ABSTRACT

Practice makes a man perfect. A student gets theoretical knowledge from classroom and gets
practical knowledge from industrial training. When these two aspects of theoretical
knowledge and practical experience together then a student is fully equipped to secure his
best.

In conducting the project study in an industry, students get exposed and have knowledge of
real situation in the work field and gains experience from them. The object of the summer
training is to provide an opportunity to experience the practical aspect of technology in any
organization. It provides a chance to get the feel of the organization and its function.

During the 45 days of my industrial training, in the first day of the week in this industry, I was
given a task to learn about kitting system that I must know all the tools which is necessary for
every electrical engineer. Indeed, I had to prepare a set of tools by according tooling list. After
a week, I was given a manual book to learn how to operate those machines. There were a lot
of machines at my sub-department; Circuit Breakers, Control Contactors power Contactors.

After several weeks, I was starting to learn some new things. There were some technical
skills, tooling maintenance and drive functions. During the training period I learn about my
field’s fresh thing electrical audit of different branches of axis bank and drive function. I also
learnt about industry automation with drive and control logic development using contactors
for their inter locking. In the duration of 45 days, I learnt so much fresh things of my field like
Auditing, Panel drawing, Inter locking of connections.

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 Chapter - 1

INTRODUCTION

1.1 Introduction Of Ankit Electrical Company

Figure 1.1- Ankit Electricals Company

Ankit Electricals Company is promoted by Mr. Kunwar Singh and aims at fostering long-
standing business relationships with large infrastructure entities in the public and private /
corporate sector. Their manufactured electrical equipment will cater the requirements of
electrical contracting companies, builders, ESCOMs, Railways, etc. The entire designing
fabrication, assembling, wiring and testing of different MCC, PCC, RTCC, RLMS
Instrumentation Panels, Automation Panels, with PLC’s and Bus Ducts are accomplished to
customer’s specifications.

Ankit Electricals company came into effect in the year 2001-2005 as a specialized
manufacturer and supplier of electrical control panel boards.

The company is certified by CPRI & ISO 9001 and is nationally recognized for
manufacturing a vast range of LT Distribution Boards, Control Power Equipment’s and
Electrical Control Panels that include LT AC panel Boards, Metering Panel Boards,
Marshalling Boxes, RLM Units, RTCC Panel Boards, Outdoor LT Kiosks, Bus Coupler

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Panels, LT Bus Duct, Control & Relay Panels, PLC Panels, Power Factor Correction Control
Panels, Power Control Centres, Motor Control Centres, and so forth.

1.1.1 Vision
“To create a billion-dollar global electrical brand.”
1.1.2 Mission
“To add more to life with electricity”

Figure 1.2 - Ankit Electricals Logo

1.1.3 Infrastructure
We fabricate Panel Board with 3.0mm, 2.5mm, 2.0mm, and 1.6mm CRCA sheet or in
accordance with client’s needs. These Panel Boards are treated with seven tank
chemical process and powder coated with approved shade by the client. All the
switchgear components supplied by us are checked for easy operation and functioning
before installing to the Panel Board.
TURNKEY PROJECTS & SERVICES
 33/11 KV CABLE LAYING
 33/11KV VCB, RMU
 33/11 KV TRANSFORMER
 LIGHTING ARRESTORS
 EARTHING
 LT CABLE LAYING
 LT PANELS

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 Figure 1.3- Fabrication

1.1.4 Plant & Equipment

Prior to the final dispatch, the complete range of products undergo strict quality
testing.
Apart from keeping the quality as prime requirement, we also maintain strict quality
testing. Apart from keeping the quality as prime requirement, we also maintain
meticulous project execution schedule and provide an excellent after sales service
support. This well-defined strategy combined with our business ethics is the main
reason that our clients trust us and prefer Ankit Electricals products than other
ordinary products.

1.1.5 Products
AE supplies a wide range of products as follows and undertakes design, fabrication
and erection of all types of Control Panels. Every care is taken during fabrications,
wiring and mounting, to ensure the accurate functionality of the manufactured
equipment. The components wires, meters sourced are of ISI quality. Also, the
company customizes the products according to customer’s requirements and
specifications.
 Power Control Centres
 Motor Control Centres
 Double Bus Bar Panels

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  Control & Relay Panels
 Power Factor Correction Capacitor Panels
 Synchronizing Panel
 Auto Load Management Panels
 Variable Frequency Drives (VFD) Panels
 Prepaid Meter Panels
 Fire Fighting Panels
 Soft Starter Panels
 Control Desk & Mimic Panels
 Bus Ducts & Rising Mains
 Plc Panels & Automation Panels
 33 KV HT Panels
 11 KV HT Panels

1.1.6 Quality Assurance

we take proper inspection and testing measures in order to ensure fabrication of
absolutely flawless products. We adopt the following inspection & testing procedures:
 Inspection during Fabrication
 Visual Inspection is carried out to ensure
 Grinding of welds outside the panels is smooth and without any blemishes
 Gap between the doors, when assembled, is uniform
 Full dimension checks are carried to ensure compliance with customer
drawings
 Functional Inspection
 The various accessories in the control panel are inspected to ensure
 Door locks are tightened & are free from ratting
 Bus bar is supported

1.1.7 Testing & QC

Testing:

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 Equipment mounted on the panel is functional Air installation test is carried out with
the help of megger.
Designed & verified by testing as per IEC61439(TTA)
TESTS:
 Resistance to corrosion
 Degree of protection IP-13
 Internal separation of PSC-Assemblies (From 4b)
 Verification of Temperature Rise
 Dielectric Properties
 Mechanical Operation
 Mechanical Impact (IK05)
 Lifting
 Marking
 Clearances & creepage Distances
 Verification of short circuit withstand
 Strength
 Degree of Protection IP-55(category-1)
 Degree of Protection IP-55(category-2)
 Degree of Protection IP-65

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 Figure 1.4 – panel testing & MFM setting
1.1.8. Customers & Govt. Approvals

Figure 1.5 customers & govt. approvals

1.2 Safety Practices

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In the Ankit Electricals workshop, we used safety methods, because of electrocution is
mainly due to serious injury. The operation of tools and machineries also cause to
hazards. We considered about personal safety, human health and equipment safety.
Below safety instructions were followed in workshop for the prevent from electrical
hazards,
 Before installation, wiring, operation, maintenance and inspection of the panel,
instructions or the catalogue were studied carefully to ensure proper
operations.
 We got the assistance from supervisor, before testing the experiment with
electrical supply.
 Proper testing and checking instruments were used to find the live parts.
 We used only tools and equipment with non-conducting handles when working
on electrical devices.
 We kept in mind to never handled electrical equipment when hands, feet, or
when standing on a wet floor.
 We kept the workplace dry and free from oil, water and grease.
 The power source was disconnected before servicing or repairing electrical
equipment.
 We kept in mind to use the equipment in a range of the rated voltage and
current shown on the name plate.

