Detailed Project Report on generator manufacturing unit

GENERATOR MANUFACTURING UNIT [CODE NO.3656]

A diesel generator converts mechanical energy (movement) into electrical power, and channels it through power cables. It can be helpful to imagine electricity flowing through wires in much the same way water flows through pipes. A generator can be thought of as a kind of ‘electrical pump’ which causes the electricity to flow through the wires. It doesn’t actually create or destroy the electrons that flow through the wires any more than a water pump creates new water. It just causes it to move in a useful fashion.

Diesel Generator set is used to generate electricity for meeting the electricity requirement of small establishments such as commercial buildings, Hotels, Railway Stations, Telephone Exchange, Shops etc. when there is a power supply failure from the State Electricity Board or other power supply undertakings.

The Generating set consist of alternator and a prime mover working on fuel. These two are coupled together and mounted on strong base. When the prime maker is started the alternator is rotated and required energy is available in the form of electricity from the alternator which can be supplied to the main switch.


COST ESTIMATION

Plant Capacity            60 Nos/Month       
Land & Building (5000 sq.mt.)      US$ 3.75 Lac         
Plant & Machinery                      US$ 87 Th.     
Working Capital for 2 Months     US$ 48.68 Lac
Total Capital Investment              US$ 53.76 Lac
Rate of Return            76%                   
Break Even Point             20%                

      
INTRODUCTION    
DG SET AS A SYSTEM    
SELECTION CONSIDERATIONS    
DIESEL GENERATOR CAPTIVE POWER PLANTS    
ADVANTAGES OF ADOPTING DIESEL POWER PLANTS ARE:    
DIESEL ENGINE POWER PLANT DEVELOPMENTS    
ENERGY SAVING MEASURES FOR DG SETS    
THE MAIN COMPONENTS OF A DIESEL GENERATOR    
THE ENGINE    
THE ALTERNATOR    
THE FUEL SYSTEM    
THE VOLTAGE REGULATOR    
THE COOLING SYSTEM    
THE EXHAUST SYSTEM    
THE LUBRICATION (OIL) SYSTEM    
THE STARTER & BATTERY SYSTEM    
THE CONTROL PANEL    
THE FRAME/HOUSING    
THE CANOPY    
TYPES OF GENERATORS:    
THEY CAN FURTHER BE CLASSIFIED INTO 3 MAIN TYPES.    
USES AND APPLICATION    
MINING    
HEALTHCARE    
COMMERCIAL    
OIL & GAS    
CONSTRUCTION    
MANUFACTURING    
TELECOMMUNICATIONS AND DATA CENTERS    
UTILITIES    
EDUCATION    
MILITARY    
B.I.S. SPECIFICATION    
PROCESS FLOW CHART    
MANUFACTURE PROCESS    
FUEL TANKS    
EXHAUST SYSTEM    
TESTING OF DG SET    
STANDARD REFERENCE CONDITIONS:    
GENERATOR LOAD BANK TESTING    
HOW DOES A LOAD BANK TEST WORK?    
STEP 1    
STEP 2    
STEP 3    
STEP 4    
STEP 5    
STEP 6    
CAUTION:    
WET-STACKING:    
BENEFITS OF LOAD BANK TESTING:    
INDIA DIESEL GENSET MARKET    
INDIA DIESEL GENSETS MARKET TO CROSS $2.9 BILLION BY 2021    
THE FUTURE OF DIESEL GENSETS IN A WORLD OF RENEWABLES    
INCREASING DEMAND FOR POWER TO BOOST INDIA DIESEL GENSET
   MARKET DURING 2016-22    
MARKET OVERVIEW    
DIESEL GENSETS – FIRING UP    
PERIOD OF VOLUME DECLINE OVER; EXPECT 10% CAGR OVER FY17-20    
DO LOWER POWER DEFICITS IMPLY LOWER DG DEMAND?    
INDUSTRIAL PRODUCTION AND CAPACITY BUILDING KEY DRIVERS,
  IN OUR VIEW    
SO WHAT DRIVES THE REVIVAL IN DG DEMAND OVER FY18-20?    
INFRASTRUCTURE SPENDING – ROADS, METRO RAIL, RAILWAYS    
DATACENTERS – A HUGE OPPORTUNITY FOR DG SET MANUFACTURERS    
HOTEL OCCUPANCY AT 9-YEAR HIGH – TO DRIVE NEW SUPPLY GROWTH    
SHIFT FROM UNORGANIZED TO ORGANIZED SEGMENT – GST TO
   HASTEN TRANSITION    
DIESEL GENSET INDUSTRY BACK ON GROWTH TRACK    
INFRASTRUCTURE SPENDING IS THE KEY DRIVER    
CUMMINS INDIA    
CUMMINS INDIA GOEM    
MAHINDRA POWEROL    
KIRLOSKAR OIL ENGINES GOEM    
PERKINS INDIA    
PERKINS INDIA DEALER    
WHAT GOES INTO MAKING A DG SET?    
THE ENGINE IS THE HEART OF THE MACHINE    
PLANT LAYOUT    
PRESENT MANUFACTURERS/SUPPLIERS OF DG SET    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF ELECTRICAL PANEL    
SUPPLIERS OF DISEL ENGINE    
SUPPLIERS OF ALTERNATOR    
SUPPLIERS OF COUPLING    
SUPPLIERS OF M.S. CHANNELS AND ANGLES    
SUPPLIERS OF M.S. FLAT    
SUPPLIERS OF M.S. PLATE    
SUPPLIERS OF PLANT AND MACHINERY    
SUPPLIERS OF EOT CRANE    
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS    
SUPPLIERS OF AIR CONDITIONING EQUIPMENTS    
SUPPLIERS OF AIR COMPRESSORS    
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS    
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS    
SUPPLIERS OF SHOT BLASTING MACHINE    
SUPPLIERS OF JIGS AND FIXTURE    
SUPPLIERS OF SUBMERSIBLE WATER PUMP    
SUPPLIERS OF MIG WELDING MACHINE    
SUPPLIERS OF POWER PRESS    
SUPPLIERS OF SHEARING MACHINE    
SUPPLIERS OF BENDING MACHINE    
SUPPLIERS OF PUNCHING PRESS    
SUPPLIERS OF GRINDING MACHINE    

APPENDIX – A:

01.    PLANT ECONOMICS    
02.    LAND & BUILDING     
03.    PLANT AND MACHINERY    
04.    OTHER FIXED ASSESTS    
05.    FIXED CAPITAL    
06.    RAW MATERIAL    
07.    SALARY AND WAGES    
08.    UTILITIES AND OVERHEADS    
09.    TOTAL WORKING CAPITAL    
10.    TOTAL CAPITAL INVESTMENT    
11.    COST OF PRODUCTION    
12.    TURN OVER/ANNUM    
13.    BREAK EVEN POINT     
14.    RESOURCES FOR FINANCE    
15.    INSTALMENT PAYABLE IN 5 YEARS    
16.    DEPRECIATION CHART FOR 5 YEARS    
17.    PROFIT ANALYSIS FOR 5 YEARS    
18.    PROJECTED BALANCE SHEET FOR (5 YEARS)