INDUSTRIAL TRAINING REPORT

By

Muhammad Awais 2022-UET-NFC-FD-EE-15

Semester Name 6th

Bachelor of Science

in

Electrical Engineering

Department of Engineering

NFC & IEFR FSD

2022-2025

INDUSTRIAL TRAINING REPORT

 Name: Muhammad Awais

Student Roll No: 2022-UET-NFC-FD-EE-15

Training Period: 9 Weeks

Training Organization: ZGL Pvt Ltd

A report submitted to NFC & IEFR Fsd

In partial fulfillment of the requirement for the degree of

Bachelor of Science
In
Electrical Engineering

Department of Engineering

NFC & IEFR FSD

 Abstract
After having intensive course work it is prerequisite to have internship in any organization in
order to get practical experience and familiarity with corporate atmosphere. During Bachelors in
Electrical Engineering Technology, I completed my internship in ZGL. I learned about
transformer and panels, during its maintenance operation, and I put all own learning experience
in this report. This is the only opportunity the student should have this experience overseen
during the industrial training period. I think I benefited the most from this experience. Also, I
learned how to work in one the importance of organization, punctuality, max Commitment, and
the importance of team spirit. There are many training programs Instead of staying in one place
for the whole period, the floors were much more useful Training In my opinion, and I need a lot
of knowledge and experience Succeed in a great challenge because in my opinion engineering is
everything No challenge and no job.
 Acknowledgement

First of all, I would like to thank Allah Almighty, for helping me starting from the beginning to the end
of my internship period. I have extended my supreme gratitude to The University of Faisalabad,
Department of Engineering Technology for providing such kind of opportunity for students to
broaden their perception on how the real world in the field of engineering looks like as well as
organizing the whole internship program and its effort to make sure that the whole internship program
to achieve its desired goals. I would also like to express my special thanks to ZGL Pvt Ltd giving me a
chance to spend my practice in his company and helping me in my day-to-day activities during the
intern time. I extend my grateful thanks to my supervisor Dr Muhammad Arshad Shehzad Hassan
for helping me in moral and material needs as well as sharing their knowledge to improve my
theoretical knowledge to the real works. Finally, I would like to express my special thanks to my
families and friends for helping me in all aspects and appreciate me spending my all time in the
workplace during my internship time.
 INDUSTRIAL TRAINING LOG BOOK

TRAINING INFORMATION

Personal Details

Student Name : Muhammad Awais

Reg No : 2022-UET-NFC-FD-EE-15

Address : Faisalabad
Email : hafizawais099@[Link]

Course of Study : Supervised Industrial / Field Training

Year/Semester of Study : 6th Semester

Training Start Date : 30-06-2025

Training End Date : 30-08-2025

Training Organization

Name : ZGL Pvt Ltd

Address : 15 km, Sheikhupura Road, Faisalabad

 Table of Contents
CHAPTER 1 Backgrounds of Training Organization.....................................................................1

1.1 Profile of the ZGL.............................................................................................................1

1.2 Mission..............................................................................................................................1

1.3 Vision................................................................................................................................1

1.4 Manufacturing...................................................................................................................1

1.5 Services.............................................................................................................................1

1.6 Core Values.......................................................................................................................2

1.7 Important Message............................................................................................................2

2 CHAPTER NO 2 (16 weeks schedule)...................................................................................3

CHAPTER NO 3 TRANSFORMER...............................................................................................4

2.1 Introduction.......................................................................................................................4

2.2 Standard Ratings...............................................................................................................5

2.3 Tank..................................................................................................................................5

2.4 Transformer Radiators......................................................................................................5

2.5 Transformer Conservator..................................................................................................6

2.6 Transformer top sheet.......................................................................................................7

2.7 Buchholz Relay.................................................................................................................8

2.7.1 Buchholz Relay Working Principle...........................................................................9

2.8 Silica Gel Breather............................................................................................................9

2.8.1 Working Principle of Silica Gel Breather................................................................10

2.9 Tap Changers..................................................................................................................10

2.10 Transformer Core Material..........................................................................................10

2.11 Transformer Windings................................................................................................11