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 Figure 1.6 – Electrical Safety Signs
Following safety methods were used to prevent from hazards while machinery works in
workshop.
 We used personal protective equipment such as Safety shoes, Gloves, Ear Plugs,
Mufflers, Safety Goggles and etc.
 Used appropriate tools and equipment for work.
 Before done the work, instruction was read properly.
 We followed out to wear suitable cloth, not too tight and not too loose.
 After the work was finished, cleaned the surface and electrical switch off the
machineries power supply.
 We kept the floor of workplace free from oil, water and grease.
 Used cleaners for the clean the body.
The company has a response for all electrical work, systems and equipment under their
control. They must ensure that and are given sufficient information of any known hazards or
risks to health and safety to enable them to work safely;

 Suitable control measures are in place and followed.

 Installed suitable equipment for perform and the environment within which it will be
expected to work.
 Equipment was calibrated correctly.
 Danger signs, Warning information and other safety procedures were presented in
working place.
 First aid facilities and sick room was arranged in the company.
 Safety equipment and cleaners were provided in the workshop.
 Working areas were marked according to the proper standard.

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 Chapter - 2

2ELECTRICAL WORKSHOP TOOLS & MACHINES

2.1 Ankit Electrical Workshop
In Ankit Electricals Workshop, Power Electrical Panels were designed as per the IEC
standards. These power electrical panels were trusted for Safety Reliability and Quality in
Low Voltage Power Distribution. Power Electrical Panels made available in various
specifications in Industrial Electrical workshop.
 Distribution Panels
 Changeover Panels
 Motor Control Panels
 Capacitor Bank Panels
 Auto Power Factor Control (APFC) Panels
 Variable Frequency Drive (VFD) Panels
 Synchronizing Panel
 Fire Fighting Panels
The Power Electrical Panels consist of metering devices, protective devices, switching
devices, conductors, bus bar chambers, indicators, circuit breakers, capacitors and many other
types of equipment.
Before designing electric panel, the following details should be incorporated into it.
 Location and dimension of the panel
 Load description, Amperage, Voltage required
 Cable size and conduit size
 Type of insulation.
 Ventilation, temperature and space arrangement in the panel
 IEC regulation

2.1.1. Panel Assembling Procedure

 First of all, the panel box, cover plates, panel door, mounting plate and benches were
selected according to the given drawing.
 Door arrangement was fixed by using Panel hinge according to general arrangement.
 The door Beading and panel key mount was attached to the door.

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  The cover plate bracket was prepared by using drill machine, tap cutting tool, flat
screw driver.
 Switch gear benches and din rails were arranged on the mounting plate according to
drawing.
 Mark holes position to fix the benches, din rail bracket, profile using pencil and drilled
all holes using drilling machine.
 Taped all holes using tap cutting tool.
 Din rails and benches were fixed by using flat screw.
 Arrange bus bars, bus bar insulators, neutral link, neutral bar, earth bar, earth link as
general arrangement using bus bar bend machine
 Made the holes to fix bus bar insulators, earth link, and neutral link etc. on mounting
plate and all holes were taped.
 All items were fixed according to general arrangement using proper tools.
 The door arrangement of indicators and other equipment was prepared according to
drawing by using drill machine and Jig saw.
 All electrical equipment were fixed in to the proper place and mounting plate was
fixed in to the panel box
2.1.2 Power Circuit Wiring Procedure
 The cable ducts were cut in to suitable size and fixed in to the panel box.
 The relevant wire size was selected according to current rating chart.
 The cable length was defined and cut the wires using wire cutter.
 The Lug was fixed to the wires using lug cramping tool and End cap was fixed in to
the cable according to phase colour.
 Wiring was done according to the wiring diagram, Allen key, Phillips and flat screw
drive.
 Marked the tighten nut using permanent maker pen.
 Checked the wire connection, cable size and connection.
2.1.3. Control Circuit Wiring Procedure
 Auto cable was used to wire the control circuit.
 The cable length was defined and cut the wire using side cutter, wire striper.

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  Print the tube number using ferrule print machine.
 Lugs were fixed to cable using cramping tool.
 The control side was wired by including numbers, Phillips and flat screw drive were
used.
 Wire combines between control side and power side.
 The control line was neatly arranged by using spirals and cable ties.
 Checked the wires connection.
2.2. Tools & Machines Used in Workshop
When I was assembling the panels in the workshop, following tools and machineries
were used. Before I used these tools and machineries safety rules and operating instruction
were followed correctly.

Figure 2.1 - Tool box

2.2.1. Basic Tools
 Hammer `
 Screwdriver (Slot-head)
 Phillips Screwdriver
 Pliers
 Hacksaw
 Allen Keys
 Side Cutter
 Wrench (Box-End Wrench, Socket Wrench, Pneumatic Wrench, Open-end Wrench)
 Measuring Tape
 Cable Cutters

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 Cable cutters are useful to cut cables. Gilbow cutter (heavy-duty cable cutters) cuts the
large size cables & common bas bar.

Figure 2.2- Cable Cutter

 Crimping Tool
A crimping tool is a tool designed to crimp or connect a connector or lug to the end of
a cable. To use this crimping tool, each wire is first placed into the correct position.
The hydraulic crimping tool crimps high gauge wire easily with steady hydraulic
power.

Figure 2.3- Crimping Tool

2.2.2. Machineries
 Jig Saw
A Jig Saw is a useful in cutting shapes, curves and removing parts from the panels.

Figure 2.4 - Jig Saw

 Electric Drill
A Drill is a driving tool attachment, usually a drill bit. It is used for drilling, tapping
and boring holes in various materials. Some electric drills drown with rechargeable

batteries.

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 Figure 2.5 - Electric Drill
 Pneumatic Pop-Rivet Gun
A pneumatic pop rivet gun is designed to fix the rivet nuts together without too much
effort from the person handling the gun. The pneumatic pop rivet gun used
compressed air hoses.

