VISVESVARAYA TECHNOLOGICAL UNIVERSITY

JNANA SANGAMA, BELAGAVI-590018

Report on Internship
At
“SWITCH GEAR AND CONTROL AUTOMATIONS”
Submitted in partial fulfillment for the award of degree
BACHELOR OF ENGINEERING
IN
“MECHANICAL ENGINEERING”
Submitted By
Girisha B C

USN:1JS17ME418
Under the guidance of
Internal Supervisor External Supervisor
Dr. B. G. Prasantha Mr. P.N.Keshav Prasad
Assistant Professor, Managing Director,
Dept of Mechanical Engg Switch gear and control automation

DEPARTMENT OF MECHANICAL ENGINEERING

J.S.S ACADEMY OF TECHNICAL EDUCATION
JSS Campus, Dr. Vishnuvardan Road, Srinivaspura, Bangalore, Karnataka 560060
2019-2020
 JSS ACADEMY OF TECHNICAL EDUCATION
JSS Campus, Dr. Vishnuvardan Road, Srinivaspura, Bangalore, Karnataka 560060

DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE
This is to certify that the Internship entitled carried out at “Switch gear and control
automations” by Mr. Girisha B C (1JS17ME408), Bonafide students of JSS Academy
of Technical Education, in partial fulfillment for the degree of Bachelor of Engineering in
Mechanical Engineering course of Visvesvaraya Technological University, Belgaum
during the academic year 2019-2020. The Internship work has been approved as it
satisfies the academic requirements for the award of Bachelor of Engineering degree.

Signature of Supervisor Signature of HOD

Dr. B.G. Prashantha Dr. Bhimasen Soragaon
Assistant Professor, Professor, HOD
Dept of Mechanical Engg Dept of Mechanical Engg

EXAMINERS: SIGNATURE WITH DATE:

1.

2.

JSSATE, Dept. of Mechanical Engineering 2

 ACKNOWLEDGEMENT

I would like to express my profound thankfulness to Dr. C Ranganathaiah, Director,

JSS Academy of Technical Education, for his constant support in providing amenities to
carry out this course in this admired institution.
I express my thankfulness to Dr. Mrityunjaya V. Latte, Principal, JSS Academy of
Technical Education, for providing me excellent facilities and academic environment
which have helped me in satisfactory completion of the Bachelor Degree.
I express a heartfelt gratitude to my Head of the Department Dr. Bhimasen Soragaon
Professor, Dept. of Mechanical, JSS Academy of Technical Education, for his valuable
support.
I extend my sincere thanks and heartful gratitude to my internal guide Dr. B. G.
Prasantha Assistant Professor, Dept. of Mechanical, JSS Academy of Technical
Education, for his valuable support.

The internship opportunity I had with “Switch gear and control automations” was a
great chance for learning and professional development. Therefore, I consider myself as a
very lucky individual as I was provided with an opportunity to be a part of it. I am also
grateful for having a chance to meet so many wonderful people and professionals who led
me though this internship period.

Bearing in mind previous I am using this opportunity to express my deepest gratitude and
special thanks to the MD Mr. P.N.Keshav Prasad of “Switch gear and automations”
who in spite of being extraordinarily busy with his duties, took time out to hear, guide and
keep me on the correct path and allowing me to carry out my project at their esteemed
organization and extending during the training.

I express my deepest thanks to Mr. Anand, manager of for taking part in useful decision
& giving necessary advices and guidance and arranged all facilities to make life easier. I
choose this moment to acknowledge hisntribution gratefully.

Finally, I take this opportunity to extend my earnest gratitude and respect to my parents,
teaching & non-teaching staffs of the department, the library staff and all my friends, who
have directly or indirectly supported me during the period of my industrial training
programme.

Girisha B C
Mechanical Engineering
USN: 1JS17ME408
JSS Academy of Technical Education
CONTENTS

1. Introduction
1.1History
1.2Industry quality policy
1.3Certification
2.Production of the company
1.INTRODUCTION

VISION:

Our Vision is reliable source in providing better engineering solutions and products with
best quality in the market.

MISSION:

To work towards achieving our vision and provide products to our customers with reliable,
sustainable and valuable Manufacturing Solution.