2.12 Transformer Winding Materials..................................................................................12

2.13 Transformer Winding Types.......................................................................................13

2.13.1 Multi-Layer Helical Windings.................................................................................13

2.13.2 Helical Windings or Spiral Windings......................................................................13

2.13.3 Disc Windings.........................................................................................................13

2.13.4 Foil Windings..........................................................................................................14

2.13.5 Cylindrical Windings...............................................................................................14

2.13.6 Cross over Windings................................................................................................14

2.13.7 Disc & Continuous Disc Winding...........................................................................14

2.13.8 Aluminum Windings...............................................................................................15

2.14 Transformer Temperature Indicator............................................................................15

2.15 Transformer oil............................................................................................................16

2.16 Surface Preparation and Painting................................................................................17

2.16.1 General.....................................................................................................................17

2.16.2 Cleaning And Surface Preparation..........................................................................17

2.16.3 Protective Coating...................................................................................................18

2.16.4 Paint Material...........................................................................................................19

2.16.5 Painting Procedure...................................................................................................19

2.16.6 Damaged Paintwork.................................................................................................20

2.16.7 Dry Film Thickness.................................................................................................20

2.16.8 Tests For Painted Surface........................................................................................20

2.17 Cable connection in transformer.................................................................................21

2.18 Terminal Markings......................................................................................................22

2.19 Lightning Arrestors.....................................................................................................22

2.20 Methods of Transformers Testing...............................................................................22

 2.20.1 Turns Ratio Test......................................................................................................22

2.20.2 Insulation Resistance Test.......................................................................................22

2.20.3 Resistance Test........................................................................................................23

2.21 Reasons for testing......................................................................................................23

2.22 Routine Tests...............................................................................................................23

2.23 Type Tests to Be Conducted on One Unit...................................................................24

2.23.1 Acceptance Tests.....................................................................................................24

2.23.2 Tests At Site.............................................................................................................24

2.23.3 Inspection.................................................................................................................24

2.24 Documentation............................................................................................................25

2.25 Packing And Forwarding.............................................................................................25

2.26 Guarantee.....................................................................................................................25

3 Chapter – 4 Medium Voltage Switchgear.............................................................................26

3.1 Introduction.....................................................................................................................26

3.2 Range of MV Switch Gears............................................................................................27

3.3 Features...........................................................................................................................28

3.4 MV Switchgear Components..........................................................................................28

3.5 MV Switchgear working.................................................................................................28

3.6 MV Switchgear Safety....................................................................................................29

3.7 Electrical Hazards...........................................................................................................29

3.8 Electrical Shock..............................................................................................................29

3.9 Electrical Burns...............................................................................................................29

3.10 Fire and Explosion.......................................................................................................29

3.11 Heat Built Up...............................................................................................................29

3.12 Mechanical Hazards....................................................................................................29

3.13 MV Circuit Breaker.....................................................................................................30

3.14 Vacuum Circuit Breaker..............................................................................................30

3.15 Oil Circuit Breaker......................................................................................................31

3.16 Gas Circuit Breaker.....................................................................................................32

3.17 Current Transformer....................................................................................................33

3.17.1 Rated Primary Current.............................................................................................34

3.17.2 Rated Secondary Current.........................................................................................34

3.18 Potential Transformer..................................................................................................34

3.18.1 Connection of Potential Transformer......................................................................35

3.19 Busbars........................................................................................................................35

3.20 Load Break Switch......................................................................................................36

3.21 Protection Relay..........................................................................................................37

3.22 DC Supervision Relay.................................................................................................38

3.23 Energy Meter...............................................................................................................38

3.24 Surge Arrester..............................................................................................................39

3.25 Low Voltage Switchgear.............................................................................................40

3.25.1 Introduction..............................................................................................................40

3.25.2 Incomer....................................................................................................................40

3.25.3 Sub Incomer.............................................................................................................40

3.25.4 Feeders.....................................................................................................................41

3.26 DOL Starter.................................................................................................................41

3.26.1 Over Current Protection...........................................................................................42

3.26.2 Over Load Protection...............................................................................................42

3.26.3 Construction of DOL Starter...................................................................................43

3.27 Star-Delta Starter.........................................................................................................43

 3.27.1 Operation and Working...........................................................................................43