Figure 2.6 - Pneumatic Pop-Rivet Gun

 Industrial Heater
Industrial Heater is used to plastic welding, bending, bus bar insulation and many
other purposes.

Figure 2.7 - Industrial Heater

2.2.3. Nuts & Bolts
The following nuts and bolts were used for the panel assembling and connecting
devices in to the panel box by me.
 Nail
 Screw
 Flat washer
 Spring washer
 Bolt (CSK Bolt - 4x10mm, 4x12mm, 5x10mm, 5x12mm, 5x16mm, 5x20mm)
(PH Bolt - 5x35mm, 5x20mm, 4x10mm, 4x12mm)
(Hex Bolt - 8x30mm, 8x15mm, 6x8mm, 6‹12mm, 6‹15mm, 6‹20mm)
 Allen Bolt
 Self-tapping bolt

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  Nuts
 Stud nuts

Figure 2.8 - Nuts and bolt

2.2.4. Panel Accessories Used In Workshop
 Panel plate  Beading
 Panel hook  Cables ties
 Panel holder  Name plates &danger stickers
 Panel hinge / Chrome hinge  Earth bar
 Panel key

 Din rail
Din rail is a metal rail of a standard type widely used for mounting circuit breakers
and industrial control equipment inside panel.

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 Figure 2.9 - Din rails
 Insulator Mounts
 Bus Bar Insulator mounts are used for connecting line and neutral bar with panel
mounting board and connecting bus bar with panel board.

Figure 2.10 - Insulator mounts

 Cable Duct
Cable duct is wire and cable management product for routing and concealing electrical
wiring in control panels. Available in many sizes.

Figure 2.11 - Cable ducts

 Wire End Caps
The wire end caps are used for easily identified wire. These end caps can be obtained
various colour according to electrical colour code.

Figure 2.12 - Wire End Caps

2.3. Electrical Protective Devises Used In The Panels

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 The electrical panel was designed with protective devices. Protective devises were
used for human protection, system protection and equipment protection. In Ankit Electricals
panels were consisted with various types of protective devises. I was able to get knowledge
about using purpose, working principle, connection and testing of these protective devices.

2.3.1 Fuses
A fuse is a type of protection device in electrical applications. Fuses are designed to
open circuits the filament when excessive currents are present due to overloads or faults and
to prevent further damage to the system. Short circuit, system overload, other device failures,
lightning, static electricity or system overload are some common results in blown fuses.
 Cartridge Fuse
In cartridge fuse the fuse wire is enclosed in a transparent glass tube or bulb, the whole
unit is sealed off. In case the fuse blows, it is to be replaced by new one as the
cartridge fuse cannot be rewired due to its sealing. In cartridge type fuses have many
other sub types as MCB type, screw type, etc.
 HRC Fuse (High Rupturing Capacity Fuse)
HRC Fuse consists of highly heat resistant material (such as ceramic) body having
metal-end caps, which is welded by silver current carrying element. HRC Fuse has
high rupturing capacity. It has constant fusing characteristics and operates fast.
2.3.2. Miniature Circuit Breakers (MCB)
In electrical panels, MCB was used as the basic protective device.
MCBs are designed to automatically protect against overloads and short circuits, preventing
damage to cables and equipment. Trip characteristics normally cannot adjustable. MCB has
thermal-magnetic operation. Over current

Figure 2.13 – MCBs

protection is got the system by the thermal trip unit of the breaker. Short circuit protection is
got to system by the magnetic trip unit of the breaker. The MCBs‟ are in

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single pole, double pole, try pole and four pole types. Every circuit breaker has a voltage
rating that designates the maximum voltage it can handle and a continuous current rating,
which is the maximum continuous current carry without tripping. The value of the kA rating,
determines how much current the circuit breaker can withstand under fault conditions. When
we consider MCBs we can see various MCBs with different ampere ranges and internal
situations (Tripping). MCBs are classified according to the ampere.
Type B - operate 3-5 times rated current and suitable for lighting loads
Type C - operate 5-10 times rated current and suitable for lighting and motor loads.
Type D - operate 10-20 times rated current and suitable for heavy units, welding plants
[Link]. Standard Dimensions of MCBs
 I was able to measure the standard size (in mm) of the MCB and RCCB. It was very
important for the panel designing and arranging the panel box.

Figure 2.14- Standard dimensions of MCBs

[Link]. MCB Distribution Box Designing
 I designed fallowing Distribution Boxes for the 300 houses in the housing apartment.
This was designed for single phase 30A house.
 I have been used 30A isolator switch, 30A RCCB, four MCBs of 10A and six MCBs
of 6A according to the requirement. All were orange production.
 4mm2 CU/PVC insulated wire was used for the wiring and single-phase common bus
bar was used to connect the MCBs.
2.3.3. Residual Current Circuit Breaker (RCCB)
The Residual Current Circuit breakers (RCCB or RCD) are the safest device to detect and trip
against earth leakage currents, thus ensuring protection against electric shock caused by
indirect contacts. These devices must be used in series with an MCB. RCCB Available in 2
Pole and 4 Pole for domestic and Industrial application
1. Electromagnet

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 2. Current transformer secondary winding
3. Transformer core
4. Test switch
L – Live conductor
N – Neutral conductor

Figure 2.15 - 4 poles RCCB

RCCB works on the principle that in an electrical circuit the incoming current is the same as
out going current. RCCB incorporates a core balance. The primary winding lies in series with
the supply mains and load. Secondary winding is connected to a very sensitive relay. During
flow of leakage current in the circuit an imbalance is created in the circuit which gives rise to
leakage flux in the core. This leakage flux generates an electrical signal that is sensed by the
relay and it trips the Mechanism thereby disconnecting the supply. When pressing the TEST
button 'T', a fault is simulated via the Test resistance & RCCB trips.
The RCCBs with a rated residual operating current (I∆n) of 30mA or less are used in place of
more conventional RCCBs with higher residual operating current ratings. The Rated current
range varied 10mA to 1A.
2.3.4. Moulded Case Circuit Breakers (MCCB)
In every panel which I wired MCCB was used as the main breaker. I was able to
connect trip coils, auxiliary contacts, inter lock and panel holders with MCCB. In Ankit
Electricals workshop I had used “ABB”, “Schneider”, “L&T”, and “Legrand”, “C&S”
brands‟ MCCBs.
The Moulded case circuit breakers have been developed for use in commercial and industrial
protection. MCCB has thermal-magnetic operation. Trip current may be adjustable in larger
ratings.
I was able to identify the main features of a MCCB more than MCB,
 High short circuit current breaking capacity ( < 20kV).
 Used for high current ratings ( < 10000A )

