SF6
Y
Y
X
Y
Y
X(1250Amp SF6)
Y
Y
Y
Y
SPAR
E 3F
2 (1
250A
AC
B)
Y
Y
To A
PFC-2
4F2
(2
500A
ACB
)
Y
Y
To S
DB-1
5F1
(100
0A
ACB)
Y
Y
To A
HU-2
6F2
(1
000A
ACB
)
Y
Y
SPAR
E 7
F1 (
100A
ACB
)
Y
Y
To M
LDB-2 7F
2
(100A
ACB
)
Y
Y
To A
PFC
Pan
el
4F2
(100
0 KV
AR) 2
500
A AC
B
Y
Y
Y
Y
Y
Y
Y
Y
TO A
SSEM
BLY
OFF
ICE
11F2
(400
A M
CCB)
SPAR
E 1
1F1
(400
A M
CCB)
To S
DB-5
5F2
(10
00A
AC
B)
Y
Y
To S
DB-6
6F2
(1
000A
AC
B)
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
SPAR
E 8
F1 (
100A
ACB
)
SPAR
E 8
F2 (
100A
ACB
)
SPAR
E 9
F1 (
100A
ACB
)
SPAR
E 9F2
(100A
ACB
)
SPAR
E 10F2
(100A
ACB
)
SP
ARE
(40
0A M
CC
B)
SP
ARE
(40
0A M
CC
B)
SP
ARE
(40
0A M
CC
B)
SP
ARE
(25
0A M
CC
B)
SP
ARE
(40
0A M
CC
B)
SP
ARE
(25
0A M
CC
B)
SP
ARE
(250A
MC
CB
)
To S
DB-3
5F1 (
1000A
ACB
)
Y
Y
To S
DB-2
5F2
(100
0A A
CB)
Y
Y
To S
DB-4
6F1
(100
0A A
CB)
Y
Y
To A
HU-1
6F2
(100
0A A
CB)
Y
Y
Y
Y
SPAR
E 7F
1 (1
000A
ACB
)
To M
LDB-1 7F
2 (10
00A A
CB)
Y
Y
Y
Y
SPAR
E 8F
1 (1
000A
ACB
)
To A
HU-3
8F2
(100
0A A
CB)
Y
Y
Y
Y
SPAR
E 9F
1 (1
000A
ACB
)
Y
Y
SPAR
E 9F
2 (1
000A
ACB
)
Y
Y
SPAR
E 10F2
(100
0A A
CB)
SPAR
E 1
1F1
(400
A M
CCB)
SPAR
E 1
1F1
(400
A M
CCB)
SPAR
E 1
1F1
(400
A M
CCB)
SPAR
E 1
1F1
(250
A M
CCB)
SPAR
E 1
1F1
(250
A M
CCB)
To L
DB-2
1F3
(63A
MCC
B)
To L
DB-3 1F
4 (63
A M
CCB)
To L
DB-4
1F 5
(63A
MCC
B)
To L
DB-5 2
F1 (6
3A M
CCB)
To L
DB-6
2F2
(63A
MCC
B)
To L
DB-7
2F3
(63A
MCC
B)
SKL DG PNL:2F2
22/0.433 KV Transformer
22 KV SF6 Circuit Breaker
22 KV Tie SF6 Circuit Breaker
0.440 KV Air Circuit Breaker (ACB)
0.440 KV Tie Air Circuit Breaker (ACB)
0.440 KV MCCB
LEGENDS
Incomer from panel no. - 4
Palio Sub-station
Power Supply Layout of assembly shop
• Transformer-A transformer is an electrical device that transfers energy between two or more circuits through electromagnetic induction. Commonly, transformers are used to increase or decrease the voltages of alternating current in electric power applications A varying current in the transformer's primary winding creates a varying magnetic flux in the transformer core and a varying magnetic field impinging on the transformer's secondary winding. This varying magnetic field at the secondary winding induces a varying electromotive force (EMF) or voltage in the secondary winding. Making use of Faraday's Law in conjunction with high magnetic permeability core properties, transformers can thus be designed to efficiently change AC voltages from one voltage level to another within power networks.
