INDUSTRIAL TRAINING PROJECT REPORT

MECON LIMITED (A Govt. of India Enterprise) Ranchi- 834002

SUBMITTED BY DEVANSHU KUMAR ROLL No. 10901160911 BHAGWANT UNIVERSITY AJMER, RAJASTHAN TRAINING DATE 04.06.2012 TO 13.07.2012

ACKNOWLEDGEMENT

Working in an illustrated company like MECON was a great learning experience. I am thankful to MECON LIMITED for providing me the opportunity to work and learn under the guidance of MR. MAINAK MOITRA, without whom. I would have never been able to complete the project. I would also like to thank MR. M.S.S.N MURTHY for his support. Working under them was an experience unparalleled. I would be forever indebted to them for the knowledge, support and guidance they provided during the project

DEVANSHU KUMAR B.E. Final year BHAGWANT UNIVERSITY

INDEX
S.No
1. 2. 3. 4. 5. 6. 7.

CONTENT
COMPANY PROFILE CC-TV SYSTEM TELEPHONE EXCHANGE FIRE ALARM & DETECTION SYSTEM LOUDSPEAKER SYSTEM CONCLUSION BIBLIOGRAPHY

Page No.

COMPANYS PROFILE
MECON
MECON Limited, formerly known as (Metallurgical & Engineering Consultants (India) Limited) is a Public Sector Undertaking under the Ministry of Steel of the Government of India. It began in 1959 as the Central Engineering and Designing Bureau (CEDB) of the Hindustan Steel Limited (HSL), the first public sector steel company. Subsequently, CEDB grew as Metallurgical and Engineering Consultant (MECON), a subsidiary of the Steel Authority of India Limited (SAIL) in 1973. It later became an autonomous company reporting to the Ministry of Steel in 1978. 1st April is observed as Foundation Day in MECON. MECON Limited provides services in Power, Energy & Environment, Infrastructure, Oil & Gas, Metallurgy and other specialized areas. MECON is the first engineering consultancy organization in India to be accredited with the ISO 9001 certification. MECON GLIMPSES:

MECON LIMITED is a public sector undertaking under the Ministry of Steel, Government of India. MECON LIMITED established in 1959 under the aegis of Central Engineering & Design Bureau (CEDB), is Indias frontline engineering, consultancy and contracting organization, offering full range of services required for setting up of Project from concept to commissioning including turnkey execution. MECON is a multi- disciplinary firm with 1285 experienced & dedicated engineers, scientists and technologists, having a network of offices spread all over the country, experienced in handling consultancy assignments and EPC Projects. MECON has played a significant role in the development and expansion of Indian Industries. MECON is an ISO: 9001:2008 company and is registered with international financial institutions like WB, ADB, AFDB and has technological tie-ups with world leaders.

MISSION: "Developing into an internationally recognized centre of excellence for providing quality services in technical consultancy, design & engineering, design & supply of plant, equipment & systems, Project implementation from concept to commissioning for industrial development and up gradation ventures, development of infrastructure and other service sectors."

QUALITY POLICY :

KEY AREAS OF ACTIVITIES : METALS

Iron Making

Steel Making Rolling Mills Non- Ferrous By- products & Chemicals Raw Materials & Mining Beach Sand Mining & Mineral Beneficiation Refractories Research & Development

POWER

Power Plant- Thermal & Hydel Transmission & Distribution Non- conventional Energy sources Energy Management & Audit RLA & RMU Studies

OIL & GAS

Oil & Gas Pipelines Petrochemicals & Refineries CNG stations & City GAS Distribution POL Depots LPG bulk storage, handling, bottling & transportation Group Gathering station. Off-shore platforms & marine pipelines Retail Outlets

INFRASTRUCTURE

Civil & Structural Engineering Architecture & Town Planning Ports & Material Handling Roads, Bridges, Highways & Flyovers Defence Sector Environmental Engineering Hydro Engineering Information Technology Techno- Economics and Management Consultancy Services Healthcare Sector

CLOSED CIRCUIT TELEVISION SYSTEM (CCTV)

Introduction
As the name implies, Closed Circuit Television (CCTV) is a system in which the circuit is closed and all the elements are directly connected. This is unlike broadcast television where any

receiver that is correctly tuned can pick up the signal from the airwaves. Directly connected in this context includes systems linked by microwave, infrared beams, etc. Closed-circuit television (CCTV) is the use of video cameras to transmit a signal to a specific place, on a limited set of monitors. It differs from broadcast television in that the signal is not openly transmitted, though it may employ point to point (P2P), point to multipoint, or mesh wireless links. Though almost all video cameras fit this definition, the term is most often applied to those used for surveillance in areas that may need monitoring such as banks, casinos, airports, military installations, and convenience stores. In industrial plants, CCTV equipment may be used to observe parts of a process from a central control room, for example when the environment is not suitable for humans. CCTV systems may operate continuously or only as required to monitor a particular event. A more advanced form of CCTV, utilizing Digital Video Recorders (DVRs), provides recording for possibly many years, with a variety of quality and performance options and extra features (such as motion-detection and email alerts). More recently, decentralized IP-based CCTV cameras, some equipped with megapixel sensors, support recording directly to network-attached storage devices, or internal flash for completely stand-alone operation.

The Applications for CCTV

Probably the most widely known use of CCTV is in security systems and such applications as retail shops, banks, government establishments, etc. The true scope for applications is almost unlimited. Some examples are listed below.

Monitoring traffic on a bridge. Recording the inside of a baking oven to find the cause of problems. A temporary system to carry out a traffic survey in a town centre. Time lapse recording for the animation of plasticine puppets. Used by the stage manager of a show to see obscured parts of a set. The well-publicised use at football stadiums. Hidden in buses to control vandalism. Recording the birth of a gorilla at a zoo.

Making a wildlife program using a large model helicopter. Reproducing the infrared vision of a goldfish! Aerial photography from a hot air balloon. Production control in a factory.

The list is almost endless and only limited by the imagination.

