INDUCTION PROGRAM REPORT

Submitted to

PRIYANKA M T

HR department

TDPS

Submitted by

SHASHANK.P

ENGINEER – Quality assurance

M1390

DATE: 28-02-2025
 Brief note on Induction Program:
An induction program is the process used within many businesses to welcome new
employees to the company and prepare them for their new role. It helps in the integration of
employees into the organization. Induction involves orientation and training of the employee
in the organizational culture, and showing how he or she is interconnected to (and
interdependent on) everyone else in the organization. Induction provides new starters with
important information regarding their new employment.

Induction ensures that new employees are initiated in the expectations, performance and
culture of the Company. When used strategically, the induction process can increase employee
retention by helping them understand their role and how it fits into the company. Companies
that have a structured new employee induction processes are more likely to have higher
productivity within the workforce, as the new employee may be able to add value to the
business sooner if they can hit the ground running. Employees who have undertaken a
structured induction process will have a fair idea of how the company operates.

For employers an induction process can:

• Contribute to a positive workplace culture as it assists new employees to transition and

assimilate into the workplace.
• Encourage employee retention, reduce employee turnover and save on recruitment
costs as it helps employees feel welcome and valued.
• Ensure operational efficiency and increase productivity – employees have a full
understanding of the company and their role within it so they can hit the ground
running.
• Educate employees on compliance with company policies and procedures, and
Workplace Health and Safety.
• Enhance company reputation by creating a professional impression.

The benefits of employee induction for new staff are:

• The induction process helps new employees settle into their role quicker.
• New hires better understand their role and how it fits into the organisation.
• New starters feel respected and valued and accepted into the organisation by team
members.
• New employees better understand company processes and (workplace health and
safety) policies and procedures.
 • New staff receive necessary information as to organisational culture and standards of
behaviour to help them assimilate.
• The induction process helps establish good communication with managers and team
members.
INTRODUCTION TO TDPS:
TD Power was established on April 16, 1999, using technology acquired from Toyo Denki in
Japan. Later it was listed on the Bombay Stock Exchange and the National Stock Exchange. TDPS is
one of the leading manufacturers of AC Generators in the world with products in the output range
of 1 MW to 200 MW for prime movers such as steam turbines, gas turbines, hydro, diesel
engines and wind turbines. TDPS also manufactures special application generators for Geothermal
and Solar thermal applications. Focus is on manufacturing custom-designed generators for
customers who are based all over the world. Reliability is ensured by world class manufacturing
processes and quality control. The company have service partners in 19 countries covering all
continents. Over 5000 + generators manufactured are installed in 98+countries across the globe
spanning Asian, European, American & African continents. TDPS culture is driven by its people.
The company has a diverse and dedicated team of individuals who are committed to building
innovative products that keep the world moving. The company's culture is characterized by its
focus on excellence, teamwork, and innovation.

Milestones of TDPS are as follows:

 1999: Acquired technology from Toyo Denki, Japan.

 2001: Manufacturing facility established in Bangalore at 9 machines per year.

 2009: Developed Vertical Hydro Generators with Voith, Germany.

 2011: Listed on Bombay Stock exchange and National Stock Exchange.

 2012: Agreement with Siemens for 2 pole Generators up to 250MVA

 2016: Established branch office in USA & EUROPE as TDPS USA & TDPS Europe.

 2017: Began Manufacturing generators in Turkey.

 2019: Supplied largest 4-pole generator to Germany.

 2022: Introduced a new vertical for Induction & synchronous motor. 
2024: Expanded Global footprint to 105 countries
 On Boarding: Documentation, Logistics, Arrangements:
On-boarding refers to the process of integrating new employees into an
organization and I get necessary information, resources, and support to start
my new roles effectively. This process typically includes various aspects such
as documentation, logistics, and arrangements.

 Safety, Health and Environment:

SHE gives details about the safety protocols to be followed that inside TDPS
premises. Employees are trained to be aware of their surroundings and to be
alert to potential threats. They are taught to identify and avoid accidents and
to report any concerns to their supervisor. Employees are trained on how to
evacuate the workplace in the event of an emergency. They are taught where
the safe assembly points are located, and how to get there quickly and safely
and gave the details about PPE (Personal protective equipment) to be used
during shop floor visits.