Overall SDB layout
SDB 1
SDB 3
SDB 2
SDB 4
SDB
6SD
B 5
Area Covered
bt the SDB
SDB-1(Near Roll and brake Test Area)
SDB 1
Area Covered
bt the SDB
SDB-1
Supply to Feeder no.
Rating (in kW)
Max. Current Drawn (in Amp.)
Spare*Receptacle REC 3- 11,12,13,14,15Final Line ConveyorFuel Leak TesterPBS Lifter Trim LineRoll and Brake TestBrake Fill Equipment RepairVibration Bench PanelSpare*Wheel Alignment Aim TestSpare*MLDB-3Side Moulding EquipmentSpare*Spare*
2F22F32F42F52F63F23F33F43F53F64F24F34F44F54F6
19.68.4
8.415.6
12.3
27.2
1001006340100250321006332250250
1616
* Feeder in working condition, machine name not mentioned
SDB-2 (Between PF-3 and PF-4)
SDB 2
Area Covered
bt the SDB
SDB-2
Supply to Feeder no.
Rating (in kW)
Max. Current Drawn (in Amp.)
Spare*MLDB-2Chassis Line ConveyorCoolant and Power Filling (Left)Brushless For wheelsWheel and Tyre Delivery LineCoolant and Power Filling (Right)Brake and Aircon (Backup)Spare*Receptacle REC 5- 5,6,7,8Seat Delivery LineOld Coolant and Power PanelSpare*RDB-1 Brake and Aircon (Main)
2F22F32F42F52F63F13F23F33F64F14F24F34F44F54F6
60.710.61411.219.61414
50.4
14
400250633225633232161001001001006332
* Feeder in working condition, machine name not mentioned
SDB-3 ( Trim Line and Final Line)
SDB 3
Area Covered
bt the SDB
Supply to Feeder no.
Rating (in kW)
Max. Current Drawn (in Amp.)
REDB-1External Power Supply (Right)REC 3-6,7,8,9,10Dash Board Preperation TrolleyRoll and Brake Test-2Finishing Line LDB-1.Finishing Line LDB-2Door Line ConveyorSpare*Column no. F34 LDBExternal Power Supply (Left)Door Line LifterSide Moulding EquipmentFinishing Line PowerDB-1 Colo. 35Finishing Line Power DB-1.Final Line LifterFinishing Line Power DB-2 Colo. 36Spare*Jofa Door Testing
2F22F32F42F53F23F33F43F53F64F24F34F44F5 4F65F25F35F45F5
22.4
108.4
14
22.46.88.4
40010063322501006332164001006332
1663161616
SDB-3
* Feeder in working condition, machine name not mentioned
SDB layoutSDB 4
SDB-4
Area Covered
bt the SDB
Supply to Feeder no.
Rating (in kW)
Max. Current Drawn (in Amp.)
Office AreaPilot LineLifter Paint ShopMaintenance Store & Consumable StoreGear box Oil FillingREDB-2MLDB-1Receptacle REC 3- 1,2,3,4Rear SuspensionHarf Shaft Grease FillingDecking LineFront SuspensionSemi Corner Sub BenchSLP-4 LDB Colo.-28Mean Tube LightSpare*
2F22F32F42F52F63F23F33F43F53F64F14F24F34F44F54F6
150.573
11.2
10.8
19.69.844.833.69.5
40025010032324002501006332100100251616
SDB-4
* Feeder in working condition, machine name not mentioned
SDB-5
SDB
5
Area Covered
bt the SDB
Supply to Feeder no.
Rating (in kW)
Max. Current Drawn (in Amp.)
Test Track LDB-1FR/RR Glass Glazing( main Panel)Trim Line ConveyorFirst Filling and StartingMLDB-4Paint Booth Panel REC 5- 1,2,3,4Trim Line LifterWind Shield Washer FillingWater Test ConveyorShower TestChassis Line ConveyorFuel Leak TesterFuel FillingVentilation Glass GlazingSpare* (C35, C27, E27)Column E31 LDBRepair and Finishing LineVentilation Fuel Filling Area
2F22F32F42F53F23F33F43F53F64F24F34F44F54F65F25F35F45F5
22.419.612.874.8
12.88.489.6
14
8.42.8
40010063322501006332252501003216164002502516
SDB-5
* Feeder in working condition, machine name not mentioned
SDB-6
SDB
6
Area Covered
bt the SDB
SDB-6 Supply to Feeder
no.Rating (in kW)
Max. Current Drawn (in Amp.)
