INTERNSHIP - SUNBEAM GENERATORS

INTERNSHIP REPORT

Submitted by

ABHISHEIK R (12BME001)

CHIPI CHAKKARAVARTHY.R (12BME014)

Department of Mechanical Engineering

Dr.Mahalingam College of Engineering and Technology

Pollachi - 642003

An Autonomous Institution

Affiliated to Anna University, Chennai - 600 025

 ACKNOWLEDGEMENT

First and foremost, we wish to express our deep unfathomable feeling, gratitude to our
institution and our department for providing us a chance to fulfill our long cherished of
becoming Mechanical engineers. We express our sincere thanks to our honorable Secretary Prof.
C. Ramaswamy M.E., F.I.V., for providing us with required amenities.

We sincerely thank our director Dr. S. Vijayarangan, M.E.,PhD., for his moral support
and encouragement for our internship. We wish to express our hearty thanks to Dr. M.
RamaKrishnan M.E., Ph.D., Principal of our college, for his constant motivation and continual
encouragement regarding our internship.

We are grateful to Prof. Dr. I. Rajendran M.E., Ph.D., Head of the Department,
Mechanical Engineering, for his valuable comments and guidelines.

We are grateful to Mr.Balasubramaniam General Manager for his guidance all along
the internship.
We are grateful to Mr.Shakthi HR&IR for his continuous support all along the
internship.
We are committed to place our sincere thanks to all Department Heads, all faculty
members & all those noble hearts of Sunbeam Generators that gave us immense
encouragement to bring our ideas into a realistic one that may achieve several heights.

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 TABLE OF CONTENTS
CHAPTER NO TITLE PAGE NO
1 INTRODUCTION 4
2 COMPANY BACKGROUND 5
2.1 GENERAL INFORMATION 5
2.2 COMPANY PROFILE 5
2.3 VISION STATEMENT 6
2.4 MISSION STATEMENT 6
2.5 DEALERSHIP 6
2.6 ORGANISATION CHART 7
3 COMPANY ACTIVITIES 8
3.1 HUMAN RESOURCE & ADMIN DEPARTMRNT 8
3.2 ACCOUNTS DEPARTMENT 8
3.3 MARKETING DEPARTMENT 9
3.4 INFORMATION TECHNOLOGY DEPARTMENT 9
3.5 STORES DEPARTMENT 9
3.6 DESIGNING DEPARTMRNT 10
3.7 PRESS SHOP DEPARTMENT 10
3.8 FABRICATION DEPARTMENT 11
3.9 SURFACE FINISHING DEPARTMENT 12
3.10 INTEGRATING DEPARTMENT 14
3.11 TESTING DEPARTMENT 14
3.12 QUALITY ASSURANCE DEPARTMENT 15
3.13 PACKING DEPARTMENT 15
4 BENEFITS OF THE TRAINING 16

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 1. INTRODUCTION

Power generators are important tools for anyone who wants extra protection in
emergencies against power loss. For the oil and gas industry, power generators are a very
important necessity. These generators provide key power sources for the oil and gas industry,
particularly to assist with drilling and digging. The procedure of both drilling and digging are
key to these industries, and a lot of power is needed to provide service to heavy equipment. With
the help of power generators, this can be achieved efficiently and also help to ensure that no
power loss will be suffered. A lot of different tasks are involved in the oil and gas industry, such
as deep earth and offshore drilling, pumping, and the actual delivery of the finished product.

If there is an emergency or disaster and the main power is shut down, generators can
assist with backup, allowing business to continue on as usual. This can save the industry a huge
amount of money and time.

All major companies rely on generators extensively. That’s why it’s important they
choose heavy duty, reliable generators that can give their facilities and equipment the power they
need to run smoothly and without any interruption.

The power needs of today’s Indian industry are on a steep and alarming increase by the
day and by the hour. The reason – ambitious growth plans both by the government and the
private sectors. With increasing shortfalls in power generation and frequent interruptions, the
industry can ill afford to rely solely on a single power source.