 HR, Industrial relations & Social welfare practices:

Industrial Relation: TDPS maintains good industrial relations with its

employees. They have a strong focus on employee welfare and provide their
employees with several benefits. TDPS also has several employee engagement
programs, such as sports events, cultural events and training programs. These
programs help to create a positive work environment and foster a sense of
belonging among employees.
Social Welfare practices: TDPS's CSR initiatives are an important part of
its corporate culture. The company believes that it has a responsibility to
give back to the communities in which it operates. By supporting social
welfare, TDPS is helping to create a more sustainable and equitable
future.

 Finance & Accounts: TDPS uses a standard accounting system to track

financial transactions. The system is designed to be accurate and
efficient, and it helps to ensure that the company's financial records
are up to date.

 Marketing:
 Marketing refers to the activities a company undertakes to promote the buying or selling
of its products or services. Marketing includes advertising and allows businesses to sell
products and services to consumers, other businesses, and organizations. Marketing is
the process of getting people interested in your company's product or service. This
happens through market research, analysis, and understanding your ideal customer's
interests. Marketing pertains to all aspects of a business, including product
development, distribution methods, sales, and advertising.

• Introduction to customer Base:

TDPS customers are located all over the world, including India, the United States,
Europe, the Middle East, and other 101 countries.Company has a strong track
record of delivering high-quality products and services to its customers.

• Product Range of TDPS:

TDPS generators are available in a variety of sizes, upto 200MW, and can be powered
by a variety of prime movers, including steam turbines, gas turbines, hydro turbines,
diesel engines, gas engines, gas and wind turbines.

 POSH: Prevention of Sexual Harassment:

TDPS has a strong commitment to preventing and addressing sexual harassment in the
workplace. The company's POSH policy sets out the company's expectations for
employees and outlines the procedures for reporting and investigating the allegations
of sexual harassment. This policy is a comprehensive and effective tool for
preventing and addressing sexual harassment in the workplace. The policy is clear,
concise, and easy to understand. It also provides a clear process for reporting and
investigating allegations of sexual harassment.

 QUALITY MANAGEMENT SYSTEM: (QMS)

 A quality management system (QMS) is a collection of business processes and
procedures which aim to ensure that the quality of products or services meets – or
exceeds - customer expectations. Such systems are typically repeatable and
measurable, and rely on continuous improvement. Its purpose is to ensure that every
time a process is performed, the same information, methods, skills and controls are
used and applied in a consistent manner.

TDPS is certified with ISO 9001:2015 which is a worldwide standard that provide
requirements for a strong Quality Management System. It details specific processes,
procedures and activities that organizations must create, implement, maintain and
improve to successfully manage making products or delivering services. This
certification ensures that TDPs has a robust QMS in place that is designed to meet the
needs of its customers and stakeholders. The system helps to ensure that the company
meets the needs of its customers and stakeholders, and it also helps to improve the
company's efficiency and profitability.

 Production Planning & Control (PPC):

Production Planning and Control (PPC) is the process of managing the production of
goods or services. It involves planning, scheduling, and controlling the production
process to ensure that products are produced on time, within budget.

PPC is important for any organization that produces goods or services. It helps to ensure
that production is efficient and cost-effective, and that products meet customer
expectations. By working together, these functions can help to ensure that PPC is
successful and that TDPS company is able to produce products that meet customer
expectations. Challenges faced by PPC are Change in Demand, Uncertainty in the Supply
Chain & Quality problems.
 Pre-Production Engineering:

Pre-Production Engineering is a critical phase in TD Power Systems (TDPS) that focuses

on production by ensuring the readiness of manufacturing processes, equipment and
resources. Importance of pre- production engineering is it is involved in all the process
of manufacturing and provide the support extended to production, Cost reduction and
contingencies and care points to mitigate consequences at TDPS.

 Servicing / Customer support:

The purpose of a company's customer service department is to support a company's

customers in whatever ways the customers need. A customer service department helps
answer customer questions and provides assistance at all stages of the customer
experience. TDPS company offers a comprehensive range of servicing and customer
support options to its customers. These options include:

• Remote diagnostics: TDPS company offers remote diagnostics, which

allows technicians to diagnose problems with generators and
motors without having to travel to the site. This can save customers
time and money.

• On-site servicing: TDPS company also offers on-site servicing, which

means that technicians will travel to the site to diagnose and repair
problems with generators and motors.