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  Adjustable current and tripping time rating.
 Simultaneous opening and closing of all poles.
 Test button which allows periodic testing of the mechanical trips
 Accessories such as shunt trip, under-voltage trip, Rotary Operators, motorized kit
units, mechanical-electrical interlock, auxiliary contacts are available.
 Thermal adjustment (overload)
MCCBs have a wide thermal adjustment range (long delay). The rated current ( Ir ) it
continuously adjustable from 0.4 - 1 of its nominal current (In)
 Magnetic Adjustment (short circuit)
Magnetic adjustment (short delay) is available on MCCBs. The magnetic setting (Im) is
continuously adjustable from 1 – 10 of it’s In.

Figure 2.16 - MCCB

[Link]. The Shunt Trip Coil and Under Voltage Tripping Coil (UVT)
Shunt and UVT coils are used for remote opening of circuit breaker. The Shunt trip
coil consists of an electro-magnetic trip coil that is connected in series with an external field
wired switch. When energized the shunt coil, causing the breaker’s mechanical latch to move
to the open position. Shunt coil supply is connected normally open (NO) contact point of the
component. Usually EFR, ELR are connected with the shunt coil.
UVT coil is energized and activated to close the breaker when the coil supply voltage dips
below 85% of the rated voltage. When we use the UVT coil with MCCB‟s we connect coil
supply through the normally close (NC) contact point of the component. At a fault condition,
it stops the supply flown through the UVT coil and then the UVT coil trips the breaker. So

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when a UVT coil is used in a circuit, the MCCB cannot be switched on if there is no current
supply.
[Link]. Auxiliary Contacts
Auxiliary contacts perform the function of electrically signaling the circuit breaker‟s
operating status. The auxiliary contacts change state when the circuit breaker is opened,
closed, or tripped.

Figure 2.17 - Auxiliary contacts and Tripping Coil arrangement

[Link]. Installation Process of MCCB Internal Accessories :
I was able to identify the procedure of installation procedure of the Auxiliary contact, Alarm
switch, Shunt trip coil or Under voltage trip coil.
 Before the installation process mechanical trip button was pushed to trip the MCCB.
MCCB must on trip position.
 Then bolt was unscrewed to open the front cover.
 Outer cover was removed and identified the correct installing position for auxiliary
internal accessory.
 The coil was inserted in to that position. Then the terminal block was installed on the side
of MCCB.
 The front cover was closed and fixed it with 2 screws.

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 Then coil terminals were connected to the control circuit.

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Figure 2.18 - Installation of MCCB internal accessories

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2.3.5 Air Circuit Breaker (ACB)

Air Circuit Breaker (ACB) is an electrical protection device used for short circuit and
overcurrent protection up to 15kV with amperes rating of 800A to 10kA. It operates in air
(where air-blast as an arc quenching medium) at atmospheric pressure to protect the
connected electric circuits. ACB has completely replaced by oil circuit breaker because it is
still a preferable choice to use an ACB because, there is no chance of oil fire like in oil circuit
breaker.

Figure 2.19- Air Circuit Breaker

The working principle of Air Circuit breaker is rather different from other types of circuit
breaker. The main aim of circuit breaker is to prevent reestablishment of arcing after current
zero where the contact gap will withstand the system recovery voltage. It does it same work,
but in a different manner. During interruption of arc, it creates an arc voltage instead of
supply voltage. Arc voltage is defined as the minimum voltage required for maintaining
arc .The circuit breaker increases the voltage in three different ways:
 Arc voltage can be increased by cooling arc plasma. As soon as the temperature of arc
plasma motion of particle in arc plasma is reduced, more voltage gradient will be required
to maintain the arc.
 By splitting the arc into a number of series will increases the arc voltage.
 Arc voltage can be increased by lengthening the arc path. As soon length of arc path is
increased the resistance path will increase more arc voltage is applied across the arc path
hence arc voltage is increased.

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It is operated within voltage level up to 1 KV. It contains two pairs of contact. The main pair
carries the current and the contact made of copper. An additional pair of contact is made of
carbon. When the breaker is opened, the main contact opens first. During opening of the main
contact, the arc contact remains in touch with each other. The arcing gets initiated when arc
contacts are separated. The circuit breaker is obsolete for medium voltage.      

Figure 2.20- Internal of ACB

2.3.6. The Surge Protection Device
The Surge Protection Device (SPD) is a component of the electrical installation protection
system. This device is connected in parallel on the power supply circuit of the loads that it has
to protect. It can also be used at all levels of the power supply network. This is the most
commonly used and most efficient type of overvoltage protection. It is a device used on
power systems above 1000V to protect other Equipment from lightning switching & surges. It
Does Clamp (limit) the Voltage produced by the Lightning. It only protects equipment
electrically in parallel with it.

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 Figure 2.21 – SPD device Figure 2.22 – wiring diagram of “OBO” SPD
device
2.3.7. Phase Failure Relay (PFR)
Phase failure relay is adjustable under voltage over voltage control device with the option of
additional sequence control. If it detects any under voltage, over voltage and phase losses in
power system, the relay coils is energized and trip the MCCB using under-voltage (UVT)trip
coil.

Figure 2.23 - PFR and its connection diagram

2.3.8. Overload Relay
In Ankit Electricals workshop we used overload relays for the motor control panels as a motor
protective device. I observe that, overload relay was used only after the main contactor.

The overload is a heat operated relay where a coil heats a bimetallic strip and releasing a
spring to operate contacts. It has NO & NC auxiliary contact points for the controls. If the
overload senses excess current in the load, the coil is de-energized. Electric motors need over
current protection to prevent damage from over-loading the motor, or to protect against short
circuits in connecting cables or internal faults in the motor windings.

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 Figure 2.24 - “LS” Overload relay
2.3.9. Earth Leakage Relay (ELR)
Earth leakage relay monitor the leakage of current to earth on 3 phase electrical systems. The
earth leakage relay is used in conjunction with a core balance transformer (CBCT) which is
available in five different sizes to cover all sizes of three phase installations. If make a fault
condition, this core balance transformer send a signal to the ELR. The relays are available
with either a fixed 30mA or 300mA instantaneous trip point or with a user adjustable trip
point and time delay both adjustable.

