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A REPORT ON

"ELECTRICAL CONTROL PANEL"

AN INTRNSHIP REPORT

submitted by

DABGAR MANAN ASHOKBHAI

(190143109006)

In fulfillment for the award of the degree of

BACHELOR OF ENGINEERING

In

ELECTRICAL ENGINEERING
GOVERNMENT ENGINEERING COLLEGE , BHARUCH

Gujarat Technological University, Ahmadabad

APRIL-2022

Gujarat Technological University I GEC BHARUCH

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Gujarat Technological University II GEC BHARUCH

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GOVERNMENT ENGINEERING COLLEGE, BHARUCH

DEPARTMENT OF ELECTRICAL ENGINEERIG

CERTIFICATE
Date:

This is to certify that An Internship report submitted along with the internship entitled
“ELECTRICAL CONTROL PANEL” has been carried out by DABGAR MANAN
ASHOKBHAI. (190143109006) under my guidance in partial fulfillment for the Bachelor
Of Engineering in Electrical Engineering , 8th semester of Gujarat Technological University,
Ahmadabad during academic year 2021-22.

Prof.(Dr.)AMI.T.PATEL HOD: VISHAL.Y.DOSHI

Internal guided head of department

Gujarat Technological University III GEC BHARUCH

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Gujarat Technological University IV GEC BHARUCH

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GOVERNMENT ENGINEERING COLLEGE, BHARUCH

Opp. Govt. Rest House, Old N.H 8, Bholav, Bharuch.

DECLARATION
We hereby declare that the Internship report submitted along with the Internship entitled
“ELECTRICAL CONTROL PANEL” submitted in partial fulfillment for the degree of
Bachelor of Engineering in ELECTRICAL ENGINEERING Gujarat Technological
University, Ahmedabad, is a bonafide record of original project work carried out by me at
POSITRONIC PRIVATE LIMITED under the supervision of Mr. JAYESH PRAJAPATI and
that no part of this report has been directly copied from any students’ reports or taken from
any other source, without providing due reference.

Name of the Student Sign of Student

Dabgar Manan Ashobhai

Gujarat Technological University V GEC BHARUCH

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ACKNOWLEDGEMENT

The internship opportunity I had with POSITRONIC PVT.LTD was a great chance for
learning and professional development.

Therefore, I consider myself as a very lucky individual as I was of it.

I am also grateful for having chance to meet so many wonderful people and professionals
who led me though this internship period.

I am also very thankful to our college department HOD VISHAL DOSHI sir for giving
permission for training in company.

And also thankful our college mentor Dr. AMI. T. PATEL for mentoring me through out of
duration of internship and training period.

Gujarat Technological University VI GEC BHARUCH

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ABSTRACT
This report present the experience and skills gained during 8 Week's of industrial training
under POSITRONIC PVT.LTD.

My training was on the production of different type of electrical panel like PCC panel(power
control central panel), MCC panel (motor control central panel), control panel and also
various type panels and also learning about components used for manufacturing of panel.

During this period, we also learn about the testing of electrical panel.

This report discuss the skills gained and experience gathered during the period of training.

And also justifying the relevance in equipping students with technical components to thrive
in the real world.

Gujarat Technological University VII GEC BHARUCH

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LIST OF FIGURES
Fig 1 Pcc panel……………………………………………………………………03
Fig 2 Mcc panel…………………………………………………………………..04
Fig 3 Control panel……………………………………………………………….05
Fig 4 Lt distribution board………………………………………………………..06
Fig 5 Power factor correction panel………………………………………………07
Fig 6 Auto manual change over switch…………………………………………...08
Fig 7 Fabrication department……………………………………………..............12
Fig 8 Tank process………………………………………………………………..15
Fig 9 Powder coating……………………………………………………………..15
Fig 10 Oven drying……………………………………………………………….16
Fig 11 Panel assembly……………………………………………………………17
Fig 12 Schematic layout for end product ………………………………………...22
Fig 13 Hv test kit…………………………………………………………………33
Fig 14 Air circuit breaker test……………………………………………………34
Fig 15 Insulation resistance test………………………………………………….35
Fig 16 DFT(Dry field thickness)………………………………………………...36
Fig 17 Ferrule machine…………………………………………………………..37

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TABLE OF CONTENTS
OFFLINE INTERNSHIP………………………………………………………………………………………………..I
COLLEGE CIRTIFICATE ……………………………………………………………………………………………..ii
COMPANY CERTIFICATE ……………………………………………………………..……………………………iii
DECLARATION……………………………………………………………………………………………………..iv
ACKNOWLEDGEMENT....................................................................................................................................v
ABSTRACT...........................................................................................................................................................vi
LiST OF FIGURES….………………………………………………………………………………………………….vii
TABLE OF CONTENTS...................................................................................................................................viii

CHAPTER -1- OVERVIEW OF THE COMPANY…………………….......................................01-10

1.1 History .........................................................................................................................................................01
1.2 Different scope of work ........................................................................................................................02
1.2.1 Pcc Panel (Power Control Central Panel)……………………………………………...03
1.2.2 Mcc Panel (Motor Control Central Panel)……………………………………………..04
1.2.3 Control Panel…………………………………………………………………………..05
1.2.4. Lt Distribution Boards…………………………………………………………………06
1.2.5 Automatic Power Factor Correction Panels…………………………………………...07
1.2.6.Auto Manual Changeover Panel……………………………………………………..08
1.3 Capacity of plant………………………………………………………………………………………………..09
1.4 .Organization Chart ...............................................................................................................................10

