Sudhir Group came into existence in 1973 and has today forged a unique position for itself through its commitment made towards quality & complete customer satisfaction. Covering a spectrum of services including power generation, distribution, protection, control & automation for over three decades the company has provided world class services & products to the industry. An Industry leader in the field of setting up Diesel base Captive Power Plants upto 20MW having its corporate office in Jammu and various other States & revenue of over INR 1000 Crs, it has leveraged its relationship with Cummins Ltd.
Driven through a tireless & unstinting desire for excellence in every field, the organisation has achieved an enviable position by a programme of continious improvement of quality, consistent growth, productivity & profitability, customer goodwill & employee empowerment. Converting every challenge into an opportunity, we have garnered the market forces of liberalisation, competition and globalisation through stage-of-the-art facilities & a highly dedicated and motivated team, thus creating new benchmarks in quality, speed & reliability.
The Company has a wide blue-chip customer base and operates through multiple manufacturing facilities across India and focuses on Diesel & Gas Generators, HT & LT Switchboards, Transformers and Turnkey EPC contracts. The product line includes the widest range of Diesel Gensets 7.5-3000 KVA with a fuel option of Diesel or Gas, Transformers, Packaged Substations, complete range of HT 11KV & 33KV Panels, LT Switchboards, Turnkey EPC contracts covering electrical and mechanical services. Indeed, they have achieved and leapfrogged towards unprecedented growth. But to us this is just another step in our ongoing journey to greater goals and broader horizons.
Core values of the Organisation:
- Product integration.
- Deliver value for money.
- Development of people.
- Transparency.
Mission of the Organisation:
- Sustain Business Growth
- Foster innovation.
- Drive value.
- Protect the Environment.
Vision of the Organisation: To go beyond Power Generation & the distribution equipment market with high standards for technology, integrity and professionalism.
The Company And its Tie-Up with cummins: The company had signed a tie-up with Cummins India Ltd. , manufacturer of engines. They Provide both Type of Diesal and Gas Engines to Sudhir Gensets.
Advertisement: Also the candidates up to particular level have to undergo a better of compulsory selection tests, which include Personality, aptitude test & a series of functional tests, by which competence of the candidates at the cognitive level is assured. Important factor considered while selecting an individual are the set of aptitude and values an individual possess , as this determines the ultimate adjustments between organization and employee. Many times vacancies are also filled by circulating the requirement internally, for e.g. the scheme of ‘fast track’ to managerial carriers. Candidates with the necessary aptitude under goes a selection test programmers based ‘assessment center methodology’. Those who are successful can jump almost four grades.
Training and Learning: All classes of employees are trained. Non skilled are trained to become skilled worker and skilled worker are trained to acquire multiple skills. Diploma and graduates engineers are trained for one year. There are special managements programmers and classes. In addition to the job related training all employee attend self-development programmes.
Work Culture: The SGL Seeks to create a culture where each employee, vendor, and dealer feels himself responsible and integral part of the enterprises. The work culture at SGL is open & participative. Learning is encouraged in the company. Every member respects 5 S(Methodology).
- Seiri
- Seiton
- Seiso
- Seiketsu
- Shitsuke
The 5s also helps to develop and maintain a good organizational behavior. The ultimate goal of house keeping through 5s is to reduce the cost of product by increasing productivity and contributing to total quality.
Techniques used in SGL Jammu:
- CAPP : computer aided process planning
- SQC : statistical quality control
- JIT : just in time
- PPE : process planning engineer
- PDCA : plan do check list ( dr. Fleming’s philosophy)
How a Generator Works: Basically speaking, a generator is a device which uses a magnet in order to induce a flow of electric current in a circuit, much like how a water pump pushes water through a hose. A generator functions because of the relation between magnetism and electricity. If electrons (the parts of an atom which carry a negative charge) move through something conductive like a wire, they generate a magnetic field. Conversely, if a magnetic field is placed near a wire and moved, its motion causes the electrons in the wire to move because of a change in electrical potential.
This is known as a current. In the 1830s, Michael Faraday discovered this principle and built the first electromagnetic generator known as the Faraday disc, which used a copper disc rotating between the poles of a horseshoe magnet. In 1832, the first dynamo was built consisting of a power-producing armature moving within a stationary magnetic field.
Types of Generators: The first generators were used in industry and later on to provide electrical power to homes. The past few years have seen the proliferation of engine-generator sets also known as gensets or simply generators for a variety of purposes. There are gasoline generators, diesel generators, liquefied petroleum gas generators, and propane generators; there are even human-powered generators, such as those found in some types of radios and the small sets found in bicycle lights.
- Standby Generators
- Portable Generators
- Commercial Generators
Alternator: An alternator is an electromechanical device that converts mechanical energy to electrical energy in the form of alternating current. Most alternators use a rotating magnetic field with a stationary armature but occasionally, a rotating armature is used with a stationary magnetic field; or a linear alternator is used. In principle, any AC electrical generator can be called an alternator, but usually the term refers to small rotating machines driven by automotive and other internal combustion engines. An alternator that uses a permanent magnet for its magnetic field is called a magneto. Alternators in power stations driven by steam turbines are called turbo-alternators.