Sunbeam generators private limited, a Chennai based organisation, has taken a fitting call
as an effective response to this critical need of the Indian industry, specializing in the design,
manufacturing and supply of Canopied Diesel Generators(DG) sets for use as an alternate power
source in a wide market spectrum.

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 2. COMPANY BACKGROUND

2.1 GENERAL INFORMATION

S. No Particulars Details
1 Name Sunbeam Generators Private Limited
Apts. 5th & 6th floor,
Victoria Gardens,
2 Registered office
No.20, Inner ring road,
Koyamedu, Chennai 600017
R.S. No. 23/3A, 3B, 3C, 3D
Canal road,
3 Manufacturing facilities
Koodapakkam,
Pudhucherry - 605502
4 Phone No. 0413-2661032
5 Website www.sunbeampower.com
9.00 am to 1.00 pm
6 Staffing hours
1.30 pm to 5.30 pm

2.2 COMPANY PROFILE

SUNBEAM is an ISO 9001:2000 certified company, perfection in design and fuel

efficiency is guaranteed in all the aspects of power generation. Sunbeam, the power of silence is
one of the top players in the alternate power market segment – manufacturing and supplying
canopied DG sets to offices, hotels, restaurant, hospitals, banks and homes. It offers 24X7
services to its proud customers who rely on sunbeam for its best-in-class products with service.

Sunbeam’s manufacturing facility is in southern India. It sprawls over a 1,00,000 sq.ft

area. It was born out ideology of an integrated process line. Puducherry features a fantastic
infrastructure setup and to fully meet client expectations.

Sunbeam believes in keenly listening to its client, even to the smallest detail in his needs
which in way the company possesses the capacity to provide world class technical support, i.e.,
total solutions in short. It has been constant endeavour to create a new market with top notch
quality and unparalleled customer delight. As a consequence it has striven towards this end by
taking their business beyond the boundaries if commerce to render it as a lasting relationship.

Sunbeam generators private limited has been started in the year 1996 by
Mr.C.R.Madanagopal at Coimbatore. They started doing manufacture for all diesel generating
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sets like Kirloskar, Ashok Leyland and Caterpillar at Puducherry. In the year of 2000, Kirloskar
oil engines limited has introduced GENPOWER policy. As per the policy, they have short listed
their OEM’s (Original Equipment Manufacturers) from 32 to 11. In that list sunbeam was not
selected as OEM and Sunbeam was doing business only in a small way doing smaller range of
DG sets.

In the year of 2002, the present Managing Director Mr.P.S.Pushparaj took over the
company, obtained the OEM from kirloskar and started manufacturing and selling of kirloskar
diesel generator sets in the state of Tamilnadu, Puducherry and Andaman & Nicobar Islands.

In the year of 2005, government of India implemented noise pollution control act and all
DG set manufacturers are forced to sell the DG sets along with sound proof enclosures. Due to
this norm, sunbeam had moved to a bigger place and invested in machineries, land and
equipment. Sunbeam had set up all facilities to manufacture a sound proof diesel generator sets
like Turret punch press, Cutting and Bending machine, Foam fixing, Pre-treatment and powder
coating plant.

2.3 VISION STATEMENT

Even strive to be a centre of excellence in sheet metal enclosures, providing world class
solutions in the field of standby/alternate power, to eventually become a market leader in these
segments.

2.4 MISSION STATEMENT

The company firmly believe in rightfully paying back to society what it deserves by their
unstinting efforts in delivering a socio-commercial brand rendered with a technological face,
embodying top notch products that sustain and nurture the industry and the home.

2.5 DEALERSHIP
 Sunbeam generator has their dealership throughout the country. They have in Tamilnadu,
Orissa, and Andaman & Nicobar Islands.
 In Tamilnadu they have in Chennai, Vellore, Salem, Erode, Trichy, Tiruppur,
Coimbatore, Karur, Karaikal, Madurai, Tuticorin and Nagarcoil.
 In Orissa, they have their dealers in Balasore, Sambalpur, Bhubaneswar and Rayagada.
 In Andaman & Nicobar Island, they have their dealership in Port Blair.