CHAPTER: 2 OVERVIEW OF DIFFERENTPLANT/UNIT/DEPARTMENT/SHOP

OF THE ORGANIZATION………………………………………………………………..12
2.1 Manufacturing Department……………………………………………………. .…12
2.1.1 Fabrication Division………………………………………………………………….12
2.1.2 Paint Division…………………………………………………………………. …….13
2.1.2 Assembly Division…………………………………………………………………...17
2.1.4 Marketing Department……………………………………………………………….18
2.1.5 Purchase Department……………………………………………………………….…18
2.2 List the technical specification of major equipment used in each department………..19
2.2.1 Specification Of Pcc Panel…………………………………………………………...19
2.2.2 Specification Of Mcc Panel…………………………………………………………..19
2.2.3 Specification Of Control Panel………………………………………………………20
2.2.4 Lt Distribution Boards………………………………………………………………..20
2.2.5 Automatic Power Factor Control Panel……………………………………………...20
2.2.6 Auto Manual Changeover Panel……………………………………………………21

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CHAPTER: 3 LAYOUT OF PRODUCTION/PROCESS BEING CARRIED OUT IN

COMPANY………………………………………………………………………………….22
3.1 Prepare schematic layout which shows the sequence of operation for manufacturing of
end product……………….……………………………………… . ………….………..22
3.2 Explain in Detail About Each Stage Of process…………..……………………………23
3.2.1.Designing Of Electrical Panels…………………………………………………..……23
3.2.2.Different Procees To Be Carried Out During Fabrication Of Electrical Control Panel..24

Chapter: 4 MANUFACTURING PROCESS OF PANEL……………………………….25

4.1. Manufacturing of electrical control panel………………………………………………25
4.4.1 Order Entry…………………………………………………………………………….25
4.1.2 Design and Submittal Generation……………………………………………………..25
4.1.3 Pre-Production Review………………………………………………………………..26
4.1.4 Production start………………………………………………………………………..27
4.1.5 Quality Control………………………………………………………………………..28
4.1.6 Shipping……………………………………………………………………………….29

CHAPTER : 5 ASSEMBLY OF PANEL…………………………………………………30

5.1.Assembly………………………………………………………………………………....30
5.2As the given steps are considered for the assembly………………………………………30
5.2 Wiring…………………………………………………………………………………….31

CHAPTER:6:SKILLS/TECHNIQUES LEARNED DURING TRAINING……………32

6.1 quality checks………………………………………………………………………….32
6.2 Electrical checks……………………………………………………………………….32
6.2.1. HV Test………………………………………………………………………………..33
6.2.2. Air circuit breaker Test………………………………………………………… …….34
6.2.3.Insulation resistance……………………………………………………………………35

CHAPTER :7 INSTRUMENT USED FOR PANEL……………………………………36

7.1 DFT (dry field thickness)………………………………………………………………..36
7.2. Ferrule Machine………………………………………………………………………...37

CHAPTER: 8 APPLICATION OF PANEL………………………………………………38

CHAPTER - 9- CONCLUSION AND DISCUSSION...................................................44-45

9.1.Overall Analysis Of Internship………………………………………………………….44
9.2 Photographs And Date Of Surprise Visit By Institute…………......................................44
9.3 Dates Of Continuous Evaluation…………………………………………………………44
9.4summary Of Internship……………………………………………………………………45

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CHAPTER: 1 OVERVIEW OF THE COMPANY

1.1 HISTORY

positronic private limited is a private incorporated since 1973.

It is classified as non-government company is registered at Registrar of Companies,

Ahmadabad.

Headquartered in Vadodara (Gujarat, India), positronic Group is the one of leading

provider of Turn-Key Electrical, Instrumentation, Automation and SCADA Solutions to
Power plants, Oil & Gas, Water supply, Chemical, defense utilities & other Industries.

Since its inception in the 1973, positronic has been one of the few Indian companies that
served the local market in India as well overseas for Oil & Gas, Water and other
industrial projects.

Over the years since its incorporation, the company expanded its operations by adding
innovative manufacturing capabilities. It added new manufacturing locations in
Ahmadabad and Vadodara in India to its portfolio till date.

Current company managing director is siddharth bordevekar and approximately 140

employees are working in this company.

A positronic PVT.LTD annual turnover is 10-25 crore.

positronic tech private limited corporate identification number is (CIN):

U32201GJ979PTC003569
And its GST number is 24AACCP7866N1ZS.

Email Address: -siddarth@positronicindia.com

Address: - positronic houses, No-882/2, GIDC, makarpura, Vadodara-390014, Gujarat,

India

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1.2 DIFFERENT PRODUCT AND SCOPE OF WORK

positronic private limited made/manufacturing some different type of electrical panel.

 List of company manufacturing electrical panel:

1. PCC PANEL (POWER CONTROL CENTRAL PANEL)

2.MCC PANEL (MOTOR CONTROL CENTRAL PANEL)

3. CONTROL PANEL

4.LT DISRIBUTION BOARDS

5. AUTOMATIC POWER FACTOR CORRECTION PANELS

6. AUTO MANNUAL CHANGEOVER PANEL

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1.2.1. PCC PANEL (POWER CONTROL CENTRAL PANEL)

Fig 1 Pcc panel

PCC panel full form is Power Control Center in Distribution and control for a various
electrical power source in Industry.

Therefore, it is the most important thing about electricity.

In Other Words, PCC panels are a distribution boards rule contain any power and would be
simply power distribution.

Panels are used to supervise and control the voltage and power of the power system.

These panels are made of high-quality raw material and are extremely sturdy in fabrication.

Main power instrument panel which consists of feeder breakers and provide breakers, monitoring
devices and control devices.

A reputed PCC panel manufacturer read all field data received for electrical power panels are
designed.

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1.2. 2.MCC PANEL (MOTOR CONTROL CENTRAL PANEL)

Fig 2 Mcc panel

The Motor Control Center (MCC) is the central location for controlling electric motors.