Spare*Below The PBS AreaLDB-1 (LP-1) [G33]LDB-3 (LP-3) Semi Corner Sub Bench AssemblyLDB-2 (LP-2)LDB-4 (LP-4)Spare*Spare*Spare*New HSD TankBumper Preparation Area
2F22F32F42F52F63F23F33F44F24F34F44F5
127.742.83146.2
400250100633210063162501006332
* Feeder in working condition, machine name not mentioned
B26
B37
B36
B32
B35
B34
B33
B31
B30
B29
B28
B27
C26D26E26F26J26 I26 H26
G26
C37
C36
C32
C35
C34
C33
C31
C30
C29
C28
C27
D37
D36
D32
D35
D34
D33
D31
D30
D29
D27
D27
E37
E36
E32
E35
E34
E33
E31
E30
E29
E28
E27
F36
F32
F35
F34
F33
F31
F30
F29
F28
F27
G36
G32
G35
G34
G33
G31
G30
G29
G28
G27
H32
H31
H30H29H28
H27
I37
I36
I32
I35
I34
I33
I31
I30
I29
I28
I27
J37
J36
J32
J35
J34
J33
J31
J30
J29
J28
J27
RDB-1,R1 ckt
LP13 from
MLDB 2,2F4
From SDB-3,
2F4
RDB-1,R4 ckt
From SDB-1,
2F3
RDB-1,R1 ckt
LP-12 From
MLDB 2, 2F2
LP-5 From MLDB 2,
2F2
RDB-1 R2 ckt
RDB-1
Y2 ckt
RDB-1,R1 ckt
LP13 from MLDB 2,2F4
RDB-1, B3 cktRDB-1 to trim Line
From SDB-
4, 3F4
RDB-1, B2 ckt
LP8 from MLDB 2,1F2
RDB-1, Y4 ckt
From SDB-3,
2F4
E35 LDB-2 to C34 REP
C33 REP to C33 REP
From SDB-4, 3F4
C35 LDB-1 to
C35 REP
LP-1 From MLDB-2.
From SDB-5,
5F2
I27 REP to C36 REP
RDB-1, B4 ckt
From SDB-
1, 2f4
RDB-1, Y1 ckt
C31 REP to C31 REP.
MLDB-2 to LP-8
From SDB-3, 2F4
C29 REP to
C30 REP
RDB-1,
B1ckt
LP-9 From
MLDB-2
From SDB-
5, 5F2
RDB-1, R1 ckt
SDB-4 to
MLDB-1.RDB-1, Y1 ckt
RDB-1, R1 ckt
From SDB-6,
4F3.LP4
From MLDB-
1
H35 DB to H36 REP
RDB-1 B3
ckt
RDB-1, R5 ckt
From SDB-1, 2F3
From
SDB-1, 2F3
RDB-1, R3
ckt
H29 REP to
H30 REP
H29 REP to
H30 REP
H231REP to H32 REP
H33 REP to
H33 REP
H33 REP to
H34 REP
RDB-1, R3 ckt.
H35 REP to
H35 REP
31 LDP-7 to E32
REP
E34 DB to E34 REP
RDB-1, Y2 ckt
MLDB-2 to LP-11
RDB-1, Y3 ckt.From
SDB-2, 2F4
MLDB-1 to LP-3.
From SDB-2,
4F1
RDB-1, B4 ckt
From SDB-3, 2f4
F29 REP to
F30 REP
From SDB-4,
3F4F29
REP to F30 REP
C37 REP to
C36 REP From
SDB-2,
4F1.E35 LDB-2 to E35 REP
RDB-1, B3 ckt.