3.27.2 Application of Star-Delta Starter.............................................................................45

3.27.3 Characteristics and Features of Star-Delta Starter...................................................45

3.27.4 Advantages..............................................................................................................45

3.27.5 Disadvantages..........................................................................................................45

3.28 Forward Reverse Starter..............................................................................................46

3.28.1 Working of Reverse Forward Starter.......................................................................46

3.28.2 Operation of Reverse Forward Starter.....................................................................47

3.29 LDR.............................................................................................................................47

3.29.1 Working...................................................................................................................47

3.30 Main Incomer ACB Panel...........................................................................................47

3.30.1 Features....................................................................................................................48

3.31 LV Switchgear Components.......................................................................................48

3.31.1 Introduction..............................................................................................................48

3.31.2 Components.............................................................................................................48

3.31.3 Circuit Breakers.......................................................................................................49

3.31.4 Operation.................................................................................................................49

3.32 MCB............................................................................................................................50

3.32.1 Working...................................................................................................................50

3.33 MCCB.........................................................................................................................51

3.33.1 MCCB Operates.......................................................................................................52

3.34 ACB.............................................................................................................................52

3.34.1 Working Principal....................................................................................................52

3.34.2 Application and uses................................................................................................53

3.35 Magnetic Contactor.....................................................................................................53

 3.35.1 Magnetic Contactor Parts........................................................................................54

3.35.2 Magnetic Contactor Functions.................................................................................54

3.36 Ampere Meter..............................................................................................................55

3.36.1 Connection of Amp Meter.......................................................................................56

3.37 Volt Meter...................................................................................................................56

3.38 Indication Lights..........................................................................................................57

3.39 Selector Switch............................................................................................................57

3.40 Terminal Blocks..........................................................................................................58

3.41 Appendix A.................................................................................................................60

4 References..............................................................................................................................61
 List of figures
Figure 3.1 Transformer....................................................................................................................4
Figure 3.2 Transformer tank............................................................................................................5
Figure 3.3 Transformer Radiators....................................................................................................6
Figure 3.4 Transformer conservator................................................................................................7
Figure 3.5 Transformer top sheet.....................................................................................................7
Figure 3.6 Buchholz relay................................................................................................................8
Figure 3.7 Silica gel breather...........................................................................................................9
Figure 3.8 Tap changers................................................................................................................10
Figure 3.9 Transformer core material............................................................................................11
Figure 3.10 Transformer winding..................................................................................................12
Figure 3.11 Transformer temperature indicator.............................................................................15
Figure 3.12 Transformer oil...........................................................................................................16
Figure 3.13 Cleaning and Surface Preparation..............................................................................18
Figure 3.14 Protective Coating......................................................................................................19
Figure 3.15 Dry film thickness......................................................................................................20
Figure 3.16 Complete paint body ready........................................................................................21
Figure 3.17 Transformer cable connection....................................................................................21
Figure 4.18 Metering penal............................................................................................................27
Figure 4.19 Vacuum interrupter....................................................................................................31
Figure 4.20 Oil Circuit Breaker in switchyard..............................................................................32
Figure 4.21 Gas circuit breaker.....................................................................................................33
Figure 4.22 Current transformer....................................................................................................34
Figure 4.23 Potential transformer.................................................................................................35
Figure 4.24 Busbar.........................................................................................................................36
Figure 4.25 Load break switch......................................................................................................36
Figure 4.26 Protection relay..........................................................................................................38
Figure 4.27 DC Supervision Relay................................................................................................38
Figure 4.28 Energy meter..............................................................................................................39
Figure 4.29 Surge arrester..............................................................................................................39
Figure 4.30 Dol starter...................................................................................................................42
Figure 4.31 Star-delta starter.........................................................................................................44
Figure 4.32 Forward Reverse Starter.............................................................................................46
Figure 4.33 Main incomer ACB panel..........................................................................................48
Figure 4.34 MCB...........................................................................................................................50
Figure 4.35 MCCB........................................................................................................................51
Figure 4.36 Air Circuit Breaker.....................................................................................................53
Figure 4.37 Magnetic contactor.....................................................................................................55
Figure 4.38 Ampere meter.............................................................................................................55
Figure 4.39 Volt meter...................................................................................................................56
Figure 4.40 Indication lights..........................................................................................................57
Figure 4.41 Selector Switch...........................................................................................................58
Figure 4.42 Terminal blocks..........................................................................................................59
CHAPTER 1 Backgrounds of Training Organization
1.1 Profile of the ZGL
ZGL Private Limited has been in business of Manufacturing of Electrical Equipment including
Transformer, Switchgear, Automation and Electrical inspection & testing services since 1995.
ZGL has a vast experience in designing, Manufacturing, Installation, Testing & Commissioning
of Electrical Systems. We can assist you right from the initial concept to completion. ZGL has
been an established and popular company with an excellent track record.
ZGL team strictly follows all International and National standards, engineering practices and
economy to provide its clients with the most reliable and safe solutions. Here at ZGL, we believe
in hard work and provide right advice to our customers to save their time and money.