Which has a motor starter, fuse or circuit breaker and power disconnected.

A special instrument called a motor control panel is used to control motors in most industries.

In many commercial & Industry applications multiple electric motors are required and it is often
desirable to control some of the motors.

The apparatus designed for this type of function is the motor control centers MCCs.

A motor control center 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.

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1.2.3.CONTROL PANEL

Fig 3.Control panel

A control panel is a flat, often vertical, area where control or monitoring instruments are
displayed or it is an enclosed unit that is the part of a system that users can access, such as the
control panel of a security system.

In its simplest terms, an electrical control panel is a combination of electrical devices which use
electrical power to control the various mechanical functions of industrial equipment or
machinery.

An electrical control panel includes two main categories: panel structure and electrical
components.

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1.2.4.LT DISTRIBUTION BOARD

Fig.4.LT Distribution Board

A distribution board (also known as panel board, breaker panel, or electric panel) is a component
of an electricity supply system that divides an electrical power feed into subsidiary circuits,
while providing a protective fuse or circuit breaker for each circuit in a common enclosure.

This is also called Instrument Control Panel.

Normally, a main switch, and in recent boards, one or more residual-current devices (RCDs) or
residual current breakers with over current protection (RCBOs) are also incorporated.

The range has been designed with unique features ensuring user safety, convenience, easy
handling, and quick simple installation.

Safeguarding you from any kind of short circuits or over currents, the special application
distribution boards are built to last long.

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1.2.5.AUTOMATIC POWER FACTOR CONTROL PANEL

Fig 5 Automatic power factor control panel

The Best way is to install Auto Power Factor Correction Panel (APFC), which automatically
controls the Power Factor of the Power System close to unity.

This panels are fully integrated with latest technology Power Factor Relay and Power Saving
Capacitors.

Automatic Power Factor Control (APFC) Panels APFC or Automatic Power Factor Control
Panels are mainly used for the improvement of Power Factor.

Power Factor can be explained as ratio of active power to apparent power and it is a key factor in
measuring electrical consumption.

Everyone knows that how costly electricity has become in present time.

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1.2.6. AUTO MANNUAL CHANGE OVER PANEL

Fig.6 Auto manual change over switch

The changeover panels start in capacity at 40 amps and can be manufactured to ratings exceeding
2500 amps.

Options include: Wall, floor or plant mounting enclosures.

In case of power failure, the manual changeover switch can be changed to the generator /
inverter position.

This way, power supply will continue to the load points through the inverter or generator.

When power supply restores from the power house, simply switch back the changeover switch
position to the “Main Power Supply”.

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1.3.ORGANIZATION CHART

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1.4. CAPACITY OF PLANT

 GENERAL
Positronic has over 40 years of experience in serving Power Plants/ Generation Oil & Gas,
Petrochemical, Utilities, power generation and other industry sectors.

The company offers a full turnkey capability for all types of electrical, instrumentation, control,
automation and SCADA projects.

 ELECTRICAL ENGINEERING
Our electrical engineering section is fully equipped to design, Manufacture, install and
commission electrical systems for all type of industrial applications, activities.

 INSTRUMENT ENGINEERING
The company has extensive experience of instrumenting new plants and re- instrumenting
existing plants. Instruments type includes pressure, temperature, level and flow measuring
instruments & various intrinsically safe instruments for hazardous area installation. Instrument
supplier with whom we are familiar.

 Fisher Rosemount
 Honey well
 Indfoss
 Switzer
 Mass precision
 Yokogawa
 Symens
 Enders&Hauser
 Wicca
 MTL
 STAHL
 BettyNevada

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 PLC & SCADA ENGINEERING

Positronic provides complete PLC & SCADA solutions, for in-plant and wide area applications,
based on a variety of communication
Typically, data from plant-connected sensors are collected either in form of instrument signals or
in form of digital communication.

SCADA software packages which Positronic is giving is Wince a product from SIEMENS.

 ELECTRICAL INSTRUMENT AND CONTROL PANEL

Manufacture of Instrument, Electrical and Control panels is undertaken by experienced and
skilled technicians, for both Safe area application and Hazardous Area application.

All manufacturing activities are closely monitored and controlled by experienced

engineers/supervisors.

 SYSTEM SUPPORT
Positronic provides comprehensive support for the systems that it supplies and also undertakes
support of third party equipment and systems.

Typically, a support contract will provide for preventive/corrective maintenance with guaranteed
response times.

 QUALITY ASSURANCE
All of the company’s activities are subject to quality assurance under our Quality Management
System, which is accredited to ISO-9001: 2015.

 SERVICING & RAVPING

Fabrication, Removal of old instruments & installation of new, if required we also modify the cut
outs suitable to new instruments

Painting of existing old panels / JBs with proper surface finish with Epoxy/PU spray painting

Wiring modification, ferrule replacements in existing old panels

Loop checking and preparation of drawings of old existing panels.

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Chapter: 2 Overview of different plant/unit/department/shop of the

organization
It includes the details about the work being carried out in each department.

2.1 MANUFACTURING DEPARTMENT:

For the manufacturing of electrical panel there are 3 step:

 Fabrication division
 Paint division
 Assembly division

2.1.1 FABRICATION DIVISION

POSITRONICS has fully operational one-stop machining, fabrication division.

The company goal is to provide the best quality fabricated and machined panels on time.

Their systems are updated with the latest engineering software and machine programmers, we
ensure that part integrity is controlled and maintained to enhance the company quality output.

The company have an array of machines for quality manufacturing and engineering with fully
skilled operators.

fig 7 Fabrication department

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2.1.3.PAINT DEVISION
Positronic has in house fully functional Paint division with 7TH tank pre-treatment plant and
painting facility catering to customized requirements of their clients.

they follow all the safety standards pertaining to the requirements of the paint shop and also the
quality protocols as per standard.