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2.6 ORGANISATION CHART

Managing Director

Works Marketing

IT HR & IR Finance Commercial & Purchase

Executive Director Project & Purchase Marketing Global

Manufacturing
Direct Marketing Channel Partners

Design & Senior Works Quality Maintenance Safety &

development Manager Security

Section Heads

Press Fabrication Surface Integration Testing

Shop Finish

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 3. COMPANY ACTIVITIES:

Company activities are under taken by various departments. They are

3.1 Human Resource Department

3.2 Accounts Department
3.3 Marketing Department
3.4 Information Technology Department
3.5 Stores Department
3.6 Design Department
3.7 Press Shop Department
3.8 Fabrication Department
3.9 Surface Department
3.10 Integration Department
3.11 Testing Department
3.12 Quality Assurance Department
3.13 Packing Department

3.1 HUMAN RESOURCE & ADMINISTRATION DEPARTMENT

Sunbeam is made up of people and function through people. The resources of men,
materials, and machinery are collected co-ordinated and utilized through people. This resources
by themselves cannot fulfil the objectives of an organization. They need to be unit in to team.
All the activities of an organization are initiated and completed by the persons who make up the
organization. Therefore people are the most significant resources of any organization. skill,
creative abilities ,talents and aptitudes obtained in the population.

FUNCTIONS:

The function of this department can be analysed under the following three heads.

1. Procurement and development of personnel.

2. Payroll accounting.
3. Safety measures.

3.2 ACCOUNTS DEPARTMENT

Account is an ancient art which was followed mainly to record transaction of the business
to satisfy the requirements imposed by the fiduciary relationship between the business and its

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owner’s as well as the third party connected with the business credits, financial institutions etc.,
it is the subsidiary of every business organization without which it is very difficult to survive.

ACCOUNTING POLICIES

Sunbeam Generators Private Limited. Follows the mercantile system of accounting and
recognizes income and expenditure on accrual basis. The company is an SMC for the year 2008
as defined in the companies (Accounting Standards) Rule 2006 and all the financial statements
have been prepared on the historical cost convention and in accordance with generally accepted
accounting principles and in compliance in all material respect, with the notified accounting
standard and notes thereto. Differences between actual results and estimates are recognized in the
period in which they materialized.

3.3 MARKETING DEPARTMENT

Marketing means “the place where the seller and buyer share their transaction and it is
surrounded by other companies, competitors public and government. It’s concepts that deals
activities like identifying and meeting human and social needs in .simple way in sunbeam as
meeting needs profitability”

There must be goods and services exchanged between the producer and the consumer by
their values determined in terms of money value.

3.4 INFORMATION TECHNOLOGY DEPARTMENT

IT deals with the use of electronic computers and computer software to convert, store,
protect, process, transmit and securely retrieve information

When computer and communication technologies are combines the result is information
technology. Information technology is general terms that describe any technology that helps to
produce, manipulate, store, communicate and disseminate information. Presumably, when
speaking of information technology as a whole it is noted that the use of computers and
information in sunbeam.

3.5 STORES DEPARTMENT

Efficient store keeping is indispensable to material control. The stores department thus
renders services to the purchase department, by receiving materials. In sunbeam, they follow first
in first out method and a material control mechanism. By maintaining a proper account of

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inventories, this department also serves the accounting department. The main objectives of store
keeping are

 Prevention of under or over-stocking.

 Proper location and identification of stores items.
 Prompt issue.
 Issue in the required quantity.
 Prevention of loss due to defective storage.
 Avoidance of wastage.
 Prevention of pilferage theft and accidents and
 Minimization of storage and handling costs.

3.6 DESINGING DEPARTMENT

 Canopy is designed using the software

 Solidworks
 Canopy (enclosure) enclosing the generator and acting as proofing material(acoustic).
 Two types of designing
 Air-cooled type
 Water cooled type

Air-cooled Type:

 Air coolant-to absorb the high temperature

 Foam reducing the sound to 75db.