1.2 Mission
To provide quality products and services to the complete satisfaction of our customers.

1.3 Vision
To be recognized as Pakistan’s top ranked electrical manufacturing, trading and service
providing company through our commitment to core values. We shall introduce ourselves in
international market as a reliable brand of electrical about us equipment through our safe,
reliable, affordable, quality products and satisfactory services.

1.4 Manufacturing
1. Distribution and Power Transformers
2. MV Switchgear
3. LV Switchgear
4. Cable Trays
5. Solar System

1.5 Services
1. Electrical Engineers and Contractors
2. Automation and Control System
3. Inspection, Testing and Calibration
4. Erection and Commissioning

1
 5. Energy Management and Audit

1.6 Core Values

1. Quality and Professionalism
2. Putting People First
3. Continuous Improvement
4. Growth
5. Integrity and Ethics

1.7 Important Message

We have built the company through deep and lasting costumer relationship with the type of trust
that can only come over time. Our customers have known us, our skills and engaged us with their
power and engineering related issues.

ZGL is a company that will never lose sight of its heritage and history. From inception, we have
created and maintained and environment where close relationship, both between our own team
and with our customers are nurtured.

2
2 CHAPTER NO 2 (8 weeks schedule)

Department Date Plan

30-06-2025 Learn about different type of electrical
Lab testing To
tester.
department 05-06-2025
07-07-2025 Learn about inspection and measurement of
Mechanical To
mechanical body’s.
department 12-07-2025

Store 14-07-2025 Learn about finding different type of store

department To
items.
19-07-2025
Transform 21-07-2025 Learn about different types of transformer
er winding To
windings.
departme 02-08-2025
nt
Core 04-08-2025 Learn about different types and design of
departme To
transformer core.
nt 09-08-2025
11-08-2025 Learn about different steps of transformer
Transformer
To
fitting fitting.
16-08-2025
department
SGP 18-08-2025 Learn about different type of LV and HV
department To
panels.
23-08-2025
I&T 25-08-2025 Learn about different types of testing
department To
system.
30-08-2025

3
CHAPTER NO 3 TRANSFORMER
2.1 Introduction
A transformer is a passive component that transfers electrical energy from one electrical circuit
to another circuit, or multiple circuits. A varying current in any coil of the transformer produces
a varying magnetic flux in the transformer's core, which induces a varying electromotive force
(EMF) across any other coils wound around the same core. Electrical energy can be transferred
between separate coils without a metallic (conductive) connection between the two circuits.
Faraday's law of induction, discovered in 1831, describes the induced voltage effect in any coil
due to a changing magnetic flux encircled by the coil.

Transformers are used to change AC voltage levels, such transformers being termed step-up or
step-down type to increase or decrease voltage level, respectively. Transformers can also be used
to provide galvanic isolation between circuits as well as to couple stages of signal-processing
circuits.

Figure 3.1 Transformer

Since the invention of the first constant-potential transformer in 1885, transformers have become
essential for the transmission, distribution, and utilization of alternating current electric power. A
wide range of transformer designs is encountered in electronic and electric power applications.
Transformers range in size from RF transformers less than a cubic centimeter in volume, to units
weighing hundreds of tons used to interconnect the power grid.

4
2.2 Standard Ratings
The standard ratings shall be 16, 25, 63, 100,160, 200, 250, 315, 400, 500, 630, 1000, 1250,
1600, 2000 and 2500 kVA for 11 kV distribution transformers and 100, 160, 200, 315, 400, 500,
630, 1000, 1250, 1600,2000, 2500 kVA for 33 kV distribution transformers.