Radiator: Radiators are used for cooling internal combustion engines, mainly in automobiles but also in piston-engine aircraft, railway locomotives, motorcycles, stationary generating plant or any similar use of such an engine. Internal combustion engines are often cooled by passing a liquid called engine coolant through the engine block, where it is heated, then
through the radiator itself where it loses heat to the atmosphere, and then back to the engine in a closed loop. Engine coolant is usually water-based, but may also be oil. It is common to employ a water pump to force the engine coolant to circulate, and also for an axial fan to force air through the radiator.
Radiator Coolent for Engine: A coolant is a fluid which flows through or around Engine to prevent its overheating, transferring the heat produced by it to other devices that use or dissipate it. An ideal coolant has high thermal capacity, low viscosity, is low-cost, non-toxic, and chemically inert, neither causing nor promoting corrosion of the cooling system. Some applications also require the coolant to be an electrical insulator. The coolant used in SGL’s generators are of anti-freeze type(An antifreeze is a chemical additive which lowers the freezing point of a water-based liquid. An antifreeze mixture is used to achieve freezing-point depression for cold environments and also achieves boiling-point elevation (“anti-boil”) to allow higher coolant temperature. Freezing and boiling points are colligative properties of a solution, which depend on the concentration of the dissolved substance ).
Control panels: Any complex piece of machinery requires a user interface to enable the user to monitor its operations, check for efficient functioning, and intervene when required. Machines overheat, slow down, speed up or generally vary in their performance based on numerous factors such as fatigue, weather conditions, and the wear and tear of components and parts. In electrical machines, like generators, these varying changes constitute an electrical signal. Additional information about generators. These signals can be intelligently processed to control the performance of the machine.
A lot of machines in urban environments (such as signal lights and automatic doors) are completely self-managed due to such controllers. They have sensors that can detect changes in physical attributes like heat and speed and generate signals accordingly. Modern generators also have similar sensors to detect changes in all kinds of various parameters. These can be used to control the generator through a control panel. Visually, a control panel is a set of displays that indicate the measurement of various parameters like voltage, current and frequency, through gauges and meters.
These meters and gauges are set in a metallic body, usually corrosion proof, to protect from the effect of rain or snow. The panel may be set up on the body of the generator itself, which is usually the case with small generators. If they are mounted on the generator, they typically have vibration proof pads that help isolate the control panel from shocks. Control panels for a larger industrial generators can be completely separate from the generator and are typically large enough to stand upon their own. These units may also be shelf-mounted or wall-mounted next to the generator, which is common inside an enclosure or intental application like a data center.
Control panels are usually fitted with buttons or switches that help to operate the generator such as a switch-off button or turn-on key. The switches and gauges are usually grouped on the basis of functionality. This makes the panel friendly and safe for use since it minimizes the possibility of an operator accidentally selecting or executing the wrong control. Imagine trying to shut down a vibrating generator with a spring loaded lever in the middle of the night and you will appreciate why having a simple cut of switch at the control panel makes sense.
Working of control panels: The control panel is becoming an increasingly complex piece of electronics with a microprocessor that can manipulate input from sensors to help give feedback to the machine to manage itself. One such feedback could be the temperature, indicating overheating, other examples would be over/under speed and low/high oil pressure. Typically, a heat sensor inside the generator would sense the build up of heat in the generator body and pass this to the microprocessor in the control panel.
The microprocessor will then take effective measures to regulate the performance of the machine including shutdowns if, for example, the oil pressure is too low or the coolant temperature is too high, leading to buildup of heat. In industrial situations, this functionality of control panels is becoming increasingly critical. The microprocessor or microcontroller is embedded in the circuitry inside the control panel and is programmed to take in the sensor input and react to that with the programmed control rules. Control panels can be combined with an Automatic Transfer Switch (ATS) to maintain the continuity of electrical power.
The ATS detects an outage of power when your local grid fails. It signals the control panel to start the generator. Depending on the type of generator being used, the control panel may activate glow plugs (for diesel) for an adjustable length of time. It will then start the generator using an automatic starter, similar to the one you engage when you turn the keys in the ignition of your car in the morning. As soon as the engine of the generator reaches an optimum speed, the starter is disengaged. The ATS then switches to the generator power, and you can go back to business as usual, without having to frantically scramble to figure out what caused power loss. This aspect of a control panel makes it extremely useful in homes during bad weather and in industrial situations for ensuring mission-critical continuity.
When selecting an electric overhead traveling crane, there are a number of requirements to be taken into account:
- What specifications, codes or local regulations are applicable?
- What crane capacity is required?
- What is the required span?
- What is the lift required by the hoist?
- What will be the duty cycle (usage) of the crane?
- What is the hoist weight? Do you need the use of a second hoist on the bridge crane?
- What is the hook approach required?
- What length of runway system is desired?
- What factors need to be considered in the design of runway and building
structure? - What will the operating environment be (dust, paint fumes, outdoor, etc)?