OBJECTIVES:
 Manufacturing of LT switch boards
 Manufacturing of MCC panels
 PLC programming.
 Development of SCADA
 Modification of switch boards.
HISTORY:

Our company was formed in 2006, by two engineers having over nine
years of experience in the field of Automation, Design, Testing, Commissioning and
Troubleshooting of HT / LT Panels, PLC programming, Automation Panels.

Switchgear & Control Automations (SCA) are delighted to introduce

ourselves as a professionally managed company engaged in manufacturing, distributing
and wholesaling unmatched quality of Switchgears and Control automations. Backed by
two entrepreneurs with their expertise and experience in Automation, Design, Testing,
Commissioning and Troubleshooting of HT / LT Panels, DG Panels, Automation Panels
has made SCA as one of the leading techno reliable company.

Quality Assurance and Control is of the utmost importance to SCA. All our
equipment has been designed in accordance with the latest Standards. From the earliest
manufacturing stage to the final inspection, Product Quality is strictly monitored at SCA
to ensure that the most stringent requirements of Clients Specifications are met. Operator
safety and environmental protection are core concerns. SCA is focused on delivering
environmentally sound equipment that provides maximum operator safety.

Innovation and Quality has always being a prime motto which makes SCA a
first of its kind venture formed to provide best services in the LT panel and Automation
areas with commitment, reliability, timely service with utmost care and quality and to
add value engineering to the system.

Industry Quality Policy:

At Switchgear & Control Automations, quality control is not just a
process but a way of life. In fact, it is backed by minute by minute monitoring process.
We are committed towards implementing the international standards that can be easily
seen in the unmatched quality of our electric products. This quality policy that we follow
gives our company more credibility. Our ranges of products have never failed in
exceeding the expectations of our clients. We bring for our clients a range of switchgear
units that are high in performance and are completely safe to use. Our panels have been
tested at CPRI Bangalore.
Certification:
The industry is certified ISO 9001:2015, It is an non industry specific
certification and is intended for any organization that wants to implement and
maintain a quality management system.
LIST OF CLIENTS
 Honeywell Technologies
 Hewlett Packard (HP)
 Infosys Technologies Limited
 Tech Mahindra
 Ness Technologies
 Robert Bosch
 Dell Perot Systems
 Motorola Electronics
 ITPL, Bangalore (Ascendas)
 Oracle
 IBM
 HAL
2.EXPERTISE AND SERVICES OF THE COMPANY
 Manufacturing of LT Switchboards
 Design, testing and commissioning of LT Switch Boards, Synchronizing Panels,
Automation System Etc.
 PLC Programming, Development of SCADA, Commissioning of PLC Etc.
 Annual Maintenance Contract for PLC System, LT Panels, Control & Relay Panels, MCC
Panels, HVAC Panels Etc.
 Technical Consultancy Services for Power Distribution.
 Retrofitting and Modification of Switch Boards, Control Panels Etc.
 Supply and Installation of necessary Switchgear Spares and Accessories.

PRODUCTS OF THE COMPANY

1. Switch boards
 Electrical switch boards
2. Control panels
 Electrical control panels
3. MCC Panels
 MCC’s control panels
4. Automation panels
 Automation control panels
5. Synchronizing panels
 AMF and synchronizing panels

MCC PANELS

A motor control center (MCC) is an assembly to control some or all electric motors
in a central location. It consists of multiple enclosed sections having a common power bus
and with each section containing a combination starter, which in turn consists of motor
starter, fuses or circuit breaker, and power disconnect.A motor control center can also
include push buttons, indicator lights, variable-frequency drives, programmable logic
controllers, and metering equipment. It may be combined with the electrical service
entrance for the building.

ELECTRICAL CANTROL PANELS

Electrical control panels are designed and used to control mechanical equipment.

Each one is designed for a specific equipment arrangement and includes devices that allow
an operator to control specified equipment. Electrical Control Panel. Electrical
panel components control every piece of equipment in every industry.