A mobile closed-circuit TV van monitoring a street market

The shop manager provides the closed circuit television system for Control and supervision of technological processes at points, which are difficult to be observed directly, or which require monitoring from a remote control centre & General supervision. Some of the uses are discussed in details:

>>Industrial processes
Industrial processes that take place under conditions dangerous for humans are today often supervised by CCTV. These are mainly processes in the chemical industry, the interior of reactors or facilities for manufacture of nuclear fuel. Special cameras for some of these purposes include line-scan cameras and thermo graphic cameras which allow operators to measure the temperature of the processes. The usage of CCTV in such processes is sometimes required by law.

>>Traffic monitoring
Many cities and motorway networks have extensive traffic-monitoring systems, using closedcircuit television to detect congestion and notice accidents. Many of these cameras however, are owned by private companies and transmit data to drivers' GPS systems. The Highways Agency has a publicly-owned CCTV network of over 1,200 cameras covering the English motorway and trunk road network. These cameras are primarily used to monitor traffic conditions and are not used as speed cameras. With the addition of fixed cameras for the Active Traffic Management system, the number of cameras on the Highways Agency's CCTV network is likely to increase significantly over the next few years.

The London congestion charge is enforced by cameras positioned at the boundaries of and inside the congestion charge zone, which automatically read the license plates of cars. If the driver does not pay the charge then a fine will be imposed. Similar systems are being developed as a means of locating cars reported stolen. Other surveillance cameras serve as traffic enforcement cameras.

>>Transport safety

Digital Video Recorder for Public Transport

A CCTV system may be installed where an operator of a machine cannot directly observe people who may be injured by some unexpected machine operation. For example, on a subway train, CCTV cameras may allow the operator to confirm that people are clear of doors before closing them and starting the train. Operators of an amusement park ride may use a CCTV system to observe that people are not endangered by starting the ride. A CCTV camera and dashboard monitor can make reversing a vehicle safer, if it allows the driver to observe objects or people not otherwise visible.

Equipment Details:
The CCTV system shall comprise of Television camera with motorized zoom/fixed focal length lens. Weather proof housing for camera. Mounting platform. Pan & tilt head with control unit. Camera control unit Video monitors. Video switching unit. Central control desk and panel. Interconnecting video and control cables. Un-interrupted power supply unit. Cables and other associated accessories.

TV CAMERA: The camera unit shall be complete with all electronic circuitry, devices, components, control switches, standard mount foe lenses, mounting assemblies etc. Controls like back focus lens select, phase adjustment, power ON/OFF etc. provided at the rear for on the spot adjustment. The mounting assemblies of the cameras shall be individually selected depending upon the special requirements as per actual site conditions. The camera mounting platform shall be suitable for, mounting the camera assembly on the walls/ false ceilings/ column/ structures as per the area to be covered by the individual camera. Technical data Camera: TV system Scanning system Minimum scene Video output Lens type : CCIR-PAL, 625 lines, and 50 fields/sec. : 2:1 interlaced scanning : 10 lux for usable picture illumination : 1.0V (p-p), 75 ohms : Motorized zoom / fixed focal length

The camera mounting platform shall be suitable for mounting the camera assembly on walls/ false ceilings/ column/ structures as per the area to be covered by the individual camera.

The camera lenses shall be remote controlled motorized zoom/ fixed focal length type. The choice of lenses, their focal length and viewing angle shall be judiciously done for effective monitoring suited to the specific application requirements in the shop floor. Auto iris lenses with internal spot filters shall be used for varying lighting conditions.

Protective Arrangements:
To protect the CCTV camera from high temperature, dust, humidity, corrosion of the steel plant environment, weather proof housing (conforming to IP 54) shall be provided for the cameras.

The housing shall be made of rugged die-cast aluminium alloy and painted against corrosion. All latches fasteners and mounting used in the weatherproof housing shall be of anti corrosion/ anti rust metal. Heavy duty type wash & wipe unit for cleaning the front glass of the housing and blower fan for cooling the housing shall be provided as part of the weather proof housing. The control for the wash & wipe unit blower unit shall be provided in the control panel at the operators deck. Water cooling jacket for the camera

At the locations where the ambient temperature is high, the protective camera housings will be provided with water cooling jacket to protect the camera against high temperature in against high temperature in areas having ambient temperature up to 120 degrees Celsius. Cooling water will be supplied to the jacket continuously to cool the camera and keep it frilly efficient & operational. Double walled stainless steel housing will be provided for protective camera high temperature. Back cover of the water cooled housing will be detachable so that the camera can be taken out / installed from the rear for service and inspection. The cooling jacket will have temperature sensor to monitor the temperature of the camera, a toughened glass front, filter & an annuciator. Whenever the camera temperature crosses the upper threshold limit of the desired temperature there will be audio visual indication in the control panel at the operator desk. Technical Parameter SL. NO. 1. 2. 3. DESCRIPTION Type of camera used Temperature range Cooling water PARAMETERS C/CS 60-120 degree Celsius Industrial grade cooling water at 35 degree Celsius

PAN AND TILT UNIT:

The remote controlled pan & tilt unit shall be rugged in construction and smooth in operation. This unit shall be used to cover large area of interest for surveillance in different directions, as required by the control room operator. The unit shall be suitable for mounting on walls / column / structures / hanging from ceiling to meet the indoor surveillance requirement. The unit shall have complete freedom of movement throughout the entire pan & tilt scan. The unit shall comprise of pan & tilt head and control unit. The control unit shall be installed in the control panel at the operators deck. The remote control unit shall be designed to move the camera both in horizontal and vertical planes.

Operating angle : Horizontal 0 to 355 degree, Vertical +/- 90 degree Operating speed : Panning 4 degree/second, Tilting 4 degree/second

SL. NO. 1. 2. 3. 4. 5.

DESCRIPTION Angular travel in horizontal plane Angular travel in vertical plane Operating condition) Operating condition) Maximum compatible fitted) Braking

PARAMETERS 0 to 355 +/- 90 degree

speed Panning (no load 6 deg./sec speed Tilting (no load 6 deg./sec load (Load rating to be for camera, lens and housing Mechanical friction type Up to 120 degree Celsius

6. 7.