• Training: TDPS company offers training to customers on how to
operate and maintain their generators and motors. This training can
help customers to get the most out of their equipment and to avoid
problems.

• Spare parts: TDPS company also offers a wide range of spare parts
for its generators and motors. This ensures that customers can get
the parts they need to keep their equipment running smoothly.

 Packing:
It is the second step in order fulfillment, right after the picking process. The packing
process takes place in the warehouse and typically consists of choosing appropriate
materials and an appropriate container to pack the products, weighing the package and
labeling it with the relevant invoice or packing slip. Packing is the process of protecting
the products from damage and environmental factors during shipping.
 Domestic Packing: TDPS follows a strict set of guidelines for domestic
packing to ensure that its generators and motors are properly protected
during transportation These guidelines include: The use of high-quality
packing materials, such as plywood, bubble wrap, and foam. Then
careful wrapping of each generator or motor to prevent damage.

Overseas Packing: Consider the specific requirements of overseas

transport, including long transit times, different climate conditions, and
potential rough handling. Design packaging that can withstand these
challenges and protect the products adequately, Use Heat Treated Woods
moisture barrier materials or desiccants to protect products from humidity
or moisture damage during overseas transport and storage. Consider
temperature-controlled packaging for temperature-sensitive items.

Business flow can be shown as below.

Shop Floor Visit:

My shop floor visit during induction training was a valuable experience. I was able to see
how our products are made and how our employees use their skills and talents to create
something that people all over the world use. I am grateful for the opportunity to learn more
about the company and its operations. TDPS has 2 units for manufacturing process Unit 1
manufacture the product up to TC/TD 150 frame and above 150 frame will be manufactured in
Unit-2.

Below are the departments visited during shop floor study:

 • Stator & Rotor Core Assembly

• Coil, Winding & GVPI process. (VPI- Stator, Rotor, Exciter)

• Final Assembly

• Testing

• Packing and Dispatch

MANUFACTURING FLOW

A C GENERATOR
Introduction:
A generator is a machine which converts Mechanical energy into Electrical energy. The
generator works on Faraday’s law of Electromagnetic induction. Whenever a conductor cuts the
magnetic flux, EMF will be induced in that conductor. DC supply will be fed to Exciter Field through
AVR. Exciter field produces magnetic flux & EMF will be induced in Exciter Rotor i.e. AC supply. The
induced AC supply converts as DC supply through RRA (Rotating Rectifier Assembly) & the DC supply
will be fed to main rotor in which again producing magnetic field & EMF will be induced in main
Stator winding & required balanced Voltage will be taken out though main leads.
Exciter System

• All our generators come with imported digital AVR's of BASLER & ABB make. AVR is
machine mounted in case of smaller capacity generators and a separate AVR cum
Excitation panel is provided for generators for larger capacities.

• AVR cum Excitation Panel is dust-proof and vermin protected.

Parts Of Ac Generator:
1. Main Stator (Main Armature)
2. Main Rotor (Main Field)
3. Exciter Stator (Exciter Field)
4. Exciter Rotor (Exciter Armature)
5. Bearings
6. Cooler
7. RRA (Rotating Rectifier Assembly)
8. Discharge Resister
9. Slip Ring Unit
10.PMG (Permanent Magnet Generator)

Different Types of Ac Generator:

In rotating field there are two types based on Rotor Type used

a. Salient rotor type

i. Strip on edge type (solid hub construction)

ii. Strip on width type dovetailed construction (pole brick construction)

iii. Dove tail type hub iv. Bolted pole tip type hub
v. Bolted type
b. Cylindrical rotor type
Normally for high speed generators (steam, gas turbine).The rotor core made up of silicon steel or
CRCA laminations punched with slots by keeping damper portion as a pole. The coils are formed in a
rectangular shape by using insulated copper and inserted into slots (like concentric winding). T =
Cylindrical rotor
D = Open type
C = Close type
W = Salient pole type
V = Vertical cylindrical or salient pole type
EXAMPLE – TD – 84, Indicates that stator stampings outer diameter is 840mm.
TD – 172, Indicates that stator stampings outer diameter is 1720mm

 COIL, WINDING & VPI:

a) Material preparation: The coils are typically cut to the correct length using
looping machine

b) Coil Winding: The winding is critical in the coil winding process. The winding
machine controls the speed and tension of the wire as it is wound around the
mandrel. This ensures that the coil is wound evenly and that the wire does not
break.