- What are the necessary crane and trolley speeds?
- What is the supply voltage/phases/amperage?
- What control system is desired?
- Is there existing cranes on the runway?
- What safety considerations are to be followed?
- Consider maintenance aspects of the crane.
- Consider other accessories such as lights, warning horns, weigh scales, limit switches, etc.
Types of electric overhead cranes: There are various types of overhead cranes with many being highly specialized, but the great majority of installations fall into one of three categories:
- Top running single girder bridge cranes
- Top running double girder bridge cranes
- Under-running single girder bridge cranes.
Electric Overhead Traveling (EOT) Cranes come in various types:
- Single girder cranes – The crane consists of a single bridge girder supported on two end trucks. It has a trolley hoist mechanism that runs on the bottom flange of the bridge girder.
- Double Girder Bridge Cranes – The crane consists of two bridge girders supported on two end trucks. The trolley runs on rails on the top of the bridge girders.
- Gantry Cranes – These cranes are essentially the same as the regular overhead cranes except that the bridge for carrying the trolley or trolleys is rigidly supported on two or more legs running on fixed rails or other runway. These “legs” eliminate the supporting runway and column system and connect to end trucks which run on a rail either embedded in, or laid on top of, the floor.
- Monorail – For some applications such as production assembly line or service line, only a trolley hoist is required. The hoisting mechanism is similar to a single girder crane with a difference that the crane doesn’t have a movable bridge and the hoisting trolley runs on a fixed girder. Monorail beams are usually I-beams (tapered beam flanges)
Double Girder Cranes: In SGL we use Double girder cranes. Double girder cranes are faster, with maximum bridge speeds, trolley speeds and hoist speeds approaching 350 fpm, 150 fpm, and 60 fpm, respectively. o They are useful cranes for a variety of usage levels ranging from infrequent, intermittent use to continuous severe service. They can lift up to 100 tons. o These can be utilized at any capacity where extremely high hook lift is required because the hook can be pulled up between the girders. o They are also highly suitable where the crane needs to be fitted with walkways, crane lights, cabs, magnet cable reels or other special equipment.
EOT Crane Configuration:
- Under Running (U/R)
- Top Running (T/R)
Under running cranes: Under Running or under slung cranes are distinguished by the fact that they are supported from the roof structure and run on the bottom flange of runway girders. Under running cranes are typically available in standard capacities up to 10 tons (special configurations up to 25 tons and over 90 ft spans). Under hung cranes offer excellent side approaches, close headroom and can be supported on runways hung from existing building members if adequate. The Under Running Crane offers the following advantages:
- Very small trolley approach dimensions meaning maximum utilization of the building’s width and height.
- The possibility of using the existing ceiling girder for securing the crane track.
Top Running Cranes: The crane bridge travels on top of rails mounted on a runway beam supported by either the building columns or columns specifically engineered for the crane. Top Running Cranes are the most common form of crane design where the crane loads are transmitted to the building columns or free standing structure. These cranes have an advantage of minimum headroom / maximum height of lift.
Basic crane components: To help the reader better understand names and expressions used throughout this course, find below is a diagram of basic crane components.
- Bridge – The main traveling structure of the crane which spans the width of the bay and travels in a direction parallel to the runway. The bridge consists of two end trucks and one or two bridge girders depending on the equipment type. The bridge also supports the trolley and hoisting mechanism for up and down lifting of load
- End trucks – Located on either side of the bridge, the end trucks house the wheels on which the entire crane travels. It is an assembly consisting of structural members, wheels, bearings, axles, etc., which supports the bridge girder(s) or the trolley cross member(s).
- Bridge Girder(s) – The principal horizontal beam of the crane bridge which supports the trolley and is supported by the end trucks.
- Runway – The rails, beams, brackets and framework on which the crane operates.
- Runway Rail – The rail supported by the runway beams on which the crane travels.
- Hoist – The hoist mechanism is a unit consisting of a motor drive, coupling, brakes, gearing, drum, ropes, and load block designed to raise, hold and lower the maximum rated load. Hoist mechanism is mounted to the trolley.
- Trolley – The unit carrying the hoisting mechanism which travels on the bridge rails in a direction at right angles to the crane runway. Trolley frame is the basic structure of the trolley on which are mounted the hoisting and traversing mechanisms.
- Bumper (Buffer) – An energy absorbing device for reducing impact when a moving crane or trolley reaches the end of its permitted travel, or when two moving cranes or trolleys come into contact. This device may be attached to the bridge, trolley or runway stop.
Hoists: A hoist is a device used for lifting or lowering a load by means of a drum or lift-wheel around which rope or chain wraps. Cranes and Hoists are somewhat interchangeable terminology since the actual lifting mechanism of a crane is commonly referred to as a hoist. Hoists may be integral to a crane or mounted in affixed position, permanently or temporarily. When a hoist is mounted to a trolley on a fixed monorail, two directions of load motion are available: forward or reverse, up or down. When the hoist is mounted on a crane, three directions of load motion are available: right or left, forward or reverse, up or down. Figure on the next page shows a rope hoist for double girder crane application.
