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


Rating (in kW)


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


SDB-3 ( Trim Line and Final Line)

SDB 3

Area Covered

bt the SDB


Rating (in kW)


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


SDB layoutSDB 4

SDB-4

Area Covered

bt the SDB


Rating (in kW)


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


SDB-5

SDB

5

Area Covered

bt the SDB


Rating (in kW)


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


SDB-6

SDB

6

Area Covered

bt the SDB

SDB-6 Supply to Feeder

no.Rating (in kW)


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


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


P507MLDB-1 TO HOIST 4



(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



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

Engineering

To Study the power supply of the Assembly Shop