Since product Quality is company main motto.

The company Paint division is fully equipped with skilled staff to ensure quality completion of
our product.

The 7th tank process is:

1. Degreasing
2. Water rines-1
3. DE rusting
4. Water rinse -2
5. Surface activation
6. Phosphating
7. Passivation

1.DEGREASING-
Room temperature process

Duration is 10-30 minutes

For cleaning the sheet metal surface of grease

Oils, soils, lubricant, oxide films, heat temperature by ALKALINE DEGREASER

2.WATER RINES-1
Rinsing process is carried out

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3.DERUSTING-
Room temperature process

For cleaning the sheet metal surface of rust by mixed HYDROCHLORIC ACID.

Duration is 05-120 minutes.

4.WATER RINES-2
Rinsing process is carried out

5.SURFACE ACTIVATION
Room temperature process

For activating the sheet metal surface for Zn &Mn phosphate coating by activation chemicals.

Duration: 20 minutes.

6.PHOSPHATING-
Room temperature process

Duration 15-20 minutes

For sealing pores of sheet metal surface for obtaining maximum corrosion resistance over
phosphate coating by DECXYLITE.SOLUTION.

7.PASSIVATION
In this process after the phosphating then chrome layer cover to the zinc phosphate.

They reduce the rust protect to the metal parts.

Duration is 1-10 minutes.

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Fig.8. 7th tank process

 POWDER COATING-
After the 7th tank process they can apply dry powder on structure via spray gun.

When the powder is sprayed on sheet metal plates is stick to its surface because of static
electricity.

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Fig 9 Powder coating

 OVEN DRYING
After the powder coating on panel they will send to in oven for drying.

In the oven they will be produce 200 degrees. Celsius temperature for drying sheet metal parts by
hot air.

Duration is almost 24 hours for oven drying.

Fig 10 Oven drying

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2.1.3ASSAMBLY DIVISION
We have 40000 sq. ft. of large assembly area with infrastructure set up to cater to a variety of
panels and systems applications like DCS, SCADA, PCC, MCC, instrumentation panels, PLC
panels, and more varieties.

We have a team of qualified and experienced engineers and technicians available round the clock
to cater clients need for quality and timely delivery.

Fig 11 Assembly department

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2.1.4 MARKETING DEPARTMENT:

A Brief Introduction to Our Finance Capabilities.

Managing the marketing process and workflow.

Take strategic risks

Continuous Improvement

Customer Feedback and satisfaction

Experienced executives.

More than 10 years of marketing expertise

Marketing representatives in Delhi, Mumbai, Pune, Ahmedabad

Reports to Director & MD

2.1.5 PURCHASE DEPARTMENT:

A Brief Introduction to Our Finance Capabilities.

Handles all the material requirements

Responsible for raw-material follow ups.

Reports to Manager Manufacturing

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2.2 List the technical specification of major equipment used in each

department.

2.2.1 SPECIFICATION OF PCC PANEL:

3 Manufacture name- positronic pvt.ltd

4 Rated voltage- 415v,3 phase,4 wire ,50hz, ac
5 Rated current- 6000 A
6 Sheet steel thickness-1.6mm, CRCA for door and gland plates
7 Incoming entry- bottom cable
8 Outgoing entry- bottom cable
9 Design ambient temperature- 50. Celsius
10 Paint shed- RAL 7035/ RAL 7032
11 Material of bus bar- aluminum
12 Circuit breaker type- air circuit breaker

2.2.2.SPECIFICATION OF MCC PANEL:

 Manufacture name- positronic pvt.ltd

 Rated voltage- 415v,3 phase,4 wire,50hz, ac
 Rated current- 400A to 3000A
 Ambient temperature- 40. Celsius to 50. Celsius
 Incoming entry- top and also bottom cable
 Outgoing entry- top and also bottom cable
 Material of bus bar- aluminum
 Paint of panel- powder coating
 Design-custom design
 Circuit breaker type- feeder circuit breaker

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2.2.3.SPECIFICATION OF CONTROL PANEL:

 Manufacture name- positronic pvt.ltd

 Rated voltage- 415v,3 phase,4 wire,50hz, ac and dc
 Rated current- 3000A
 Ambient temperature- 50. Celsius
 Incoming entry- top cable
 Outgoing entry- top cable
 Material of bus bar- aluminum and copper
 Paint of panel- powder coating
 Design- Indian standard custom design
 Circuit breaker type- molded case circuit breaker

2.2.4.LT DISRIBUTION BOARDS:

 Manufacture name- positronic pvt.ltd

 Rated voltage- A.C. 3phase, 4 wire, 433V or AC single phase 2 wire, 230V, 50hz
 Rated current- 6000A
 Ambient temperature- 45. Celsius
 Incoming entry- top cable
 Outgoing entry- top cable
 Material of bus bar- aluminum and copper
 Paint of panel- powder coating
 Design- Indian standard custom design
 Circuit breaker type- molded case circuit breaker (MCCB

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2.2.5.AUTOMATIC POWER FACTOR CONTROL PANEL:

 Manufacture name- positronic pvt.ltd

 Rated voltage- A.C. 3phase, 4 wire, 433V
 Rated current- 6500A
 Ambient temperature- 45. Celsius to 50. Celsius
 Incoming entry- top cable & bottom
 Outgoing entry- top cable & bottom
 Material of bus bar- aluminum and copper
 Paint of panel- powder coating
 Design- Indian standard custom design
 Circuit breaker type- air circuit breaker (ACB)

2.2.6.AUTO MANNUAL CHANGEOVER PANEL:

 Manufacture name- positronic pvt.ltd

 Rated voltage- A.C. 3phase, 4 wire, 415v
 Rated current- 5500A
 Ambient temperature- 50. Celsius
 Incoming entry- top cable & bottom
 Outgoing entry- top cable & bottom
 Material of bus bar- aluminum and copper
 Paint of panel- powder coating
 Design- Indian standard custom design
 Circuit breaker type- air circuit breaker (ACB)

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Chapter: 3 Layout of production/process being carried out in

company
3.1 Prepare schematic layout .