2.3 Tank
The internal clearance of tank shall be such, that it shall facilitate easy lifting of core with coils
from the tank without dismantling LV bushings. All joints of tank and fittings shall be oil tight
and no bulging should occur during service. Inside of tank shall be painted with varnish/hot oil
resistant paint. The top cover of the tank shall be slightly sloping to drain rain water. The tank
plate and the lifting lugs shall be of such strength that the complete transformer filled with oil
may be lifted by means of lifting shackle.

Figure 3.2 Transformer tank

Manufacturer should carry

out all welding operations as per the relevant ASME standards and submit a copy of the welding
procedure and welder performance qualification certificates to the customer.

2.4 Transformer Radiators

We are reckoned among the well-established Transformer Radiators Manufacturers and
Suppliers in the market. The Transformer Radiators that we deal in are exclusively used in Power
and Distribution transformers. The Transformer Radiators provided by us are of superior quality

5
that matches up to the international quality standards. Furthermore, the skilled workers engaged
in the construction of Transformer Radiators take all the specifications of the customers in
consideration. In addition to this, the on-time delivery of Transformer Radiators also results in
attaining complete customer satisfaction.

Figure 3.3 Transformer Radiators

2.5 Transformer Conservator

Transformers of rating 63 kVA and above with plain tank construction, the provision of
conservator is mandatory. For corrugated tank and sealed type transformers with or without inert
gas cushion, conservator is not required. When a conservator is provided, oil gauge and the plain
or dehydrating breathing device shall be fitted to the conservator which shall also be provided
with a drain plug and a filling hole [32 mm (1¼”)] normal size thread with cover. In addition, the
cover of the main tank shall be provided with an air release plug. The dehydrating agent shall be
silica gel. The moisture absorption shall be indicated by a change in the color of the silica gel
crystals which should be easily visible from a distance. Volume of breather shall be suitable for
500g of silica gel conforming to IS 3401 for transformers up to 200 kVA and 1 kg for
transformers above 200 kVA. The capacity of a conservator tank shall be designed keeping in
view the total quantity of oil and its contraction and expansion due to temperature variations. The
total volume of conservator shall be such as to contain10% quantity of the oil. Normally 3%
6
quantity the oil shall be contained in the conservator. The cover of main tank shall be provided
with an air release plug to enable air trapped within to be released, unless the conservator is so
located as to eliminate the possibility of air being trapped within the main tank. The inside
diameter of the pipe connecting the conservator to the main tank should be within 20 to 50 mm
and it should be projected into the conservator so that its end is approximately 20 mm above the
bottom of the conservator so as to create a sump for collection of impurities. The minimum oil
level (corresponding to -50C) should be above the sump level.

2.6 Transformer
top sheet
in transformer top sheet, fit at the top
of transformer tank. Figure 3.4 Transformer conservator All LV & HV
terminal are install at that top sheet. Another tap changer, temperature indicator meter,
conservator tank and other components are installed at.

Figure 3.5 Transformer top sheet

7
2.7 Buchholz Relay
A Buchholz relay is a safety device mounted on (some) oil-filled power transformers and
reactors, equipped with an external overhead oil reservoir called a “conservator”. Buchholz
relays are used as a protective device, as they are sensitive to the effects of dielectric failure that
can occur inside the equipment they protect. Buchholz relays are a type of gas detection relay.

Buchholz relays have two main elements. The upper element consists of a float. The float is
attached to a hinge in such a way that it can move up and down depending upon the oil level in
the Buchholz relay container.

A mercury switch is fixed on the float. The alignment of the mercury switch hence depends upon
the position of the float.

The lower element consists of a baffle plate and a mercury switch. This plate is fitted on a hinge
just in front of the inlet (main tank side) of the Buchholz relay in a transformer in such a way that
when oil enters in the relay from that inlet in high pressure the alignment of the baffle plate along
with the mercury switch attached to it, will change.

In addition to these main elements, a Buchholz relay has gas release pockets on top. The
electrical leads from both mercury switches are taken out through a molded terminal block.