c) Coil Lamination: The lamination process protects the coil from moisture and
heat. The insulation is typically made of a material such as epoxy or polyester.
The pressure is applied using a lamination press.

d) Coil Testing: Surge test is conducted on each coil to detect insulation

weaknesses in coils and windings. The test is performed by applying a high-
voltage, short-duration pulse to the coil or winding. If the insulation is weak,
the pulse will cause a breakdown of the insulation and a short circuit.
 After completing coil surge test coils are inserted to core and make connections as per
the design.

e) VPI: Vacuum Pressure Impregnation (VPI) is a process used to insulate and

seal electro-mechanical parts. The process involves first evacuating the air from
the part, then filling it with a resin or varnish under pressure. This process
helps to improve the dielectric strength, mechanical strength, and thermal
conductivity of the part, as well as protect it from moisture and contaminants.

The VPI process is performed in a vacuum chamber. The Stator & Rotor core is
placed in the chamber and the air is evacuated. This removes any air bubbles or
moisture that may be present in the part, which can degrade its performance.
Once the chamber is evacuated, the resin or varnish is introduced under
pressure. The resin or varnish is forced into the pores of the part, filling them
and providing insulation and protection.

 Stator and Rotor Core Assembly:

The core stacking & assembly process is a precision process. The

laminations must be stacked accurately to ensure that the core has the correct
magnetic properties. The laminations must also be stacked tightly to prevent air
gaps from forming, which would reduce the efficiency & cause humming Noise.
The robotic stator core stacking machine is a six-axis robotic arm that is programmed to
stack the stator cores in a precise and accurate manner which is significantly faster than
the manual stacking process. The machine also ensures that the laminations are stacked as per
requireemnt which is important for the performance of the stator.

After stacking of laminations, pressing is done to make the laminations fixed tightly
followed by Heating and then the core will be hand over to coil section for Winding purpose.
CRCA or CRNGO will be used as a laminating material at TDPS & skew will be provided for
machines upto 195 frame size.

 Final Assembly:

Final assembly process is a critical step in the manufacturing process. It ensures that the
product is assembled with zero deviation on process and that it meets quality and should
follow the manufacturing standards. After completing VPI process cable connection are done
then moved to final assembly after Insulation Test. In Final
 Assemble components like frame, Stator Core, Rotor Core, Bearings, Cooler, MTB &NTB,
Space heaters. Excitation system, AVR & PMG.

 Final Testing:

Final Testing Includes below series of Tests to confirm the performance and Temp rise
of the machine. Routine & type test are the two types of tests conducted on machine.

Routine Tests
 Resistance measurement of all windings

 Insulation resistance measurement before and after HV

 High Voltage test on all windings

 Open Circuit and short circuit characteristics

 Efficiency test by summation of losses method.

 Phase sequence  Voltage balance

 Rotor impedance

 Functional check of accessories with Generator

 Vibration measurement  Shaft voltage.

 Noise Level test

Type Tests
 Open Circuit Heat run  Short Circuit Heat run
 Momentary Over Current Test

 Sudden Short Circuit test @ 30% rated voltage

 Recording of no-load wave form, harmonics and THF calculation

 Determination of reactance values by sudden short circuit test

 Packing and Dispatch:

After painting & completion ready machine is packed with jungle wood for export
machines will have special packing wood / container /flat rack. Base frame will have heavy
wooden long blocks with flanks & side walls will have flanks with some suitable ‘X & ‘Y’ axis
stiffeners. Main machine will be mounted on base frame after side walls & finally top cover
will be covered. For lifting purpose extra M.S. ‘L’ shape plates is fixed at lifting area where the
wire rope is lashed. Packed machines will be dispatched suitable trailers / trucks /Container or
flat racks.

 Conclusion:

During these 6 days of the Induction program, I have learned a great deal
regarding Generator Manufacturing process, testing procedures, FAT
details and how the TDPS work in time bound to complete the task on time
and make the OTD 100%. It’s really a good opportunity for me to undergo
this Induction program and learned many things regarding manufacturing
as well as overall working structure of the company in detail. Practical
knowledge is very important in the manufacturing sector, which will really
help for the design team where I belong in TDPS, it’s a nice training which
really helps in my day-to-day work.

I would like to thank my all trainers and colleagues for their help and
support during my induction training. I am grateful for their patience and
guidance. Thanks to HR team