Figure 2.25–ELR Figure 2.26 – connection of ELR

2.3.10 Earth Fault Relay (EFR)

Earth Fault Relay is used for the protection from earth faults. The function of EFR is as same
as ELR. Instead of a CBCT, four separate CT‟s is used to connect an EFR. It is an Electronic
Trip Unit, designed to protect the Electrical installation in case of faults or leakage currents
beyond a pre-set level. The tripping range for both fault current and delay time to be adjusted.

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 Figure 2.27 - EFR
It has four current transformers. If there is a fault condition, these CTs send a signal to the
earth fault relay. Then its electronic circuit sends a signal to the protection component’s
normally open contact. Then this normally open contact point gets closed. Now that signal is
sent to the shunt coil through the normally close contact point. Then the shunt coil is
energized and trips the breaker.

[Link]. Characteristic Settings Procedure of Earth Fault Relay

I was able to perform the set fault current and trip time of DELAB Earth Fault Relay
 Press [Select] once to enter mode (it will show the existing value Range 0.03 ~ 30 A)
 Set the desired Fault current using the [Up / (+) or down / (-)] button.
 Press [ Select] to store / confirm new value
 Press [ Select] until mode is displayed. (It will show the existing value Range 0.05 ~
20s)
 Set the desired trip time using the [Up / (+) or down / (-)] button.
 Press [ Select] to store / confirm new value.
2.4. Measuring Devises Used In The Panels
2.4.1. Current Transformer
Current transformers can reduce or "step-down" current levels from thousands of
amperes down to a standard output of a known ratio to either 5 Amps or 1 Amp for normal
operation. CTs are used with watt meters, power factor meters, watt-hour meters, protective
relays and metering applications, because they are insulated away from any high-voltage

28
power lines. Its primary winding is just a conductor or bus bar placed through a central hole.
The secondary winding may have a large number of coil turns wound on a laminated core as
shown below.

Figure 2.28 – CTs

Figure 2.29 - Working principle of CT

The current transformer should never be open-circuited or operated with no-load attached
when the main primary current is flowing. If the ammeter is to be removed, a short circuit
should be placed across the secondary terminals first. This is because when the secondary is
open-circuited it will produce a large secondary voltage. Current transformers are available in
Ring type, Bushing type, square type, bar type and etc
Accuracy decreases with increased burden (load) or low line current. Accuracy Class of
Metering CTs:
Table 2.1 - Metering Accuracy Classes of CTs
Metering Class CT
Class Application
0.1 To 0.5 Precision measurements or protection
1 General industrial measurements more sensitive

29
 3 General industrial measurements
5 Approximate measurements

Figure 2.30 - CT connection

 When I was connecting the CT, the ratio of the CT was not matched to the panel
current value.
 The CT ratio was 150/5A. But the panel MCCB was 63A.
 So, I used the double turns for reduce the CT ratio as explain below.
Increasing the number of primary turns can decrease the turn’s ratio. A current transformer
with a 300 to 5 turn’s ratio can be changed to a 150 to 5 turn’s ratio by passing the primary
twice through the window. Also, the turn’s ratio can be either increased or decreased by
wrapping wire from the secondary through the window of the current transformer.

2.4.2. Core Balance Current Transformer

The Core Balance Current Transformer is a current transformer is used for earth fault
protection in grounded three phase systems. It is also known as the zero-sequence current
transformer. Each phase conductor and neutral should pass through the core balance current
transformer. It is essential that each conductor passes through the device in the same
direction.

Working principle of Core Balance CT:

The net resultant flux being zero does not induce any current in the secondary of the
transformer. Thus, the secondary current of the core balance current transformer when all the
three phases are healthy is zero. When an earth fault occurs in one of the phases, the zero-
sequence fault current which flows is not cancelled by the flux of the other two phases and

30
hence induces a current in the secondary. The core balance current transformer can be
connected to an earth fault relay which can be used to generate the tripping signal.

2.4.3. Indicator
Indicators are used to get information about states of equipment such as ON (red), OFF
(Green), TRIP (Orange). Indicators are available in read yellow blue and orange and 12V to
230V.

2.4.4. Ammeter

An ammeter is a measuring instrument used to measure the electric current in a circuit.

Current transformers and ammeters are used together as a matched pair in which the design of
the current transformer is such as to provide a maximum secondary current corresponding to a
full-scale deflection on the ammeter. For most current transformers the primary and secondary
currents are expressed as a ratio such as rated current: 5A.

Figure 2.31– Connecting diagram of an Ammeter

[Link]. Connecting Process of An Ammeter
 I was able practice connecting process of the Ammeter in to the panels.
 In 3 phase system, 3 position selector switch was used to select the 3 phases R, Y or B.
 CTs were connected in to the selector switch.
 The selector switch was connected with the Ammeter A1 and A2
2.4.5. Voltmeter
A voltmeter is an instrument used for measuring electrical potential difference between two
points in an electric circuit. Analog voltmeters move a pointer across a scale in proportion to

31
the voltage of the circuit. The voltmeter selector switch is used to select the two phases or
phase neutral in 3 phase system.

Figure 2.32 – voltmeter

2.4.6. KWH Meter (Energy Meter)
KWH Meter is used to measure the kW power. Mainly we use two types of KWh meters.
Those are single-phase kWh meters and three phase kWh meters. These three phase & single-
phase meters are can be dividing again like this C/T type and direct type. Mostly we use C/T
type energy meters. In some panels, used digital KWH meters.

2.4.7. Digital Power Analyser

Power analyser accurately measure electrical power characteristics of the system. Power
analyser, also called power meters or watt meters, provide precise measurements of power
supply system. This is useful for getting to power consumption and many more values of the
system.

I was able to refer metering performed of Schneider PM 700 digital analyser,

 Current - (per phase/ neutral) min/max Current demand: present
 Voltage - (line-line/ line-neutral) per phase, min/max
 Power: - real (kW), reactive (KVAR), apparent (kVA), per-phase, total
 Energy: - real (kWh), reactive (KVARH), apparent (KVAH)

32
  Signed power factor: - total, min/max
 Frequency: - present, min/max
2.5. Switching Devises Used in The Panels
2.5.1 Relay
A relay is a switching device. Relays are used where it is necessary to control a circuit by a
low power signal with complete electrical isolation between control and controlled circuits or
where several circuits must be controlled by one signal.