Figure 3.6 Buchholz relay

8
2.7.1 Buchholz Relay Working Principle
The Buchholz relay working principle is very simple. Buchholz relay function is based on a very
simple mechanical phenomenon.

It is mechanically actuated. Whenever there will be a minor internal fault in the transformer such
as an insulation fault between turns, breakdown of core of the transformer, core heating, the
insulating transformer oil will be decomposed in different hydrocarbon gases, CO2 and CO.

The gases produced due to the decomposition of transformer insulating oil will accumulate in the
upper part of the Buchholz container which causes a fall of the oil level in it.

2.8 Silica Gel Breather

Whenever an electrical power transformer is loaded, the temperature of the transformer
insulating oil increases, consequently the volume of the oil is increased. As the volume of the oil
is increased, the air above the oil level in conservator will come out. Again at low oil
temperature; the volume of the oil is decreased, which causes the volume of the oil to be
decreased which again causes air to enter into conservator tank.

The natural air always consists of more or less moisture in it and this moisture can be mixed up
with oil if it is allowed to enter into the transformer. The air moisture should be resisted during
entering of the air into the transformer, because moisture is very harmful for transformer
insulation. A silica gel breather is the most commonly used way of filtering air from moisture.

Silica gel breather for transformer is connected with conservator tank by means of breathing
pipe.

9
 Figure 3.7 Silica gel breather

2.8.1 Working Principle of Silica Gel Breather

Silica gel crystal has tremendous capacity of absorbing moisture. When air passes through these
crystals in the breather; the moisture of the air is absorbed by them. Therefore, the air reaches to
the conservator is quite dry, the dust particles in the air get trapped by the oil in the oil seal cup.
The oil in the oil sealing cup acts as barrier between silica gel crystal and air when there is no
flow of air through silica gel breather. The color of silica gel crystal is dark blue but, when it
absorbs moisture; it becomes pink.

When there is sufficient difference between the air inside the conservator and the outside air, the
oil level in two components of the oil seal changes until the lower oil level just reaches the rim of
the inverted cup, the air then moves from high pressure compartment to the low pressure
compartment of the oil seal. Both of these happen when the oil acts as core filter and removes the
dust from the outside air.

2.9 Tap Changers

Tap changers are used to adjust the secondary voltage of transformers. They are designed to
change the turn ratio of the transformer as required. There are two types of tap changers: On-load
tap changers and Off-load tap changers.

Off-load tap changers are designed to operate only when the transformer is not supplying any
loads whereas on-load tap changers are capable of operating without interrupting the current
flow to the load. Automatic tap changers are also available.

Figure 3.8 Tap changers

10
2.10 Transformer Core Material
The core shall be stack / wound type of high grade Cold Rolled Grain Oriented or Amorphous
Core annealed steel lamination having low loss and good grain properties, coated with hot oil
proof insulation, bolted together and to the frames firmly to prevent vibration or noise. The core
shall be stress relieved by annealing under inert atmosphere if required. The complete design of
core must ensure permanency of the core loss with continuous working of the transformers. The
value of the maximum flux density allowed in the design and grade of lamination used shall be
clearly stated in the offer.
The transformers core shall be suitable for over fluxing (due to combined effect of voltage and
frequency) up to 12.5% without injurious heating at full load conditions and shall not get
saturated. The bidder shall furnish necessary design data in support of this situation.

No-load current up to 200kVA shall not exceed 3% of full load current and will be measured by
energizing the transformer at rated voltage and frequency. Increase of 12.5% of rated voltage
shall not increase the no-load current by 6% of full load current.

No-load current above 200kVA and up to 2500kVA shall not exceed 2% of full load current and
will be measured by energizing the transformer at rated voltage and frequency. Increase of
12.5% of rated voltage shall not increase the no-load current by 5% of full load current.

Figure 3.9 Transformer core material

11
2.11 Transformer Windings
Transformer winding includes different turns of copper coil bundles where every bundle is
connected to form a winding. Windings mainly depend on the input-output supply otherwise on
the range of voltage. The transformer winding diagram is shown below.

Transformer winding is available in two types like primary winding and secondary winding.
Transformer winding operation is, that the primary winding gets electrical energy from the
source whereas secondary winding transmits electrical energy to the load.