E33 REP to
E33 REP
From SDB-5,
5F2.MLDB-2 to LP-10,1F4
SLP-4From
SDB-4, 4F4
MLDB-1 to LP-6.
From SDB-2,
4F1
E31 LDB-7 to E37 REP.
MLDB-1 to LP7, 2F4
From SDB-2,
4F1.E
RDB-1, Y2 ckt
H31 DB to H31 REP.
REDB-2
From SDB-4,
3F2
H37
H36
F37G37
H35
H34
H33
(H35) MLDB 3P525 MLDB 3 to Ven roll & brake 1P526 MLDB 3 to Ven roll & brake 2P520 MLDB 3 to lifter for repairP525 MLDB 3 to Ven roll & brake 1P524 MLDB 3 to Ven wheel Alig.H35 DB to h35 REP
(G26)
MLDB 1
FROM SDB-4, 3F3
P506 MLDB-1 TO HOIST 3
P504 MLDB-1 TO HOIST 2
P507MLDB-1 TO HOIST 4
P460 MLDB-1 TO HOIST 1
P508 MLDB-1 TO HOIST 5
(F31)
TO R3 CKT B35 TO B4 CKT H31
TO B3 CKT I33 TO R2 CKT I29
TO Y3 CKT G33 TO B5 CKT H31
TO Y1CKT F27 TO R4 CKT D35
TO B2 CKT F35 TO Y2 CKT J30
TO R5 CKT F37 TO Y4 CKT G29
TO R1 CKT H27 TO B1 CKTJ28
Notations
B32
B31
PILLAR WITH NO POWER SUPPLY
PILLAR WITH POWER SUPPLY
Power circuits
MCB-The MCB has some advantages compared
to fuse.1. It automatically switches off the electrical circuit during abnormal condition of the network means in over load condition as well as faulty condition. The fuse does not sense but miniature circuit breaker does it in more reliable way. MCB is much more sensitive to over current than fuse.
Contractor-A contactor is an electrically controlled switch used for switching a power circuit, similar to a relay except with higher current ratings.
A contactor is controlled by a circuit which has a much lower power level than the switched circuit.
Control circuits
Limit Switch- In electrical engineering a limit switch is a switch operated by the motion of a machine part or presence of an object. They are used for controlling machinery as part of a control system, as a safety interlocks, or to count objects passing a point. They were first used to define the limit of travel of an object; hence the name "Limit Switch".
RELAY- A relay is an electrically operated switch. Many relays use an electromagnet to mechanically operate a switch, but other operating principles are also used, such as solid-state relays. Relays are used where it is necessary to control a circuit by a low-power signal (with complete electrical isolation between control and controlled circuits), or where several circuits must be controlled by one signal.
Proximity Sensor -A proximity sensor is a sensor able to detect the presence of nearby objects without any physical contact. A proximity sensor often emits an electromagnetic field or a beam of electromagnetic radiation (infrared, for instance), and looks for changes in the field or return signal. The object being sensed is often referred to as the proximity sensor's target. Different proximity sensor targets demand different sensors. For example, a capacitive or photoelectric sensor might be suitable for a plastic target; an inductive proximity sensor always requires a metal target
Photo Sensor- A photoelectric sensor, or photo eye, is a device used to detect the distance, absence, or presence of an object by using a light transmitter, often infrared, and a photoelectric receiver. They are used extensively in industrial manufacturing
[Conceptual through-beam system to detect unauthorized access to a secure door. If the beam is broken, the detector triggers some remote alerting device.]
Electrical Drawing of Final Line Lifter
Electrical Drawing of Final Line Lifter
Electrical Drawing of Final Line Lifter
What I have learned Learned about the power supply of the assembly shop, its
distribution to different machines SDBs. Studied the sdbs, its ratings and the maximum current
drawn from it. In the sdbs, there are some spare feeders which can be
used for further expansion. Learned about the ldbs, mldbs ( gives supplies to the
tube lights, fans and to the overhead lamps) Learned about the basic power and control circuits like MCb,
contractor ,limit switch, photo sensor, proximity sensor, its application (control circuits is used in lifters, conveyor etc.)
Thank You