Rated temperature range

CCTV MONITOR: The Black & white / colour CCTV monitor shall be suitable for industrial application and compatible for the TV cameras.

It shall be of fully solid state, modular in design and shall provide a bright, clear and well-defined picture display on the TV screen. All controls for power supply on/off, brightness, contrast, vertical hold etc. shall be provided on front panel for readily adjusting the video signal. The rear panel shall be equipped with input and output BNC connectors for coupling the video output to other TV equipment. The video monitor shall be housed in a dust- proof metal enclosure with antidazzling light shield. It shall be suitable for rack mounting / moon control console / ceiling hang type as par the site requirement.

The specifications of the Camera to be used and different requirements: Picture tube size Scanning system : 19 diagonal : CCIR-B PAL, 625 lines and 50 field/sec

Horizontal resolution : Better than 600 lines Vertical scan rate Power supply : 50 Hz : 240V, 50Hz, single phase AC.

VIDEO SWICHING UNIT: The unit shall be suitable for switching & channelling of incoming video signals from different TV cameras to a single monitor. The switching unit shall have on screen camera identification and on screen operation status. It shall confirm to the technical parameters given below.

CONTROL PANEL: The control panel shall facilitate easy operation and enable the operator to have a clear and easy view of the pictures transmitted by various cameras. All remote camera controls i.e.; control of camera, control of motorized zoom lens assembly, pan & tilt head , control of blower unit , wipe & wash unit of the weather proof housing and its associated equipment shall be mounted on one desk mounted type console and shall be installed in the control pulpits. The control panel shall indicate the temperature of the camera (the temperature inside the water-cooling jacket) & there will be an audiovisual indication in case the temperature violates the desired limits.

INTERCONNECTING CABLES: The inter connection cables shall include: Coaxial cable for transmission of video signal from camera to the monitor. Multi-core control cable for remote control of camera and pan & tilt unit through remote control units from the operator console, as required. Power supply cables for providing power supply to various equipments.

Coaxial Cable

Multi-core Cable

Power Supply Cable

The supplier shall furnish detailed technical specification of various types of cables proposed to be used for providing interconnection between various units of the CCTV system.

POWER SUPPLY: All the equipment of the CCTV system shall work on 240 V, 50Hz, single phase AC power supply. The tenderer shall also supply and install the necessary power supply equipment required for feeling stabilized power supply to CCTV system. An uninterrupted power supply (UPS) system shall be supplied and installed by the tenderer for providing necessary stabilized and continuous power supply to the complete equipment at the control centre. The power supply equipment shall include all transformers, chargers and maintenance free battery bank (for 30 minutes back up), inverters, distribution boards etc. including all necessary cabling and other accessories.

Technological developments:

Todays High-definition CCTV cameras have many computer controlled technologies that allow them to identify, track, and categorize objects in their field of view. >>Video Content Analysis: VCA is the capability of automatically analyzing video to detect and determine temporal events not based on a single image. As such, it can be seen as the automated equivalent of the biological visual cortex. A system using VCA can recognize changes in the environment and even identify and compare objects in the database using size, speed, and sometimes color. The cameras actions can be programmed based on what it is seeing. For example; an alarm can be issued if an object has moved in a certain area, or if a painting is missing from a wall, and if someone has spray painted the lens. VCA analytics can also be used to detect unusual patterns in a videos environment. The system can be set to detect anomalies in a crowd of people, for instance a person moving in the opposite direction in airports where passengers are only supposed to walk in one direction out of a plane or in a subway where people are not supposed to exit through the entrances. VCA also has the ability to track people on a map by calculating their position from the images. It is then possible to link many cameras and track a person through an entire building or area. This can allow a person to be followed without having to analyze many hours of film. Currently the cameras have difficulty identifying individuals from video alone, but if connected to a keycard system, identities can be established and displayed as a tag over their heads on the video. There is also a significant difference in where the VCA technology is placed, either the data is being processed within the cameras (on the edge) or by a centralized server. Both technologies have their pros and cons. >>Facial recognition system: It is a computer application for automatically identifying or verifying a person from a digital image or a video frame from a video source. One of the ways to do this is by comparing selected facial features from the image and a facial database. The combination of CCTV and facial recognition has been tried as a form of mass surveillance, but has been ineffective because of the low discriminating power of facial recognition technology and the very high number of false positives generated. This type of system has been proposed to compare faces at airports and seaports with those of suspected terrorists or other undesirable entrants.

Eye-in-the-sky surveillance dome camera watching from a high steel pole

Computerized monitoring of CCTV images is under development, so that a human CCTV operator does not have to endlessly look at all the screens, allowing an operator to observe many more CCTV cameras. These systems do not observe people directly. Instead, they track their behavior by looking for particular types of body-movement behavior, or particular types of clothing or baggage.

>>Retention, storage and preservation:

Most CCTV systems record and store digital video and images to a Digital Video Recorder or in the case of IP cameras directly to a server, either on-site or offsite. The amount of data stored and the retention period of the video or pictures are subject to compression ratios, images stored per second, image size and duration of image retention before being overwritten. Recordings are usually kept for a preset amount of time and then automatically archived, overwritten or deleted. The amount of time the videos are kept allow retrieval and review in the event a crime was committed or the information needs to be studied for any number of reasons.

>>Closed-circuit digital photography (CCDP)

Closed-circuit digital photography (CCDP) is more suited for capturing and saving recorded high-resolution photographs, whereas closed-circuit television (CCTV) is more suitable for livemonitoring purposes. However, an important feature of some CCTV systems is the ability to take high resolution images of the camera scene, e.g. on a time lapse or motion-detection basis. Images taken with a digital still camera often have higher resolution than those taken with some video cameras. Increasaingly, low-cost high-resolution digital still cameras can also be used for CCTV purposes. Images may be monitored remotely when the computer is connected to a network.

>>IP cameras

A growing branch in CCTV is internet protocol cameras (IP cameras). IP cameras use the Internet Protocol (IP) used by most Local Area Networks (LANs) to transmit video across data networks in digital form.