Figure 2.33 – relay and relay base

Relay consists with coil, normally open and normally closed contact points. When current
starts flowing through the control coil, the electromagnet starts energizing and contact points
are changed their position.

Coil voltage can be 12V to 230V AC or DC. Also contact current rating is important factor.
According to the contact pin arrangement, relays are categorized as 8 pins, 11 pins, 14 pins
and etc. relay is fixed with its base.

2.5.2. Contactor

I was able to identify the contactor construction and usages, because contactor was used in
every motor control panel. It was used for the high-power application switching on power
circuit. Also, I connected timers, auxiliary contact points (side and top), timers and
mechanical interlock to the contactors according to the requirement. In Orange Electric
workshop I had used “ABB”, “Schneider” and “Legrand” “L&T” , “C&S” brands‟
contactors.

33
Contactor is also a type of relay. The contactor consists with normally Open contacts and also
auxiliary contact points. Also, it can connect auxiliary contact points (side and top), timers
and mechanical interlock.

Figure 2.34 – Contactor Figure 2.35 – Auxiliary

A contactor consists of mainly 2 parts-Fixed and movable jaws. the fixed jaws are firmly
connected with the circuit and is a provided with a coil having movable jaw as soon as current
is allowed to flow from the circuit the coil gets charged and due to electromagnetic effect, it
attracts the movable metal jaw, thus the circuit is complete with the contact provided by the
movable jaw. This is the functioning of contactor. When current through the coil loss, coils
demagnetize and open the contacts. The coil consists with shaded pole core, because of
avoiding the current zero position of the AC supply.

The current rating of the contactor is depending on its category. The categories in standard are
described as:

 AC-1 - non-inductive or slightly inductive loads, resistance furnaces

 AC-2 - Starting of slip-ring motors: starting, switching-off
 AC-3 - Starting of squirrel cage motors. (Inductive and resistive loads)

34
  AC-4 - Starting of squirrel-cage motors with inching and plugging duty.
2.5.3. Timer Relay

Timer relays are simply control relays with a time delay built in. Their purpose is to control
an event based on time. The difference between relays and time delay relays is when the
output contacts open & close: on a control relay, it happens when voltage is applied and
removed from the coil; on time delay relays, the contacts can open or close before or after
some time delay.

Figure 2.36- Timers Figure 2.37 - Analog timer internal connection

The timers are divided into many categories according to their performance,

 ON delay
Upon application of input voltage, the time delay begins. At the end of the time delay, the
output is energized. Input voltage must be removed to reset the time delay relay & de
energized the output. 

 OFF delay
Upon application of input voltage, the time delay relay is ready to accept a trigger. When the
trigger is applied, the output is energized. Upon removal of the trigger, the time delay begins.
At the end of the time delay, the output is de-energized.

35
According to the requirement, Timer relay characteristics are selected according to fallowing
parameters.

 Input coil current range - 12v to 440V (DC / AC)

 Time settings - seconds, minutes, hours, days, month, years
 Analog, digital, 24 hours, programmable, star-delta, etc.
 Pin configuration - 8 pin, 11 pins, and 14 pins etc.
2.5.4. Push Buttons

The push-buttons & selector Switches are momentary contact device used for giving the ON
and OFF commands. Push button has normally open (NO) contacts and normally closes (NC)
contacts. Some selector switch has 2-stay part and some has 3-stay part and also spring return
selector switches are available. Emergency Push Button is another type of push button. Those
push buttons can connect auxiliary contact points

Figure 2.38 – Push button and emergency button

2.5.5. Selector Switches

Selector switch has 2 parts or 3 parts. It is used to select the power path.

2.6. Cables
I was able to refer the cable current caring capacity table and selected the wires for panel
wiring. In panel wiring normally we used PVC insulated type single core copper wires.

The selection of cables for panel wiring was best done with reference to the latest and specific
manufacturer’s cable data and application guides with tables giving cable dimensional, and
current rating information.

36
The cross-sectional area of the conductors chosen should be of the optimum size to carry the
specified load current or short circuit short term current without overheating and should be
within the required limits for voltage drop.

Figure 2.39 - PVC insulated cables

2.6.1. Cable Insulation Materials

 PVC (Polyvinyl Chloride) – is the most commonly used thermoplastic insulator for
cables. It is cheap, durable and widely available. PVC Normal operating temperatures
are typically between 750C and 1000C (depending on PVC type)
 PE (Polyethylene) – is part of a class of polymers called polyolefin. Polyethylene has
lower dielectric losses than PVC and is sensitive to moisture under voltage stress (i.e.
for high voltages only).
2.6.2. Cable Lug

Lugs were used to connect the wire to terminals. Cable lug was connected with connecting
end of the cable using wire crimping tool. Suitable Cable lug sizes depend on the wire cross
section area. In our workshop were so many types of lug. Such as Normal lug, U lug, and O
lug.

37
 Figure 2.40 – cable Lugs

2.6.3. Cable Numbering Tube

Numbering tubes are used to identify the cable in control circuit. Tube Printer is used to print
the numbers.

Figure 41 - Cable Numbering Tube

2.6.4. Current Ratings of Single Core PVC Insulated Cable

Table 2.2 - Current ratings of single core PVC insulated cable

38
2.7. Bus Bars
The bus bar is a strip or bar of copper brass or aluminium that conducts electricity within a
switchboard, distribution board, substation, battery bank, or other electrical apparatus. Its
main purpose is to conduct a substantial current of electricity. The cross-sectional size of the
bus bar determines the maximum amount of current that can be safely carried.

39
 Figure 2.42 – Bus bars

2.7.1. Bus Bar Sizes and Current Capacity

Table 2.3- Bus bar current capacity

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41
 Chapter-03

PANELS AND THEIR TESTINGS

3.1 Distribution Panels

3.1.1 Main Distribution Panel

Main Distribution panel Board (MDB) is a panel or enclosure is used to distribute electrical
power to numerous individual circuits or consumer points, is taken in from the transformer or
an upstream panel. An MDB typically has a single or multiple incoming power sources and
includes main circuit breakers and residual current or earth leakage protection devices. A
MDB is comprised of a free standing enclosure, a bus bar system, MCCB's, metering and
support equipment and required current transformers. Panels are assembled in a systematic
manner such as incomer section and outgoing section.