Fig:12 Schematic Layout Which Shows A Sequence Of Operation For End

Product

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3.2 Explain In Detail About Each Stage Of Process

3.2.1.Designing Of Electrical Panels

With many of our customers, this step occurs before we receive an order.

1. During design preparation, we review estimated panel components and revise as

appropriate. Next, we automatically create blank panel drawings in our panel design

software. Next, we automatically load panel components into our panel design

software. In short, we automatically create the sandbox (drawings) and fill them with

toys (components).

2. During drawing design, we place (locate) all panel components on the Layout

drawings and interconnect them on the Power, Control, and Field drawings. Our

panel design software automatically keeps track of each component and adds

drawing cross reference (line number) data.

3. After drawing design, we automatically produce an engineering submitter by clicking

Produce Submitter. The resulting bookmarked PDF document includes the following

1) Cover Sheet, 2) Table of Contents, 3) Product Data sheets for each provided part,

4) Enclosure Layout, Power Schematic, Control Schematic, Field Connection

drawings for each panel, 5) Bill of Material for each panel.

4. We email the engineering submittal for review and approval.

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3.2.2. DIFFERENT PROCEES TO BE CARRIED OUT DURING

FABRICATION OF ELECTRICAL CONTROL PANEL

• Cutting section: All the loaded CI sheets are sheared as per requirement in cuttingSection for
channels doors and closures as per the dimensions and sizes of the Work jobs .

• Bending section: All the sheared sheets are made into channels and doors, Partitions as per the
given work job.

• Drilling section: The sheets are drilled (hole) as per required.

• Fixing section: After baked in oven all materials come into fixing section where All channels,
doors, partitions are fixed and final switch gear fixing is completed and sent to packing section.

• Welding process : Shielded Metal Arc Welding (also known as SMAW or stick Welding)
involves using a stick with an electric current in order to form an electric Arc that joins the
metals together. Shielded Metal Arc Welding is commonly used In industrial and steel
fabrication.

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Chapter: 4 MANUFACTURING PROCESS OF PANEL

4.1. Manufacturing of electrical control panel

Manufacturing is a process .It takes time to accurately produce an electrical Control panel to
order. To be a successful control panel manufacturer you need a flexible Process that allows you
to produce quickly and accurately. Having experienced people, Great software and automated
production equipment helps

. Each step of the control panel manufacturing process should prepare data for The next step.
Your quoting software should generate design and production data as you Quote a panel. When a
quote turns into order your design and production software should Use the data generated during
the quoting process. Our order work flow is as follows.

1 . Order Entry

2. Design and submitter Generation

3.Pre-production review

4.production chart

5.quality control

6.shipping

4.1.1. Order Entry

When we convert a quote to a control panel manufacturing order several things

occur Automatically:
1. Store a snapshot of all as sold data in our database
2. Create a new Job Order in our database
3. Create a new Job Directory on our File Server
4. Move as sold Quote files into the new Job Directory
5. Send an Order Acknowledgement email to selected customer contacts.

4.1.2. Design and Submittal Generation

With many of our customers, this step occurs before we receive an order.

1. During design preparation, we review estimated panel components and

revise as appropriate. Next, we automatically create blank panel drawings in

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our panel Design software. Next, we automatically load panel components

into our panel Design software. In short, we automatically create the
sandbox (drawings) and fill Them with toys (components).
2. During drawing design, we place (locate) all panel components on the
LayoutDrawings and interconnect them on the Power, Control, and Field
drawings. Our Panel design software automatically keeps track of each
component and adds drawing cross reference (line number) data.
3. After drawing design, we automatically produce an engineering submitter by
Clicking Produce Submitter. The resulting bookmarked PDF document
includes the Following 1) Cover Sheet, 2) Table of Contents, 3) Product
Data sheets for each Provided part, 4) Enclosure Layout, Power Schematic,
Control Schematic, Field Connection drawings for each panel, 5) Bill of
Material for each panel.
4. We email the engineering submitter for review and approval.

4.1.3.Pre-production Review

1. After Engineering Submitter approval, Quality Control reviews the panel design
on last time to insure it’s production ready. This reduces production delays by
solving Problems before the parts are ordered.

2. After Quality Control review, we determine the earliest potential production

start Date. Then we send quote requests to all parts vendors with our earliest
potential Production start date as the desired delivery date. We allow each vendor
to confirm Our parts pricing is correct and our requested delivery can be met or
advise us Otherwise.

3.After all vendor responses are received, we schedule production and send
purchase Orders to all parts vendors with confirmed pricing and the desired
delivery date as One week prior to start of production.

4.1.4.Production start
All required control panel manufacturing data has already been prepared, so we can begin
(prepare for final assembly) before the parts arrive. This allows us to shift when certain aspects
of control panel manufacturing occur to facilitate a quick delivery schedule or to normalize
production loading.

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Prepare Wires for Final Assembly

We use industrial wire processing equipment to produce all wires 14 Gauge or smaller.