Easy Connect Wireless IP camera

IP can optionally be transmitted across the public internet, allowing users to view their camera(s) through any internet connection available through a computer or a 3G phone. For professional or public infrastructure security applications, IP video is restricted to within a private network or VPN.

>>Wireless security cameras

Many consumers are turning to wireless security cameras for home surveillance also. Wireless cameras do not require a video cable for video/audio transmission, simply a cable for power.

Wireless security camera

Wireless cameras are also easy and inexpensive to install. Previous generations of wireless security cameras relied on analog technology; modern wireless cameras use digital technology which delivers crisper audio, sharper video, and a secure and interference-free signal.

CCTV camera vandalism

Unless physically protected, CCTV cameras have been found to be vulnerable against a variety of (mostly illegal) tactics:

Some people will deliberately destroy cameras. Some cameras can come with DustTight, Pressurized, Explosion proof, and bullet-resistant housings. Spraying substances over the lens can make the image too blurry to be read. Lasers can blind or damage them. However, since most lasers are monochromatic, color filters can reduce the effect of laser pointers. However, filters will also impair image quality and overall light sensitivity of cameras (see laser safety article for details on issues with filters). Also, complete protection from infrared, red, green, blue and UV lasers would require use of completely black filters, rendering the camera useless.

TELEPHONE EXCHANGE
The telephone exchange presently being used in the industrial complexes are designed with latest digital switching technology and offer utmost reliability and efficiency in operation ensuring instant communication. The number of extension lines may vary from 50 lines to 1, 00,000 lines depending upon the requirement.

INTRODUCTION:
The telephone exchange is microprocessor based, stored program controlled, employing time division multiplexing and pulse code modulation technique. The telephone exchange is modular in construction, thus enabling system up gradation to meet future requirements in small steps. Redundancy is provided in the exchange control unit & other critical components to ensure uninterrupted operation of the exchange functions even in case of failure of these units/components. The telephone exchange are capable of simultaneously accepting, processing and delivering information in various forms such as voice, data and text in wholly integrated manner. The exchange provide all familiar distinct tones, such as dial tone, busy tone, NU tone, ring back tone etc. Adequate protection of exchange is provided against electrical short circuits and heavy current flow as a result of induced or conducted lightning or power systems faults. The exchange is also protected against electromagnetic and electrostatic interference. Present day telephone exchange provides introduction of remote maintenance of the exchange. The exchange shall work on 48V DC power supply. All auxiliary power supplies required for equipment shall be derived internally from the 48 V supply. All the components used in the telephone exchange are rated for round the clock continuous operation.

Equipment details:
The telephone exchange system shall broadly comprise of : Telephone exchange equipment and peripherals Main distribution frame with protection devices Power supply equipment including rectifier cum charger Back up battery set and interconnecting cables & wires Auto-telephone instruments Telephone cable network comprising cables wires distribution & termination devices and associated accessories required for connecting the telephone instruments to the telephone exchange.

TELEPHONE EXCHANGE:
The exchange cabinet is complete with central processing unit, control/extension/junction line/conference facility cards, switching circuits, interfacing module and devices for processing and interconnection of speech, data & text and service circuits, power supply modules, maintenance console, operator console, interconnecting cables, wires, connectors and other auxiliary equipment. The exchange is basically called as EPABX (Electronics Private Automatic Branch Exchange). The main manufactures of such exchange are SIEMENS, NEON etc. The one that used in MECON is NE1000 series which have its modules bigger in size than that of SIEMENS. These are digital electronic circuits with normally extensions from 512-6144. It uses pulse code modulation for speech path. It allows the transmission of data, voice and image processing for office automation. It also allows internet, word processing, simultaneous and bidirectional communication of data along with mail service. The main cabinet of an exchange mainly consist of two parts namely basic cabinet, and Link Terminal Equipment (LTE). Also there is a possibility for adding additional cabinet units or LTEs depending on the requirement. In MECON, the exchange uses 650 lines which can be extendible up to 1000 lines.

LINK TERMINAL EQUIPMENT (LTE):

A LTE is equipment that is used to connect actual calls between different users. It is terminated at the exchange mother-board through an Inter Unit Highway Bus. For a typical exchange, there will be a number of LTEs present. It also consists of Miscellaneous Equipment (MSEA) which is used as a Level adjustor. Each LTE consists of number of PCBs. Each PCB can have a maximum of 8 numbers connected to it. These are all again interconnected using inter unit buses. Each Printed Circuit Board (PCB) has a number of integrated chips (IC), capacitors, resistors, and LEDs present on it. These are used for the proper operation of the exchange. The LEDs are used to show the status of a particular line. Since there are a maximum of 8 lines present, there will be 8 LEDs present on each PCB for each line. The PCB consists of a 16-bit microprocessor embedded in it which is used to make computation and processing. It is also used to generate system clock and calendar. There are also other applications like mathematical manipulations and also ability of storage present in the microprocessor. The LTE also consist of electronic switching circuits that are used to switch between different users. These switching circuits are all controlled by the central Mother-board present in the exchange. The entire cabinet is divided into a number of rows. All the basic cabinets and LTEs are placed in these rows. The LTEs normally must be mounted from the lower row. To increase the capacity of the cabinet, additional units are simply mounted on to the previous rows. Each LTE has two cords connected to it. They are power supply cord and a Bus Interface Cord. The power supply cord gives the LTE a voltage of about 5V and a current of 16A. The Bus Interface cord is used to interface the LTE section to the Mother-board. The maintenance of the cabinet and the motherboard along with all its equipment is done by using peripherals like a computer, and a Line printer. Software called Hyper Terminal is used in the maintenance works. The one that is used at MECON is cgl.ht. Using the computer, the operator can know which lines are on and for

what time. So this can be used to calculate the bills, the number of hours a line is on etc. The format that is used in this software is given by, Interrupt ESCAPE Code FNC FUNCTION section : delimit p1, p2 parameter code : End section

The Function section is used to classify the function to be performed. The parameter section takes in the addresses of LTEs and the numbers of the callers i.e. the address of the terminal. The other parts are nothing but the syntax used in the software.