Figure 3.1 - Main Distribution panel

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3.1.2. Sub Distribution Panel

The Main Distribution Panel Board then feeds to the Sub distribution boards, which is
installed generally at the point where a large distribution cable terminates and several smaller
sub-circuits start. The voltages and current ratings are low. These are the switchboards that
although similar construction, are larger than a final distribution board circuit. The boards are
installed midway through the power distribution system, at the point in a large distribution
cable end, and several smaller starting sub-circuits.

Figure 3.2 – Sub Distribution Panel

3.1.3. LT Distribution Panel

I was able to create an electrical design & wire the following distribution panel in the
Ankit Electricals workshop.

Figure 3.3 - distribution panel wiring diagram

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  This distribution panel was designed for pump house. In this pump house all the
pumps will not operate at the same time, some pumps are using as the standby pumps.
 “ABB” 4 poles 125A MCCB was used as the main breaker.
 “DELB” ELR with shunt release coil was used as the protection device and “HOBUT”
200/5A core balance CT is used to get current inputs.
 According to the customer requirement, emergency stop switch was connected with
shunt coil.
 The 35mm2 copper PVC insulated wires (Kalani cables) were used to wire from main
MCCB to bus bar chamber. Thence 16mm2 for 63A, 10mm2 for 40A and 4mm2 for
16A wires were used.
 R, Y, B incoming indicators were attached to the panel door through the 2A fuse.
Problems faced during this panel wiring

This panel box was designed 250x400x150 size. The 150mm was not enough for the
200/5A core balance CT. so that I had to cut the cover plate of the panel, before the wired.

3.2 Changeover Panels

In Ankit Electricals workshop I observed Manual type and Auto type changeover panels. In
Automatic Changeover Panels we used several types of Auto transfer Switches (ATS). MCCB
type, Contactor type and Changeover type were some of them.

A changeover panel is operating on a mains power failure system. There are two types of
changeover panels.

Figure 3.4 - Changeover Panel

44
3.2.1. Manual Changeover Panel

In manual changeover panels rotary manual switch with centre off position is used to enable
selection of 2 different supplies. Most commonly a mains supply and a back-up generator
supply.

Figure 3.5 - Manual Changeover

3.2.2. Automatic Changeover Panel (ATS Panel)

The automatic panel, when the main supply is interrupted on one or all phases (after an
adjustable delay period) the generator sets will start-up automatically. After an initial warm-
up period (adjustable) the generators will synchronize with each other by means of motorized
circuit breakers or contactors onto a common bus bar. When the power will come, the
motorized change-over switch will be closed and the load will be connected to the main
supply.

45
 Figure 3.6 - Automatic Changeover Panel

3.2.3. Automatic Changeover Panel Wiring

I was able to wire the below control circuit of Automatic Changeover panel. The panel
consisted with “Telegram” ATS changeover with motorized kit.

This circuit was designed to get continues power supply from CEB or generator.
According to this panel circuit it can automatically switch on the generator when CEB
power failure.

Figure 3.7 - Automatic Changeover Panel control wiring diagram

Important points

 The “Telegram” ATS changeover unit was used separate auxiliary supply from CEB
side (used pin no 01 and 02) and generator (used pin no 03 and 04).
 There were two selector switches, one was used to Auto-Manual selector other one
was used to select CEB or Generator in manual mode.
 Phase Failure Relay (PFR) was used to detect the supply conditions in CEB and
generator.
 R2 relay was used to give a CEB ON signal to the 11th pin of changeover motorized
kit through open point (NO) of R2 6 3.

46
  R3 relay was used to give a Generator ON signal to the 10th pin of changeover
motorized kit through open point (NO) of R36 3.
 T4 timer was used to avoid the sudden change from generator supply to the CEB
supply, if CEB supply is changing quickly due to voltage fluctuation, T4 will keep
generator supply continuously.
 12th pin of the motorized kit was used to give OFF signal in to the changeover.
 For interlock purpose R3 1 5 and R2 1 5 closed points were used in the circuit.
 T4 4 1 and R17 3 closed points were used in generator starting control supply for
avoid the generator start manual or auto when the CEB supply is connected in manual
or auto mode.
3.3 Motor Control Panels
Motor Control panel consist of different motor starting methods such as Direct Online Starter
(DOL), Star-Delta Starter, Auto Transformers, Variable Speed Drives or Variable Frequency
Drives. Mainly used DOL and Star-Delta methods.

3.3.1. Direct Online Starter (DOL) Panel

This is the most common method of starting low power induction motors, where the starter is
connected directly across the three phases of the supply. However, the starting current at the
moment of switching direct-on-line can be as high as 6-8 times the rated current. A Direct
Online Motor Starter (DOL) consists of following components.

o A Circuit Breaker or Fuse(F)

o A Contactor (K1)
o An Overload Relay (OL1)
o start button (S1)
o Stop button (S0)
Typically, the contactor of the DOL circuit is controlled by separate start and stop push
buttons. When the start push button is pressed, the current flow through the control circuit and
the contactor coil which will energize the contactor coil and then the NO contactor contact get
closed and self-holding. So, the current is passed to the motor. When the stop button is
pressed or the over load coil is operated, the control circuit get broken and the contactor drops
out.

47
 Figure 3.8 – 4 DOL starter panel

Figure 3.9 – 2 DOL Starter

3.3.2. Star-Delta Starter Panel

When very large (< 5HP) motors are started by DOL, they cause a disturbance of voltage on
the supply lines due to large starting current surges. To limit the starting current surge, large

48
induction motors are started at reduced voltage and then have full supply voltage reconnected
when they run up to near rotated speed. Star-Delta starter is the reduced voltage starting
method. This type reduces phase voltage to about 58% of the running voltage, which reduce
the current and the motor’s torque.

Figure 3.10 –star delta starter panels

The Star/Delta starter is manufactured from three contactors, an on-delay timer and a thermal
overload. The currents through the winding are 1/√ 3 of the current in the line.

There are two contactors that are close during run, often referred to as the main contractor and
the delta contactor. These are AC3 rated at 58% of the current rating of the motor. The third
contactor is the star contactor and that only carries star current while the motor is connected in
star. The current in star is one third of the current in delta, so this contactor can be AC3 rated
at 1/3 (33%) of the motor rating.

In the star-delta starting method, firstly the motor starts as star after 80% of its full speed it
can run as delta. The one delay timer is sated that time of 80% of its full speed.