After the shortest distance wiring calculation program has been run in our panel design software
to determine all required wire lengths by type (color, gauge), we import the wiring data into our
wire machine and produce all required wires in sequence by type (color, gauge) as follows:

o Wire End A – Cut the wire. Strip the wire. Print directly on the wire
insulation
(Wire No, From Device ID: Terminal No) at a programmed position from
the
end
o Wire Middle – Print directly on the wire insulation (Wire No) at a
programmed
interval.
o Wire End B – Cut the wire. Strip the wire. Print directly on the wire
insulation
(Wire No, From Device ID: Terminal No) at a programmed position from
the
end
Prepare Nameplate / Device ID / Terminal labels

We use industrial color graphic printing equipment (Multi Color Printer, Adhesive Laminator,
Precision Cutter) and industrial label material (NEMA 4X label face, color foils, Adhesive) rated
-50F to 150F to produce all labels.

o Panel Identification labels

o Manufacturer Identification labels – using our customer’s brand (colors / logo)

o Operator Device labels

o Component Device labels

Final Assembly
Punch or drill all required holes to accommodate all components, DIN Rail and wire duct Per the
design drawings. Install DIN Rail and wire duct. Mount all components, pre-Produced
component Device ID labels, Terminal Block labels, and Door mounted Device Labels.

Install all pre-produced wires per the data printed on each wire and per the design drawings.

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4.1.5.Quality Control

After production is complete, we schedule Quality Control testing. Because

Quality Control reviewed the design prior to production, the focus is insuring each
control panel was final assembled per the design drawings.

All physical aspects of the panel are inspected. The placement of all physical
devices are compared to the design drawings and inspected to verify they are
mounted per the manufacturer’s recommendations. The Device ID, Terminal Block,
Panel ID and Operator Device labels are inspected to insure they’re mounted and
oriented properly.

All electrical aspects of the panel are inspected. Because wire connection data is
pre-Printed on each end and each end is pre-stripped to the manufacturer’s
recommended Strip length, the focus is insuring each wire is landed properly. Point
to point wire testing Is performed to verify visual inspection. Then power
connections are tightened per the Manufacturer’s torque recommendations. Then
function testing is performed to insure Panel functions as specified.

When UL508A third party safety certification is requested, we apply a serialized

UL508A label and log the serial number in the UL log file against the Job No.

As-Built drawings are produced from the marked up (redlined) production

drawings ana copy is placed in each control panel. All production and quality
control documentation is stored in the Job file.

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4.1.6. Shipping
When QC testing is complete, we send an automated Release to Shipping email. This notifies
our customer that we’re preparing their control panel manufacturing order for shipment. This
also gives them an opportunity to change the Shipping Address. We take detailed photos of all
panels in the shipment. This verifies how everything looked prior to shipment, and helps us
provide better troubleshooting assistance if a problem occurs in the field. 12 We package the
shipment based on the shipment type and weigh it. We apply Drop N’ Tell indicators and labels
so our customer can determine if the shipment was dropped during transport. If the shipment is
tall, we ship it direct (one truck, secured with a no tamper seal, with no terminal transfers) to
insure it doesn’t have an opportunity to be mishandled (tip over) during shipment. We also apply
Tip N’ Tell Indicators and labels so our customer can determine if the shipment was tipped over
during shipment. We determine the best shipping option through our shipping broker and
schedule pick up. When the shipment is picked up, we send an automated Shipping Notification
email. This identifies the Shipper Name, Shipper Tracking No, and Shipper Tracking Website
Link so our customer can track the shipment.

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CHAPTER : 5 ASSEMBLY OF PANEL

5.1. Assembly

• Required accessories for assembly .

o Nut and bolt .

o Push button

o Controller

o Indication lamp

o Cable ties

o Cable gland plate

o Cable lugs

o Panel lock

o Rail channel

o PVC wire duct .

5.2 As the given steps are considered for the assembly

o Take the measurements and marking on panel board for punching the hole via drill machine
and as required cut the PVC wire duct and Rail channel for assemble the electrical components .

o Assemble the PVC wire duct and Rail channel with nut and bolt on panel board.

o Assemble the number of terminal blocks , MCB , auxiliary relay , contactor on the Rail
channel .

o The second part for fabrication and assemble in panel enclosure is panel door where indication
lamp , push button , controller , panel lock , SFU handle , etc are mounted on the enclosure door.
o Panel fan assembles as GA drawing of panel enclosure for cooling purpose .

o Checking the tightness of the all the assemble parts

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5.3 Wiring
The control wiring is usually done with 2.5 Sq mm copper wire or the 1.5 Sq . m m copper wire .
We have to draw the wire as per the designed diagram in the panel and select the wire as
specified by the designer . Cable tie will use for making a bunch of wire . Given points are
consider during wiring . o Select the type of wire and gauge of wire as per requirement.

o RED , YELLOW , BLUE colours are considered for power wiring and grey colour for control
wiring .

o Measurement for wiring and cut the wire as per measurements .

o Fix the lug and ferrule on wire for wire indication .

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Chapter: 6 Skills/ techniques learned during training

 In the 8 week of training and internship we learned about some various type of
electrical panel.
 First we learning about various manufacturing process of various type of electrical
panels.
 First of all, company confirm the order of electrical panel as per consumer
requirement’s.
 After the confirm order first company create panel schematic diagram and design.
 After the panel diagram company complete fabrication process of panel.
 This fabrication process complete then its send to paint shop.
 In the paint panel outer structure pass through 7th tank procedure.
 Then panel is cover through powder coating through spray gun.
 After the powder coating panel are send to large oven for drying.
 In this oven panel are drying up to 200 degrees. Celsius temperature for 24 hours.
 After paint of panel is complete then its send to assembly department.
 In assembly department all the wiring, joints and testing are performing to panel.
 After all of this panel are dispatch to their consumer.
 For the one panel there are minimum time is 25 to 28 days.

6.1: quality checks

• Verification of material as per approved GA drawing .

• Overall dimensions as per approved GA drawing .

• Tightness of wire connection and pull test of crimping of lugs (on random basis).