SYNCHRONIZING PANELS

Synchronization panels are mainly designed and used to meet power system

requirements. These panels function both manually and with an automatic synchronizing 
function for two or more generators or breakers. They are widely used in synchronizing
generators and offering multiplex solutions.
Automation Panels or PLC Automation panels
Automation panels  use a single database with a single development
environment and a single library for reusable objects. Hardware costs are also reduced.
Combining the controller, operator interface, and remote connectivity into a single device
means only one device to purchase, install, and configure.
AUTOMATION
Automation is the technology by which a process or procedure is performed with
minimal human assistance. Automation or automatic control is the use of various control
systems for operating equipment such as machinery, processes in factories, boilers and heat
treating ovens, switching on telephone networks, steering and stabilization of ships, aircraft
and other applications and vehicles with minimal or reduced human intervention.

AUTOMATION IMPACTS
It increases productivity and reduce cost. It gives emphasis on flexibility and
convertibility of manufacturing process. Hence gives manufacturers the ability to easily
switch from manufacturing Product A to manufacturing product B without completely
rebuilt the existing system/product lines. Automation is now often applied primarily to
increase quality in the manufacturing process, where automation can increase quality
substantially. Increased consistency of output. Replacing humans in tasks done in
dangerous environments.

PROGRAMMABLE LOGIC CONTROLLER

A PROGRAMMABLE LOGIC CONTROLLER (PLC) is an industrial

computer control system that continuously monitors the state of input devices and make
decisions based upon a custom program to control the state of output devices. It is designed
for multiple inputs and output arrangements, extended temperature ranges, immunity to
electrical noise, and resistance to vibration and impact. Almost any production process can
greatly enhance using this type of control system, the biggest benefit in using a PLC is the
ability to change and replicate the operation or process while collecting and communicating
vital information. Another advantage of a PLC is that it is modular. i.e. you can mix and
match the types of input and output devices to best suit your application.

INVENTION OF PLC
PLC originated in the late 1960s in the automotive industry in the USA and were
designed to replace relay logic systems. Before, control logic for manufacturing was mainly
composed of relays, cam timers, drum sequencers, and dedicated closed-loop controllers.
The hard-wired nature made it difficult for design engineers to alter the process. Even small
changes would require rewiring and careful updating of the documentation. If even one
wire were out of place, or one relay failed, the whole system would become faulty. Often
times technicians would spend hours troubleshooting by examining the schematics and
comparing them to existing wiring. When general-purpose computers became available,
they were soon applied to control sequential and combinatorial logic in industrial
processes. These early computers required specialist programmers and strict control of
working conditions, such as temperature, cleanliness, and power quality. To meet these
challenges, the PLC was developed with several advantages over earlier designs. It would
tolerate the industrial environment, be easily extensible with additional I/O (allow for easier
reconfiguration and iteration over manufacturing process design), be relatively simple to
use, and would permit its operation to be monitored.

Early PLCs were programmed in " ladder logic", which strongly resembles a
schematic diagram of relay logic. This program notation was chosen to reduce training
demands for the existing technicians. Other PLCs used a form of instruction
list programming, based on a stack-based logic solver.

BLOCK DIAGRAM OF PLC

They consist of the CPU, Memory an I/O device. These components are integral
to the PLC controller. Additionally, the PLC has a connection for the programming and
Monitoring Unit or to connect PLC’s in other field.

The CPU is the brain of a PLC system. It consists of the microprocessor, memory
integrated circuits, and circuits necessary to store and retrieve information from memory.
PLC’s or programming terminals. The job of the processor is to monitor status or state of
input devices, scan and solve the logic of a user program, and control on or off state of
output devices. RAM or Random Access Memory is a volatile memory that would loose its
information if power were removed, hence some processor units are provided with battery
backup. Normally CMOS (Complementary Metal Oxide Semiconductor) type RAM is
used.

ROM is a nonvolatile type of memory. This means it stores it’s data even if no
power is available. This type of memory information can only be read, it is placed there for
the internal use and operation of processor units.

EEPROME or Electrically Erasable Programmable Read Only Memory is usually

an add on memory module that is used to back up the main program in CMOS RAM of the
processor. In many cases, the processor can be programmed to load the EEPROM’S
program to RAM, if RAM is lost or corrupted.

OPERATION OF PLC

PLC operates by continually scanning the program and acting upon the instructions,
one at a time, to switch on or off the various outputs. In order to do this PLC first scans
all, the inputs and stores their states in memory. Then it carries out program scan and
decides which outputs should be high according to the program logic. Then finally it
updates these values to the output table, making the required outputs go high. At his point
PLC checks its own operating system and if everything is ok, it goes back to scanning
inputs.