Water cooled Type:

 Radiator-absorb the high pressure and temperature

 Foam, rockwool - reducing the sound to 75db by absorbing it.

3.7 PRESS SHOP DEPARTMENT

 Machine: CNC Turret Punch(CNCTP)

 Model:Econ-156
 Design of canopy is fed to the CNS machine.
 Based up on the instruction machine starts its works.
 Processes undergone in press shop are

Shearing

 NC cutting the sheet metal into required size (length &thickness)

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  Shearing Machine:
 Machine Ref: SBG/PSM06
 Model: GS-3106
 Machine: NC Shearing Machine
 Cutting capacity (Max 6mm) Thickness.

Punching

 Numeric computerized shearing machines (CNS Machine) punch the holes.

Slitting

 Removing the unwanted pieces from the sheet metal i.e. Notching

Press Brake

 Sheet metal is bended at the required place.

 Sheet metal is used of TATA Stelium(Mild type)
 Thickness of sheet from 1.6 to 4mm.
 Two types of sheet metal
1. CRCA (cold role)
2. HRCA (hot role)

3.8 FABRICATION DEPARTMENT

Function

 Welding.

1. MIG Welding

2. TIG Welding

3. Spot Welding

4. Gas Welding

 Grinding Machine.
 4”standing machine
 AG7-Gtinding machine
 Drilling Machine.
 Hand drilling machine
 Sensible drill
 Chop Saw Cutting Machine.

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  Jigsaw Machine.

3.9 SURFACE FINISHING DEPARRTMENT

After fabrication the components of canopy undergoes the following treatments

Stud Welding:

Before pre-treatment all the welding work has to be finished such as providing
stud for bolts and nuts.

Pre-treatment process:

It involves nine stages such as

 Stage 1: Degreasing.
 Stage 2: Water Rinse.
 Stage 3: Derusting.
 Stage 4: water rinse.
 Stage 5: water rinse.
 Stage 6: phosphating.
 Stage 7: water rinse.
 Stage 8: passivation.
 Stage 9: water drying.
 Degreasing
 Chemical : Everclean-fon
 Dipping Time : 10-15 min
 Temperature : 60-70 Celsius
 Conc range : 75-80 points
 Tank capacity : 12000 litters
 Water rinse:
 Type of water : Industrial water
 Tank capacity : 12000 litters
 Dipping time : 1-2 min
 pH value : <9
 Temperature : Ambient
 Derusting:
 Chemical : Scale Gun-S
 Dipping Time : 10-15 min
 Temperature : Ambient

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  Conc range : 17-22 points
 Tank capacity : 12000 litters
 Water Rinse(two times):
 Type of water : Industrial water
 Tank capacity : 12000 litters
 Dipping time : 1-2 min
 pH value : >5
 Temperature : Ambient
 Phosphating:
 Chemical : Everphos AZP-44
 Dipping Time : 10-15 min
 Temperature : 60-70 Celsius
 Conc range : 18-22 points
 Tank capacity : 12000 litters
 Water Rinse:
 Type of water : Industrial water
 Tank capacity : 12000 litters
 Dipping time : 1-2 min
 pH value : >5
 Temperature : Ambient
 Passivation:
 Chemical : Everfix(NCR)
 Dipping Time : 1-2 min
 Temperature : 60-70 Celsius
 Conc range : 0-6 points
 Tank capacity : 12000 litters
 Water drying tank:
 Temperature :120 Celsius
 Dipping time : 10 min

Powder coating:

 Coating the component with powder to avoid rusting.

 The particles are coated by CORONA Discharge.

Stuffing Process:

 Stuffing the absorbing material(raw material)in the component

Effluent Treatment Plant

Two types of ETP

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  Chemical Treatment
 Line (ph<7)
 Alum(ph>7)
 Neutral(ph=7)
 Biological Treatment
 Micro Organism

Dematerialized Water Plant (DM Water Plant)

To Dematerialised the water caustic soda is used.