• Ensuring enclosure is free of debris

6.2. Electrical checks

1. HV Test

2. Air circuit breaker Test

3. Insulation resistance

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6.2.1. HV Test
A dielectric withstands test is an electrical test performed on a component or product to
determine the effectiveness of its insulation. The test is a means to qualify a device's ability to
operate safely during rated electrical conditions. Voltage withstand testing is done with a high
voltage source and voltage and current meters. A single instrument called an "HV Tester” is
often used to perform this test.

It applies the necessary voltages to a device and monitors leakage current. The current can trip a
fault indicator. The tester has output overload protection. The test duration must be under the
safety standard being used. The test time for most standards, including products covered under
IEC 60950, is 1 minute.

Fig.13 HV test

High voltage tests on power and control wiring 2.5 kV for one minute on the power circuit and 2
kV for one minute on control

• Circuit with all meters and instrument transformers in the circuit.

• Ensure that proper earthing is provided to H.V. Test set, fulfilling the interlocking required to
make the set "ON".

• Increase the H.V. voltage smoothly up to 2.5KV for the 60s and start the timer for count down.

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6.2.2.Air circuit breaker test

The air circuit breaker operated within the voltage level 1 kV. Mainly for heavy fault current on
low voltages (low voltage level above 1 kV) ABCs with an appropriate arc control device, are a
good choices. These breakers normally have two pairs of contacts.

The main pair of contacts carry the current at normal load and these contacts are made of copper.
The additional pair is the arcing contact and is made of carbon. When the circuit breaker is being
opened, the main contacts open first, and during the opening of main contacts the arcing contacts
are still in touch with each other. When a fault occurs on the electrical power system, fast and
reliable protection means everything. If a circuit breaker fails to clear the fault at that critical
moment, the resulting damage can be disastrous in terms of both personnel injury and equipment
damage.

Even though circuit breakers can be very reliable, they tend to gather dirt, moisture, and
contaminants while in service. Breakers used in hostile environments can be exposed to various
corrosive contaminants, which damage not only the insulation system but also metal components,
including the main contacts inside air circuit breakers.

Fig.14 Air circuit breaker test

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6.2.3 Insulation resistance test

To test for insulation resistance, an instrument known as a meager is used. A meager instrument
applies a known DC voltage to a given wire for a given period to test the resistance within the
insulation on that particular wire or winding. Voltage must be employed as the resistance
checked with an ohmmeter may differ when there is no report of potential differences. It should
also be noted that if you apply a voltage that is too high for that insulation to withstand, then you
could potentially damage the insulation so there is a procedure to conduct the test. When
performing insulation testing, it is recommended that auxiliary equipment, such as potential
transformers and lightning arresters, be removed from the stationary switch gear. Insulation
resistance tests are made with the circuit breaker in an open and closed position, whereas the
insulation test for the switch gear bus is made with one phase to ground at a time, with the other
two phases grounded.

Fig.15 Insulation resistance test

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Chapter :7 INSTRUMENT USED FOR PANEL

7.1.DFT (dry field thickness)

Dry film thickness (DFT) is the thickness of a coating as measured above the substrate. This can
consist of a single layer or multiple layers. DFT is measured for cured coatings (after the coating
dries). The thickness of a coating depends on the application and type of process employed.
Proper thickness should be determined by recommended coating system parameters.

A coating is the most critical component in an anticorrosive coating system. The main function
of a coating is to provide corrosion protection by adhesion to the substrate. It is critical that the
applied thickness be sufficient to ensure corrosion protection as well as proper adhesion.

Film thickness is measured to ensure its compliance with ASTM, ISO and other specifications.
There are coating inspection tools that are used at every stage of the coating process to ensure
DFT meets correct specifications.

• DFT is to be measured in microns and it is Denoted by µm.

• Specific Range Of DFT For Panel is 2.4 to 3.6 µm.

Fig.16 Dry field thickness

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7.2. Ferrule Machine

Ferrule Machine is the Printing machine. which is used for printing or given address to the wire .
So We can easy to Doing Wiring of each components it means wire Which going to one
components to other components of electrical control panel.

Ferrule Printing Machines are acknowledged for their fast marking technique under low
temperature level, utilization of thermal transfer technology based marking process and a number
of latest features. These electricity driven printing systems use AC adapter as their source of
power. The latest design of their thermal head helps to raise their marking speed. Besides storing
large amount of memory, these equipments allow their operator to access stored data in personal
computer via their application software. These adopt USB interface or pen drive to obtain data
stored in PC for high volume marking job. Parameters like font density and size can be adjusted
as per the exact printing requirements of customers.

Fig.17 Ferrul machine

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CHAPTER: 8 APPLICATION OF PANEL

APPLICATION OF ELECTRICAL CONTROL PANEL

Power Plants
• National Thermal Power Corporation Limited (NTPC) - Various Power Plants in India

• Nuclear Power corporation of India Limited - Various Atomic Power Plants and Heavy Water
plants in India

• Reliance Energy India Limited (Formerly B.5.ESLtd.)