 Main over Load Relay (OL)= full load current x 1/√3

 Size of Main and Delta Contractor (K1 & K2) = full load current x 1/√3
 Star Contactor (K3) = full load current x 1/3
3.4 Power Factor Correction Capacitor Bank
Various industries and power system loads are inductive that take lagging current which
decrease the system power factor. The poor power factor increases the current flowing in

49
conductor and thus copper loss increases. Further high reactive power flows through the line,
the apparent power (KVA) and cost of electricity bill is high.

The power factor of a circuit may also be defined as the ratio of active power (KW) to the
apparent power (KVA). The lagging reactive power is responsible for the low power factor. It
is clear from the power triangle that smaller the reactive power component, the higher is the
power factor.

Figure 3.11 –Auto power Factor controller panel

The power factor can be improved by connecting capacitors in shunt with the system
operating at lagging power factor. These static capacitors provide leading current. A number
of capacitor units are combined to capacitor bank arrangement. Capacitor bank connected in
shunt with load. They improve the electrical supply quality and increase the efficiency of the
system. Also reduce reactive power and cost effective. Power factor correction is an
investment that helps to improve company’s profit performance. The capacitor bank with
automatic regulation offers the most economical solution.

Capacitor bank offers several advantages over other methods of power factor improvement.

 Losses are low in static capacitors.

 There is no moving part, therefore need low maintenance.
 They are lightweight so it is can be easy to install.

50
3.4.1. Components Used In Capacitor Bank

 Power factor correction capacitors

Capacitors are made in metalized polypropylene film (PFC). For three-phase loads, three-
phase capacitors are used. Normally three phase capacitor is interconnected three capacitors in
delta. Capacitors are rated in KVAR. Common factors of the capacitor are Rated Voltage,
KVAR Range, frequency, temperature, and harmonics.

Figure 3.12 - Power factor correction capacitors

 Harmonic Block Reactor

Neptune filter circuit are designed as three-phase reactors with an iron core and air gap.
Harmonic Filter Reactors are made out of highest quality material and very stringent quality
control. It has been designed with properties like low temperature rise and lower flux density
so that it can operate in worst conditions of ambient and harmonic overloads. They offer very
good degree of linearity. Cheaper and non-linear reactors may trigger undesirable chain
phenomena during periods of operation with high harmonic values, such as reducing in the
inductance with consequent increase in the resonance frequency of the LC group, which
would drain off more harmonic current, further reducing its inductance and overload the
reactor more and more. Reactors are available with filtering factor of 7% and 14% in 12.5, 25,
50 and 100 KVAR rating. Any other filtering factor and rating can be made on request.

51
 Figure 3.13 - Harmonic Block Reactor
 Capacitor Switching Contactor
When we were selecting contactor, consider about Rated current (I), Reactive power (KVAR),
voltage category and Thermal current. Capacitor switching contactors consist with contacts
and damping resistors. The capacitor switching contactor designed switch the capacitor first
through contact block of three contacts in series with quick discharge damping resistor to
limit to inrush current. Normally rated current is carried by main contacts, which after closing
after about 5 MS, effectively bypass the damping resistor.

Figure 3.14 – Capacitor switching contactors

 Automatic power factor controller

52
Digital power factor controller is used to control to capacitor bank. Measurement of the
required reactive power and control the capacitor switching according to the power factor
desired or pre-set value. Also, indication of power factor, display the number of capacitors
steps switched into the system and present parameters of the system. Disconnect the
capacitors when a system voltage drop occurs. Power factor controller is selecting according
to number of switching steps

Figure 3.15- Automatic power factor controller

 Discharge resistor
Capacitors should be discharged to <10% of the rated voltage prior to being re-energized. For
this purpose, special discharge resistors are offered which can be selected in accordance with
the applied operating voltage and the desired discharge period. Standard IEC 831 requires a
discharge to 75V or less within 3 minutes.

3.5 Electrical Panel Testing

I was able to test the several panels according to the IEC stranded in the testing section of
Orange Electric Workshop. The following testing equipment were used to check the
conditions of the panels.

53
 Figure 3.16 - Panel Testing

3.5.1. Testing Equipment

 Low voltage test lamp

I used test lamp for find simple faults or detect and presence or absence of voltage at each
point. The test lamp was an electric lamp connected with two insulated wire leads. Also it
was used for identification the approximate voltage (230 or 415V) by using the brightness
of the lamps.

 Clamp meter
Clamp meter is an electrical device having two jaws which open to allow clamping around
an electrical conductor. This allows properties of the electric current in the conductor to be
measured, without having to make physical contact with it, or to disconnect it for insertion
through the probe.

Figure 3.17 - Clamp meter

 Megger tester
The Megger tester is a method of testing making use of an insulation resistance meter that
will help to verify the condition of electrical insulation. The tester generates a high DC

54
 voltage of around 500V to 5KV or more. In distribution panels, insulation resistance more
than 5 MΩ, it has enough insulation resistance.

Figure 3.18 - Megger tester

3.5.2. Panel Tests

[Link]. Visual Inspection Procedure

 The visual inspection of any installation was as important as any testing that was
carried out on an installation.
 Before Visual Inspections was done, the relevant document of the testing panel was
observed by inspector.
 The first part of a visual inspection was to ensure that the system was safe to test and
that you have enough information to be able to carry out the further test safely.
 Followings were the main visual inspection area which aimed to check in the orange
panel testing process by us.

55
 Chapter-04

CONCLUSION

The training at Ankit Electricals was very useful. As it provides very useful information
about Panels like various type of LT panels, their manufacturing etc.

As we know A low-tension line is a low volt line and a high-tension line is a

high volt line. In Indian LT supply is of 440 Volts for three-phase connection and
240 Volts for single-phase connection.

I have learnt all detailed information about all types of LT Panel, Motor Control Centre
Panel (MCC), Intelligent MCC Panel (IMCC), Change over Panel, Power Plant control
Panel (PCC), Automatic Power Factor Correction Panel (APFC / RTPFC), Bus duct up
to 6300A, Aluminum & Copper, Customized & Challenging Design as per
requirements.

In conclusion, I would like to conclude that I have learned a lot of knowledge which I
cannot obtain in the books or references. Even though it is only 45 days of training, the
experience in the industry during 45 days is valuable for me. I have learned to be
responsible for my position and be punctual on work. it can be said that “Patience is
bitter, but its fruit is sweet.”

56