HV and LV windings shall be wound from Super Enamel covered /Double Paper covered
Aluminum / Electrolytic Copper conductor. LV winding shall be such that neutral formation will
be at top. The winding construction of single HV coil wound over LV coil is preferable. Inter
layer insulation shall be Nomex /Epoxy dotted Kraft Paper. Proper bonding of inter layer
insulation with the conductor shall be ensured.

Test for bonding strength shall be conducted. Dimensions of winding coils are very critical.
Dimensional tolerances for winding coils shall be within limits as specified in Guaranteed
Technical Particulars (GTP Schedule I). The core/coil assembly shall be securely held in position
to avoid any movement under short circuit conditions. Joints in the winding shall be avoided.
However, if jointing is necessary the joints shall be properly brazed and the resistance of the
joints shall be less than that of parent conductor. In case of foil windings, welding of leads to foil
can be done within the winding.

Figure 3.10 Transformer winding

12
2.12 Transformer Winding Materials
Transformer winding materials are aluminum and copper which are the most frequently used
conductors in transformer windings. The mechanical strength and conductivity are high for
copper whereas aluminum materials are less cost and lightweight as compared to copper.
Generally, copper windings are used in large transformers whereas aluminum conductors are
used for small size and medium size transformers.

2.13 Transformer Winding Types

1. Multi-Layer Helical Windings
2. Helical Windings or Spiral Windings
3. Disc Windings
4. Foil Windings
5. Cylindrical Windings
6. Cross- Over Windings
7. Disc & Continuous Disc Winding
8. Aluminum Windings

2.13.1 Multi-Layer Helical Windings

These windings are mainly used for high voltage rating-based transformers like 110 kV & above.
These types of windings comprise numerous cylindrical layers which are wounded & connected
in series. The external layers of these transformer windings are made shorter as compared to the
inside layers for allocating the capacitance consistently. These windings are mainly used to
enhance the transformer’s surge behavior.

2.13.2 Helical Windings or Spiral Windings

Helical windings are known as spiral windings which are used for low voltage & high capacity-
based transformers, where the flow of current is higher & the turns of winding are smaller. The
transformer output changes from 160 to 1000 kilovolt-ampere & 0.23 to 15 Kilovolt.

For protecting sufficient mechanical power, the cross-sectional area of the strip is not made less
than 75mm to 100mm square. The maximum number of strips that are used to make up the
conductor in parallel is 16. These windings are available in three types like single helical, double
helical, and Disc-helical.

13
2.13.3 Disc Windings
The designing of disc windings can be done by connecting several conductor discs in series.
Initially, a disc can be formed by winding different insulated conductor turns & after that
connected in series to make disc winding. Every disc can be separated from the nearby disc with
spacers.

The main disparity between a disc & helical winding is that the helical winding includes simply a
single twist of parallel conductor for each disc whereas the disc winding includes numerous turns
for each disc. Disc type windings are used in the above 25kV rated transformer. Similar to
helical, these windings are also robust mechanically.

2.13.4 Foil Windings

Foil windings are mainly designed with thin aluminum or copper sheets where the thin insulated
sheet is covered several times to make multilayer spiral windings. This winding can be formed
either with a single or many sheets within a parallel wound on the plane side. These are
applicable in high capacity-based transformers where the current ranges from 12 – 600 A.

2.13.5 Cylindrical Windings

These windings use low voltage up to 6.6 kV & their current rating ranges from 10 – 600 A.
These windings are frequently used in multi-layer forms. In these types of windings, we utilize
circular type conductors which are wounded on vertical strips to enhance cooling conditions.

This arrangement will create oil ducts to help better cooling. These windings are applicable
where high voltage ratings are used up to 33 kV, 800 kVA & current ratings up to 80 A. For a
bare conductor, the highest diameter size used is 4 mm.

2.13.6 Cross over Windings

Cross-over windings are used in small transformers. These windings are separated into several
coils to decrease the voltage among contiguous layers where these coils are divided axially
through 0.5 to 1 mm of distance. The voltages between contiguous coils should not be above 800
– 1000 V.

The actual axial length of every coil is approximately 50 mm whereas the spacing in two coils is
6 mm to hold insulating material blocks. The coil’s width ranges from 25mm to 50 mm. The
strength of these windings is high as compared to cylindrical type windings in normal conditions.