• Gujarat Electricity Board

• Delhi Vidyut Board

• Ahmadabad electricity Company Uttar Pradesh State Electricity Board

• KONA SEEMA Power Plant

• Gujarat State Energy Generation etc. Oil & Gas Installations

Oil & Gas installation

• Corporation (ONGC) - Various Locations in India

• Clough Oil & Gas, Australia

• Reliance industries Limited – Patalganga

• Reliance industries Limited Hazira

Petroleum Refineries
• Indian O Corporation Limited (Panipat, Mathura, Baroda, Haldia, Barauni, etc)

• Bharat Petroleum Corporation Limited (Mumbai)

• Hindustan Petroleum Corporation Limited (Mumbai, Vishakapatnam, etc)

• Reliance industries Limited – Jamnagar

• Indian Petrochemical Corporation Limited – Baroda

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• Indian Petrochemical Corporation Limited Dahej

• India n Petrochemical Corporation Limited – Nagothane

• Indian Petrochemical Corporation Limited Chennai

Fertilizers
• Gujarat State Fertiltzer corporation Limited (GSFC) – Vadodara

• IFFCO Limited - Kandla AFFCO Limited – Kalol

• Gujarat Narmada Fertilizer Corporation Limited – Bharuch

• Kribhco Limited Etc. Gas Compression & Distribution System

• Indraprastha Gas Limited (IGL) - New Delhi

• Gujarat State Petroleum Limited (GSPL) – Hazira

• Mahanagar Gas Limited (NGL) - Mumbal 28

• NIKO Reources Limited – Hazira

• Gujarat Gas Company Limited Hazira Adani Energy Ltd. Ahmedabad

• Gujarat state petroleum corporation (GSPC)

Gas & Air Compressors

• Dresser-Rand(India) Private Limited

• Burchardt Compression (Formerly Sulzer India Limited)

• Kirlosar Pneumatic Company Limited

• Ingersoll Randg(India) Limited

• Neuman Esser Engineeing (India) Pvt. Limited

• Atlas Copco Ltd. Pumping Systems

• Weir Pumps Limited

• Kirloskar Brothers Limited

• Mather and Platt India Limited

• Voltas Limited • Blue star Limited

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• Batliboi and Company Limited

• Sulzer Pumps Limited

• Worthington Pumps India Limited

• Jyoti Limited

• NGEF Limited

• K.S.B. Pumps Limited

• Flowmore Pumps Pvt. Ltd. etc Cement Plants

• Gujarat Ambuja Cement Limited

• L&T Cement Limited

• Madras Cement Limited

• Chanakya Cement Limited

• Chettinad Cement Limited

• Cement Corporation of India Limited

• Madras cement

• Penna Cement etc.

Chemical & Process Plants

• Gujarat Alkalies and Chemicals Limited ( GACL)

• Gujarat Chemical and Port Trust Corporation Limited

• Heubach Colour Pvt. Limited

• Eusa Pigments Pvt. Limited

• Cadila Pharmaceuticals Limited

• Lanxess ABS Limited

• Nirma Limited

• India Gelatin Limited 29

• Sterting Gelatin Limited

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• Paramount Limited

• Capital Controls India Pvt. Limited

• J.K. Paper Mill • Indian gum industries Limited

Iron & Steel Plants

• Remi Metals Limited

• Mukund Lmited

• Bhushan Limited

• Bokaro Steel Limited

• Lloyd Steel Linited

• Steel Authority of India Rourkela

• TISCO Limited

• Panchamahal Steel Limited

• Essar Steel Limited etc.

Textile Industries
• Garden Silk Milts Limited

• Grasim India Limited

• Rajshree Polyfil

• Century Enka Limited

• Modem Textiles Limited, etc Construction groups, etc

• Gammon India Ltd.,

• National Building Construction Corporation (NBCC),

• Essar Construction Ltd.,

• L&T Limited,

• Bridge & Roof Company Limited, etc.

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Power Distribution Systems

• Volt amp Transformers Limited

• Bajaj Electrical Limited

• Crompton Greaves Limited

• Reliance Energy India Limited (Formerly BSES Ltd.)

• Tata Electric Company Limited (TEC)

• Bharat Heavy Electricals Limited (BHEL)

• Danke Electricals etc.

Water Distribution Systems

• Sadar Sarovar Nigam Limited (SSNL),

• Gujarat Water Supply & Sewage Board ( GWSSB), etc 30 Air Drying Systems

• Gaso Energy System Limited

• Puriflair India Limited

• Chill Air System Pvt. Ltd., etc.

Construction Groups
• Gammon India Ltd.,

• National Building Construction Corporation (NBCC),

• Essar Construction Ltd., • L&T Limited,

• Bridge & Roof Company Limited, etc.

ENGINEERING INDUSTRIES
• Elecon Engineering Company Limited

• Thermax Limited

• Thermopads India Limited.

• L&T Group of Companies

• Thyssen-krupp (I) Pvt. Ltd

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• ABB Limited

• Indure Pvt. Ltd.

• JCT Electronics Limited

• Tyco Thermal Controls, Belgium.

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CHAPTER – 9- CONCLUSION AND DISCUSSION

9.1 Overall Analysis of Internship

During this internship in POSITRONIC PVT LTD. We have to Analysis

 what is electrical control panel

 construction of electrical control panel
 which type of components are used for manufacturing of electrical control panel
 different types of process like designing of electrical control panel, fabrication of
electrical control panel, painting process of electrical control panel,
manufacturing of electrical control panel
 how to assemble of different components in the electrical panel board
 how to testing of electrical control panel such as High voltage test of electrical control
panel, Insulation resistance test of electrical control panel , and Circuit Breaker test.

9.2 PHOTOGRAPHS AND DATE OF SUPERVISE VISIT BY INSTITUTE MENTOR

DATE : 19/03/20122

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9.3 DATES OF CONTINUOS EVALUATION

CONTINUOS EVALUATION - 1 : 14/03/2022

CONTINUOS EVALUATION -2 : 22/04/2022

9.4 CONCLUSION
This internship was a great experience to me .

it was a real pleasure work in POSITRONIC PVT.LTD in electrical department.

i work with the nice people and its was a very good experience for me.

carrying out this internship in manufacturing and testing department allows me to be immersed
in a different ways to meet interesting people in and industry.

Learn lot of things which added my knowledge.

This was a really great experience and I also learn how to behave with people around me and
how to work with team management.

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References:
www.positronic.com
www.goggle.com
www.electricalpanel.com
www.electriacal4u.com
www.positrnicmannual.com

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