MAIN DISTRIBUTION FRAME (MDF):

MDF serves as a common terminating point of the telephone cable network. The MDF shall be compact with systematic wiring and termination, following a numbering scheme facilitating easy maintenance. MDF acts as a connection between the exchange and the actual phone lines. So it has two sides present in it namely the Exchange side, and the Line side. The exchange side is the side where the MDF is connected to the cabinet. The line side is the side where it isconnected to the phone lines. MDF is mainly an interface between input and output lines. The main reason for the use of MDF is that it allows a more number of phone lines to be connected than what actually are present in the cabinet i.e. if there are some 600 lines in the cabinet, then actually if no MDF is present there would be only 600 phones connected to it. If MDF is present, it connects more than 600 phones (say 650 lines) to the cabinet. This is done by generalizing that not all the 650 phones are actually used simultaneously. So using this principle it increases the number of telephones that are connected to the exchange. MDFs that are used are of Krone

type. MDF also consist of Tag blocks that are used to connect to the actual lines. These are then connected to the MDF through normal cables. MDF mainly consist of two section- one for input and other for outputs. Each section has a number of blocks depending upon the requirements. Each block has 10 pairs of wires connected to it and these can be allotted to 10 subscribers or 10 telephones. One block will be in the line side and the other will be in the exchange side i.e. one is connected to the phone lines and the other to the exchange. The size of the MDF depends on the number of phone lines and the capacity of the exchange. Each MDF block in the line side is provided with protection devices. These protection devices are used to provide protection to the exchange from effects like short circuit, open circuit and other voltage fluctuations. One of the mostly used protection devices is the Glass Discharge Tube (GDT). A GDT consists of a glass discharge tube that is filled inside with vacuum at the centre. When a signal goes through it, it is discharged through the tube in such a way that it is accordance with the current present in the signal. So, based on the input current of the signal, the signal is sent through it to the exchange side avoiding any adverse effects. This protection should be given at line side because generally the variations are more in the signal coming from the main phone line. Generally the MDF is mounted on a wall and the connecting wires are made through the ceiling or the flooring.

Power Supply Equipment:

Power supply to the exchange is provided from 240V, 50Hz, single phase, AC supply. The exchange shall work off 48V DC obtained through a Rectifier cum Charger or Automatic Charger cum Booster. The power supply equipment shall comprise of suitably rated stabilized rectifier cum charger feeding to the Exchange and a set of battery in parallel float working principle. The set of battery (lead acid type) works as a backup for providing un interrupted power supply to the exchange equipment in case of AC mains failure. A switching circuit in the power supply unit automatically change-over from rectifier to battery supply in case of AC mains failure.

The automatic charger cum booster is connected to the battery equipment and the also is connected to the AC mains. When the electric mains are on, AC power is delivered to the exchange. When there is no electric mains supply, then it automatically changes to the battery unit for getting the supply. When the AC mains are present, the rectifier automatically charges the battery unit. Also a booster unit is present inside, which is used to boost the power supply when needed i.e. to increase the power supply instantaneously.

Battery Unit:
This unit consists of four batteries (may be of lead acid), each with a capacity of 12V. These are all connected in series to provide a total supply of 48V DC. This battery unit should be kept in a separate room since there is a possibility of these batteries leaking the acid out. These batteries are charged through the rectifier cum charger when the supply mains are on. Some of the companies that provide batteries are EXCIDE, Amara raja, VARTA etc. This battery unit requires a completely independent room because of its heavy size. But recently, the batteries have shrunk in size and the capacity is also increased. The capacity of the batteries is measured in terms of the ampere-hours it can produce. Typically, a battery unit will have about nearly 180 Amp-Hr. This value will provide the information about how long a battery can give a backup to the exchange. Basing on the load it drives, which is about 25 A in a typical 1000 line exchange, the capacity of battery unit will be around 7-8 hours continuously. The battery room should have acid-resistance flooring and should have an exhaust fan attached to the wall. The illumination to the room may be low.

Telephone Instruments:
Telephone instruments are desk/wall mounted type, rugged in construction suitable for industrial application. The telephone instruments shall be Standard table top model Standard wall mounted model Executive secretary model Loud ringing model Multi-key model Cordless model

A standard telephone unit consists of mainly 4 sections: Cradle unit Speech unit Dial unit Bell unit

Cradle Unit:
The cradle unit consists of a spring. This acts as a switch between the line in and bell unit. When the spring is in depressed position, there will be a connection between the line in and bell unit. Since the lines in has the signal input which consists of 48V DC, the bell unit will be provided with a voltage. So whenever a call comes, and then signal in comes and the bell unit gets the voltage and the bell rings. Also when the spring is not in a depressed position i.e. the handset is lifted, then the connection between bell unit and the signal in will be removed. But the speech unit is connected always to the line in. so when the spring is not depressed, i.e. the handset is released, the speech unit gets a signal from the exchange which gives a dial tone to the line in.

Speech Unit:
The speech unit consists of an Integrated Chip TEA1060. It is mainly used to send the speech signals to the exchange and from there to the other phone. It is also used

to get the dial tone and other tones from the exchange. It will be connected to the signal in always so that it gets the input voltage at all times.

Dial Unit:
The dial unit consists of an IC UM 9559E, a number pad and sensors. Whenever the handset is lifted, the dial tone is heard. Then the number is pressed on the number pad. The dialing can be of two types Tone Dialing Pulse Dialing In the tone dialing, each number will be given some frequency, and if a number is pressed, then that particular frequency is set and given to the exchange. At the exchange the digit is identified by using the frequency. In the pulse dialing, when a digit is pressed, then the circuit is selected a number of times equivalent to the digit pressed. So, based on the number of times a circuit is selected, the digit is identified. The digit pad is attached with a sensor for each digit. These sensors are used to sense the digit that is pressed and give to the exchange, based on whether tone dialing is being used or pulse dialing. A 10 line parallel bus is used to connect the digit pad to the actual circuit, this is if the form of parallel gateway.