PROGRAMMING LANGUAGES USED FOR PLC

While Ladder Logic is the most commonly used PLC programming language, but it
is not the only one. Following table lists some of the Languages that are used to program a
PLC.

 Ladder Diagram (LD).

 Functional block Diagram (FBD).
 Structured Text (ST).
 Instruction List (IL).
 Sequential Functional Chart (SFC).
LADDER DIAGRAM

It is a graphical programming language, initially programmed with simple contacts

that simulates the opening and closing of relays. Ladder Logic programming has been
expanded to include functions such as Counters, Timers, shift Registers and math
operations.
Ladder logic is a method of drawing electrical logic schematics. It is now a
graphical language very popular for programming Programmable Logic Controllers
(PLCs). It was originally invented to describe logic made from relays. The name is based
on the observation that programs in this language resemble ladders, with two vertical "rails"
and a series of horizontal "rungs" between them.
A program in ladder logic, also called a ladder diagram, is similar to a schematic for
a set of relay circuits. An argument that aided the initial adoption of ladder logic was that a
wide variety of engineers and technicians would be able to understand and use it without
much additional training, because of the resemblance to familiar hardware systems.
Ladder logic is widely used to program PLCs, where sequential control of a process
or manufacturing operation is required. Ladder logic is useful for simple but critical control
systems, or for reworking old hardwired relay circuits. As programmable logic controllers
became more sophisticated it has also been used in very complex automation systems.
Ladder logic can be thought of as a rule-based language, rather than a procedural
language. A "rung" in the ladder represents a rule. When implemented with relays and other
electromechanical devices, the various rules "execute" simultaneously and immediately.
When implemented in a programmable logic controller, the rules are typically executed
sequentially by software, in a loop.
 By executing the loop fast enough, typically many times per second, the effect of
simultaneous and immediate execution is obtained. In this way it is similar to other rule-
based languages, like spreadsheets or SQL. However, proper use of programmable
controllers requires understanding the limitations of the execution order of rungs.

GENERALLY USED INSTRUCTIONS AND SYMBOLS FOR PLC

PROGRAMMING

Input Instruction
--[ ]-- This Instruction is Called IXC or Examine If Closed. If a NO switch is
actuated, then only this instruction will be true. If a NC switch is actuated, then this
instruction will not be true and hence output will not be generated.

--[\]-- This Instruction is Called IXO or Examine If Open. If a NC switch is

actuated, then only this instruction will be true. If a NC switch is actuated, then this
instruction will not be true and hence output will not be generated.

Output Instruction
--( )--This Instruction Shows the States of Output. i.e.; If any instruction either XIO
or XIC is true then output will be high. Due to high output a 24-volt signal is generated
from PLC processor.

Rung
Rung is a simple line on which instruction are placed and logics are created
E.g.: ---------------------------------------------

Timer
A timer is a programmable instruction that lets you turn on or turn off bits after a
preset time. The two primary types of timers are TON for “timer on delay” and TOF for
“timer off delay”. Timers in RSLogix 5000 use tag names for identification.

Counter
A counter is a programmable instruction that lets you turn on or turn off bits after a
preset count has been reached. There are different types of counters available in the
RSLogix, but the CTU (counter up) instruction covers everything we will talk about here.
Counters in RSLogix 5000 use tag names for identification.
SKILLS LEARNT/EXPERIENCE DURING THE INTERNSHIP
PROGRAM
 Professional communications
 Team work
 Decision making
 Problem solving
 Initiative and entrepreneurship skills
 Manufacturing procedures

CONCLUSION
It was a wonderful learning experience at Switch gear and control Automations for
four weeks in Bangalore. I gained a lot of insight regarding almost every aspect of plant. I
was given exposure in almost all the departments at the plant. The friendly welcome from
all the employees is appreciating, sharing their experience and giving their peace of wisdom
which, they have gained in long journey of work. I am very much thankful for the
wonderful facility from Byraveshwara Engineering Enterprises. I hope this experience will
surely help me in my future and also in shaping my career. I am pretty sure that this facility
has ability to achieve its goals as stated in vision statement.by following their quality
statement “To work towards achieving our vision and provide products to our customers
with reliable, sustainable and valuable Manufacturing Solution.”