3.10 INTEGRATING DEPARTMENT

 Assembling the components inside the canopy after surface finishing.

 Two types of models:
 R Series(water cooled type)
 Radiator-coolant
 HA Series(Air cooled type)
 Ordinary fan-coolant
 K series involve two types of integrating
o Cap one type : Each component have separate base
o Integrated type : All components have one common basement

3.11 TESTING DEPARTMENT:

 Final stage of canopy is testing

 Testing involves the following steps:
 First applying load to the canopy.
 Two types of load : Resistive load & Water load.
 Checking the condition of: Alternator, Prime mover, Radiator& Silencer.
 Checking whether any leakages are there in the components.
 Checking the battery charged or not.
 Checking the working of:
o The voltmeter, Ammeter, Pressure gauge(min- 2bar ; max- 9bar),
Temperature gauge(min-Green mark ; max-Red mark),Frequency
meter(min-49.2hz ; max-52.25hz).
 Control Gear varies for different GENSET capacity:
o 7.5 KVA to 6.25 KVA - MCB (Miniature Circuit Breaker).
o 82.25 KVA to 125 KVA – MCCB (Moulded Case Circuit).
o 140 KVA to 600 KVA - EMS (Engine Monitoring System).

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  Charging the indictor has been checked.
 Testing is conducted at No Load, 25%Load, 75%Load, 100%Load for a
particular period of time.
 Sensors are fixed to avoid some dangers.
 Any of the material is damaged then it is replaced.
 Once sensor senses the fault it makes the component to short circuit.
 Safety measures indicated by fixed to control panel in order to indicate the
problem occurring places.
 Sound level is measured using sound level meter (75db) at one meter long.

3.12 QUALITY ASSURANCE DEPARTMENT

 For every GENSET

o Quality is assured
o Quality is maintained
 Booklet is maintained for each and every GENSET.
 Job processing card (JPC) is used to make a note on report.
 Four stages of Quality checker for checking.
o Incoming material
o Maintenance
o Powder coating
o Integrating and testing

3.13 PACKING DEPARTMENT

 Labels and stickers are pasted.

 If any of the part is not powder coated then the part alone will be coated using
liquid spray.
 At last it will be covered.

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 4. BENEFITS OF THE TRAINING

Departments Benefits
2D press shop  Learnt about Laser cutting technology
 Observed the working of automatic CNC laser cutting machine
 Learnt about sheet metal shearing, punching and slitting
 Observed the working of CNC turret punch machine
 Learnt new advanced technology in automatic machining processes
3D press shop o Learnt about sheet metal forming
o Observed the working of press brake machine
o Understood the importance of sheet metal bending for the canopy
Fabrication  Learnt about the MIG welding process
 Observed the various tricks used by the welders for various welding
 Learnt about the jigs and fixture design for various components
 Learnt about gas welding and gas cutting processes
Pre-treatment o Understood the importance of pre-treatment process for a material
o Observed the degreasing and de-rusting processes
o Learnt about the phospating and passivation processes of pre-treatment
o Understood the importance of effluent treatment and pollution control
o Learnt about the RO process of effluent after-treatment
Surface finish  Understood the importance of powder coating over normal painting
 Learnt about surface coating process
 Understood the concept of using charged powder as coating medium
 Understood the importance of foam & rockwool as sound proof material
Integration o Learnt about the working of diesel engines
o Learnt about the working of brushless alternator
o Understood the concept of step by step assembling process
o Understood the importance of aesthetic works for any product
Testing  Understood the need for testing the diesel generator set
 Understood the usefulness of various sensors in the engine
 Learnt about the pollution & noise control rules for generators
 Learnt about the load test using load bank & sound test using dB meter
Control panel
Design  Understood the need for design drawing in machining process
 Learnt about the sheet metal designing software Solid Sheet
 Understood the need for a nesting software like Radan
 Learnt about the CNC programming software for Amada machines

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