Bell Unit:
This unit consists of an IC LS1240, a condenser and a volume control knob. The bell unit is connected to the line in through the cradle unit. The spring in the cradle unit acts as a switch between the bell unit and the line in. Whenever the spring is depressed, there will be connection between the bell unit and the line in. Then if a call comes, there will be a signal from the line in, which in turns on the beli by providing a voltage required for the bell. When the handset is lifted, i.e. the spring is not depressed, and then there will be no connection between the bell unit and the line in. The IC produces a sound based on the input voltage it obtained. A condenser or a capacitor will be there to maintain a uniform voltage and to reduce the variations in

the input voltage. It is also used in speech recognition. It is typically of 350 V DC and 1.5 micro farad (+/- 10%). There is also a volume control knob to adjust the sound of the ring of the phone. This is done by using a resistor-capacitor network which changes the voltage coming to the IC. Thus the IC produces the sound based on the input voltage applied and so the ring sound changes accordingly. There will also be a bridge circuit to reduce the microphone signal. Also there will be points for in line coming from the exchange and for connecting the handset. Sound proof booths for telephones: Soundproof booths are provided for the telephones to be installed in noisy areas in the shop floor. These booths are provided with audio visual indication facilities for incoming calls.

Cable Network:
The telephone exchange has a separate cable network for facilitating the provision of the specified number of telephones in various units of the plant complex. For interplant cabling, cables shall generally be laid in the manner as follows Directly buried in ground or in cable trenches with cables laid in racks In underground cable tunnels & overhead cable galleries In concrete ducts/ pipes buried in ground where burial are not possible due to presence of other service lines.

FIRE DETECTION AND ALARM SYSTEM

An automatic fire alarm system is designed to detect the unwanted presence of fire by monitoring environmental changes associated with combustion. In general, a fire alarm system is classified as either automatically actuated, manually actuated, or both. Automatic fire alarm systems are intended to notify the building occupants to evacuate in the event of a fire or other emergency, report the event to an off-premises location in order to summon emergency services, and to prepare the structure and associated systems to control the spread of fire and smoke.

FIGURE: Fire alarm system

Purpose of a fire alarm system:

It is the task of the fire alarm systems to detect a fire soon after it breaks out and o warn persons who are able to initiate suitable protective measures.

The sooner an alarm signal reaches the central alarm unit, the greater is the chance that the fire can be brought under control in good time. This helps to keep the extent of damage and the associated sequential damage and the losses due to the interruption of the plant operation as low as possible.

General principles for design of fire detection and alarm system:

Detect quickly enough to fulfill its intended functions. Reliability transmits the detection signal. Remains insensitive to phenomena other than those, which its function is to detect. Signal immediately and clearly and supervised fault that might jeopardize the correct performance of the system

Standards and statutory requirements:

The system offered shall conform to the latest editions of the following Indian standards (IS), British standards (BS), and relevant stipulations of National Fire Protection Association (NFPA) of USA. IS 2189: Code of practice for selection, installation and maintenance of automatic (Amend. In 1989) fire detection and alarm system. All requirements shall comply with statutory requirements of the Government of India & the state government, which may be enforced during the execution of the contract.

Design and arrangement of a fire alarm system:

After the fire protection goals are established - usually by referencing the minimum levels of protection mandated by the appropriate model building code, insurance agencies, and other authorities - the fire alarm designer undertakes to detail specific components, arrangements, and interfaces necessary to accomplish these goals. Equipment specifically

manufactured for these purposes are selected and standardized installation methods are anticipated during the design. Fire alarm system generally consists of the following components: Fire alarm control panel: This component, the hub of the system, monitors inputs and system integrity, controls outputs and relays information. Primary Power supply: Commonly the non-switched 120 or 240 Volt Alternating Current source supplied from a commercial power utility. In non-residential applications, a branch circuit is dedicated to the fire alarm system and its constituents. "Dedicated branch circuits" should not be confused with "Individual branch circuits" which supply energy to a single appliance. Secondary (backup) Power supplies: This component, commonly consisting of sealed lead-acid storage batteries or other emergency sources including generators, is used to supply energy in the event of a primary power failure. Initiating Devices: This component acts as an input to the fire alarm control unit and are either manually or automatically actuated. Examples would be devices like pull stations or smoke detectors. Notification appliances: This component uses energy supplied from the fire alarm system or other stored energy source, to inform the proximate persons of the need to take action, usually to evacuate. This is done by means of a flashing light, strobe light, electromechanical horn, speaker, or a combination of these devices. Building Safety Interfaces: This interface allows the fire alarm system to control aspects of the built environment and to prepare the building for fire and to control the spread of smoke fumes and fire by influencing air movement, lighting, process control, human transport and exit. Automatically actuated devices can take many forms intended to respond to any number of detectable physical changes associated with fire: convicted thermal energy; heat detector, products of combustion; smoke detector, radiant energy; flame detector, combustion gasses; carbon monoxide detector and release of extinguishing agents; water-flow detector. The newest innovations can use cameras and computer algorithms to analyze the visible effects of fire and movement in applications inappropriate for or hostile to other detection methods.

Automatic Fire detectors or fire identifiers: Automatic Fire Detection and Alarm Systems have two main purposes, in the event of a fire: to provide a warning to the occupants of a building. and to initiate the emergency plan for the premises which can include evacuation.

Figure: Automatic fire detector

When properly installed and maintained, these systems can be a significant factor in reducing the risk to life and limiting damage to your property in the event of a fire. These systems can help us to respond very quickly to genuine emergencies. Depending on the criterion to which they respond, automatic fire detectors are classified as follows: Heat detectors: A heat detector is a fire alarm device designed to respond when the convicted thermal energy of a fire increases the temperature of a heat sensitive element. The thermal mass and conductivity of the element regulate the rate flow of heat into the element. All heat detectors have this thermal lag. Heat detectors have two main classifications of operation, "rate-of-rise" and "fixed temperature." Fixed temperature heat detector:

This is the most common type of heat detector. Fixed temperature detectors operate when the heat sensitive eutectic alloy reaches the eutectic point changing state from a solid to a liquid. Thermal lag delays the accumulation of heat at the sensitive element so that a fixed-temperature device will reach its operating temperature sometime after the surrounding air temperature exceeds that temperature. The most common fixed temperature point for electrically connected heat detectors is 136.4F (58C). Technological developments have enabled the perfection of detectors that activate at a temperature of 117F (47C), increasing the available reaction time and margin of safety. This type of technology has been available for decades without the use of batteries or electricity as shown in the picture.

Figure: Fixed temperature heat detector Smoke detector: A smoke detector is a device that detects smoke, typically as an indicator of fire. Commercial, industrial, and mass residential devices issue a signal to a fire alarm system, while household detectors, known as smoke alarms, generally issue a local audible or visual alarm from the detector itself.

Figure: Smoke detector

Ionization smoke detector: An ionization smoke detector uses a radioisotope such as americium-241 to produce ionization in air; a difference due to smoke is detected and an alarm is generated. Ionization detectors are more sensitive to flaming fires than optical detectors, while optical detectors are more sensitive to smoldering fires. An ionization type smoke detector is generally cheaper to manufacture than an optical smoke detector; however, it is sometimes rejected because it is more prone to false (nuisance) alarms than photoelectric smoke detectors. It can detect particles of smoke that are too small to be visible.

Figure: Ionization smoke detector

Optical smoke detector: An optical detector is a light sensor. When used as a smoke detector, it includes a light source (incandescent bulb or infrared LED), a lens to collimate the light into a beam, and a photodiode or other photoelectric sensor at an angle to the beam as a light detector. In the absence of smoke, the light passes in front of the detector in a straight line. When smoke enters the optical chamber across the path of the light beam, some light is scattered by the smoke particles, directing it at the sensor and thus triggering the alarm. Also seen in large rooms, such as a gymnasium or an auditorium, are devices that detect a projected beam. A wall-mounted unit sends out a beam, which is either received by a separate monitoring device or reflected back via a mirror. When the beam becomes less visible to the "eye" of the sensor, it sends an alarm signal to the fire alarm control panel. According to the National Fire Protection Agency, "photoelectric smoke detection is generally more responsive to fires that begin with a long period of smoldering (called smoldering fires)." Also, studies by Texas A&M and the NFPA cited by the City of Palo Alto California state, "Photoelectric alarms react slower to rapidly growing fires than ionization alarms, but laboratory and field tests have shown that photoelectric smoke alarms provide adequate warning for all types of fires and have been shown to be far less likely to be deactivated by occupants." Although optical alarms are highly effective at detecting smoldering fires and do provide adequate protection from flaming fires, fire safety experts and the National Fire Protection Agency recommend installing what are called combination alarms, which are alarms that either detect both heat and smoke, or use both the ionization and photoelectric / optical processes. Also some combination alarms may include a carbon monoxide detection capability. Not all optical or photoelectric detection methods are the same. The type and sensitivity of the photodiode or optical sensor, and type of smoke chamber differ between manufacturers.

Figure: optical smoke detector

Flame detector: There are several types of flame detector. The optical flame detector is a detector that uses optical sensors to detect flames. There are also ionization. flame detectors, which use current flow in the flame to detect flame presence, and thermocouple flame detectors. Combined with the ionization smoke detector it is also suitable for supervising high room e.g. oir craft hanger & rooms with highly inflammable materials. it can also be used where deception probability due to simulation flame characteristics is especially high e.g. motor test stand The flame detectors respond to the modulated radiation in the infra red range emitted by flames. Non automatic fire detectors: The person in the affected room or area operates non automatic fire detectors by hand, usually. The non-automatic fire detectors are preferable mounted in escape routes at exits, stairways, in areas with a special fire hazard and spread over buildings covering a large area.

Depending on where they are used, there are different type manual fire alarm call points.

Fire Alarm Control Panel: Fire Alarm Control Panel is the controlling component of a Fire Alarm System. The panel receives information from environmental sensors designed to detect changes associated with fire, monitors their operational integrity and provides for automatic control of equipment, and transmission of information necessary to prepare the facility for fire based on a predetermined sequence. The panel may also supply electrical energy to operate any associated sensor, control, transmitter, or relay. There are four basic types of panels: coded panels, conventional panels, addressable panels, and multiplex systems.

Figure: Fire alarm control panel

Conventional panels have been around ever since electronics became small enough to make them viable. conventional panels are used less frequently in large buildings than in the past, but are not uncommon on smaller projects such as small schools, stores, restaurants, and apartments. A conventional Fire Alarm Control Panel employs one or more circuits, connected to sensors (initiating devices) wired in parallel. These sensors are devised to dramatically decrease the circuit resistance when the environmental influence on any sensor exceeds a predetermined threshold. In a conventional fire alarm system, the information density is limited to the number of such circuits used. To facilitate location and control of fire within a building, the structure is subdivided into definite areas or zones. Floors of a multistory building are one type of zone boundary. An Initiating Device Circuit connected to multiple devices within the same "zone" of protection, effectively provides 2 bits of information about the zone corollary to the state of the circuit; normal, or off normal and alarm or quiescent. The state of each Initiating Device Circuit within a zone displays at the Fire Alarm Control Panel using visible indications called Annunciators. These Annunciates may employ a graphical representation of the Zone boundaries on a floor plan (Zone map) using textual descriptions, illuminated icons, illuminated sections, or illuminated points on the map corresponding to Initiating Circuits connected to the Fire Alarm Control Panel. For this reason, slang often inaccurately refers to initiating circuits of a Fire Alarm Control Panel as Zones. Larger systems and increasing demand for finer diagnostic detail beyond broad area location and control functions expanded the control by Zone strategy of conventional systems by providing multiple initiating circuits within a common Zone, each exclusively connected to a particular type of initiating device, or group of devices. This arrangement forms a device type by Zone matrix whose information is particularly suited to the Tabular Annunciate or In multistory buildings employing a Tabular Annunciate or for Example; rows of indicators define the floors horizontally in their stacked relationship and the type of device installed on that floor displays as columns of indicators vertically aligned through each floor. The intersection of the floor and device indicators provides the combined information. The density of information however remains a function of the number of circuits employed. Even larger systems and demands for finer diagnostic and location detail led to the introduction of addressable fire alarm systems with each addressable device providing specific information about its state while sharing a common communication circuit. Annunciation and location strategies for the most part remain relatively unchanged.

Power Supply: The power supply, which is usually integrated in the fire alarm panel, consists of two power sources each independent of the other. One is the main supply, the other is a chargeable battery that in the event of a main failure automatically supplies power to the fire alarm system without interruption. The battery is constantly kept in a state ready for operation,. Faliour of one of the power source is indicated as a fault on the fire alarm panel.

LOUDSPEAKER:
This system is intended to provide instantaneous and reliable communication as per the technological requirements between various process control points, senior operation and maintenance personnel of the shop/plant. 1. LSIS(Loudspeaker Intercommunication System) 2. LSTBS(Loudspeaker Talkback System) 3. General Announcement System

LSIS(Loudspeaker Intercommunication System)

The system is microprocessor based and consists of a Central Control Unit(CCU) number of subscriber stations, power supply equipment and interconnecting cable network. The subscriber stations can be switched in as desired through the central control units. The system shall provide the following modes of communication amongst its various subscribers: a) Master to subscriber b)Subscriber to master c)Subscriber to subscriber through master d)Subscriber to subscriber direct

There is no limitation on no of simultaneous communication channels. In point to point call mode , a subscriber can called a chosen subscriber by pressing the switch or no allotted for the called subscriber . Priority calls for a subscriber by pressing priority breaks in. Group calls from a subscriber is possible and diagnostic features is inbuilt in the system. The equipment is designed for reproducing high level perfectly intelligible speech and shall have high operational reliability under adverse reliable condition such as corrosive and dusty atmosphere , high temperature, humidity and vibration of industrial complexes . In principle all subscriber station shall be connected to the central unit by ordinary standard twisted , multi paired PVC insulated , PVC sheathed telephone cable. Equipment details : The system microprocessor based and consist of the following : a)CCU for system b)No of subscriber stations c)Power supply units including set of backup battery d)Interconnecting cables CCU:- CCU is microprocessor based intended foe automatic speech path switching and blocking between various subscriber station connected to the system.It is modular in design and is hosed in dust proof , self supporting or wall mounting cabinet with a lockable rear door . The CCU is provided diagnostic features that is facility for monitoring and checking the function subscriber station . Subscriber stations:- Each subscriber station consist pre amplifier ,an amplifier ,a loudspeaker a noise compensated microphone , power supply equipments and a switch board carrying no of push button for station selection and group calls and junction boxes. Power supply:-The equipment is suitable for operation from a centralized 240 Volt, 50 Hz Single phase AC mains power supply. On failure of AC supply the system will automatically switch over to inverter supply derived from a set of back up battery. Interconnecting Cables:-The CCU shall be connected with all the subscriber stations using multi pair telephones cables and shall have termination facility as required for incoming as well as outgoing cables.Each subscriber stations is connected to its loudspeaker through a pair of copper cables . Each subscriber station will be connected to the centralized power supply source by a core , 1.5 sq.mm . ATC , PVC , insulated and PVC sheathed power supply cables.

LSTB(Loudspeaker talkback system)

Loudspeaker Talkback System works in one to one mode in which A calling person lift the handset and press to PAGE to call the desired person. Paging announcement is heard by all the loudspeaker except that of the calling station or calling person . After announcement calling person releases the press to PAGE and waits for response of called person . Called person will go to the nearest station and communicate with the calling person directly in private mode.

Various modes of Loudspeaker Talkback System is:1. Press-to-Talk Mode: As the term implies, the operator merely presses the Off/Listen/Talk switch to its Talk position to communicate with other stations on the system. The loudspeaker acts as a microphone in this position. The spring-loaded switch will return to the Listen position when released. The Off/Listen/Talk switch will mute the loudspeaker when placed in the Off position. The signal lamp will still operate with this switch turned Off. 2. Headset/Handset Mode: Plugging a headset or telephone handset into the front panel will cause the LS-3 to function exactly as a headset station. The LS-3 detects the presence of the headset or handset, and automatically disconnects the loudspeaker. The Microphone On/Off switch is used to mute the microphone in the headset or handset. The Off/Listen/Talk switch should be left in the Listen position in this mode.

3. Full Duplex, Hands-free Mode: When an LSM-1 or 2 gooseneck microphone is plugged into the front panel , the LS-3 detects this and shifts to its full duplex, hands-free mode. The gooseneck microphone and the built-in loudspeaker operate simultaneously, with none of the clipping off of initial consonants, as happens in a VOX operated circuit. The operator may speak and listen at the same time, without any switching. The very

high side tone rejection performance of Production Intercom systems permits this use without feedback, and at surprisingly high levels. For best performance in this mode, the recessed side tone control must be optimized. Only one LS-3 may be used in this mode within any one acoustic environment. Attempting to use more than one without acoustic isolation may result in serious feedback problems. In a noisy environment, the Microphone On/Off switch may be used to mute the output of the

microphone to other stations.

There are five modes of control, determined by the position of the recessed Override level control accessible through the front panel, and adding or removing links on the rear PC board. Mode 0: No override function Mode 1: Switch to preset override volume level Mode 2: As mode 1, plus shunts Off/Listen/Talk from Off to Listen Mode 3: As mode 1, plus shunts Off/Listen/Talk from any position to Listen. Mode 4: As mode 1, plus shunts Off/Listen/Talk from Talk to Listen

CONCLUSION

It was a great opportunity undergoing a summer training programmed at MECON. Not only during these 45 days I, learnt about various methods of communication used in the industries and many other things related to studies, also gave me an insight about how people work in the industries. I also got to understand the work environment in the industries that will definitely prove fruitful in my life when my chance to work in such an environment comes by.