14
2.13.7 Disc & Continuous Disc Winding
This type of winding is normally used in high capacity-based transformers where these windings
include several discs or flat coils in a series or parallel configuration. The formation of these
coils can be done using rectangular strips which are spirally wounded within a radial direction.

The conductors in these types of windings are single or multiple strips within a parallel
configuration that is wound on the level side. So this conductor’s formation will make the
construction very strong.

The discs in these windings are divided from each other with pressboard sectors where these
sectors are connected to vertical stripes.

Here, the area of the conductor ranges from 4 to 50 mm square & the current ranges from 12 to
600 A. The least width of the transformer oil duct is 6 mm mainly for 35 kV. The main benefit of
these types of windings is that they provide maximum mechanical axial strength.

2.13.8 Aluminum Windings

Aluminum windings are the most predominant choice to use in different transformers in North
America like dry type and low voltage. In most areas all over the world, the copper winding is
the main winding material but the main reason to choose this aluminum winding is its initial cost
is low.

Aluminum winding is more flexible as compared to copper so making it very easy. The
maximum resistivity of aluminum provides inherently fewer eddy losses within the windings.
This reduces the possibility of hot spots. Transformers with aluminum winding or copper
winding have the same losses & performance. Aluminum wound coils are bigger as compared to
copper coils.

2.14 Transformer Temperature Indicator

In the transformer, the winding is an essential component with high temperatures. So once the
load increases then the winding temperature will be increased. Thus, to control the temperature
parameter within the transformer, the top oil & winding temperature is measured. The winding
temperature within the transformer is measured through WTI (Winding Temperature Indicator)
& the Transformer Oil’s temperature is measured with Oil
Temperature Indicator.

15
 Figure 3.11 Transformer temperature indicator

The main function of the Winding Temperature Indicator (WTI) is to specify the temperature of
low voltage & high voltage winding of the Transformer to operate the trip, the alarm & cooler
control contacts. In the below figure, the black needle shows the CWT (current winding
temperature) whereas the red color needle shows the highest winding temperature.

Here, two handles are provided to set the winding temperature for the trip & alarm. The Green
color handle shows the winding temperature setting for the Alarm whereas red color handle
shows the setting for Trip temperature.

2.15 Transformer oil

In all oil-immersed transformers, transformer oil provides added insulation between the
conducting parts, better heat dissipation, and fault detection features. Hydro-carbon mineral oil is
used as transformer oil. It is composed of aromatics, paraffin, naphthene’s, and olefins.
Transformer oil has a flashpoint of 310 degrees Celsius, a relative permeability of 2.7, and a
density of 0.96 kg/cm3.

Figure 3.12 Transformer oil

16
The insulating oil shall comply with the requirements of IS 335. Use of recycled oil is not
acceptable. The specific resistance of the oil shall not be less than 35 X1012 ohm-cm at 27oC
when tested as per IS 6103. Oil shall be filtered and tested for break down voltage (BDV) and
moisture content before filling. The oil shall be filled under vacuum. The design and all materials
and processes used in the manufacture of the transformer, shall be such as to reduce to a
minimum the risk of the development of acidity in the oil.

2.16 Surface Preparation and Painting

2.16.1 General
All paints, when applied in a normal full coat, shall be free from runs, sags, wrinkles, patchiness,
brush marks or other defects. All primers shall be well marked into the surface, particularly in
areas where painting is evident and the first priming coat shall be applied as soon as possible
after cleaning. The paint shall be applied by airless spray according to manufacturer’s
recommendations. However, where ever airless spray is not possible, conventional spray be used
with prior approval of purchaser.

2.16.2 Cleaning And Surface Preparation

After all machining, forming and welding has been completed, all steel work surfaces shall be
thoroughly cleaned of rust, scale, welding slag or spatter and other contamination prior to any
painting. Steel surfaces shall be prepared by shot blast cleaning (IS9954) to grade Sq. 2.5 of ISO
8501-1 or chemical cleaning including phosphating of the appropriate quality (IS 3618).
Chipping, scraping and steel wire brushing using manual or power-driven tools cannot remove
firmly adherent mill-scale. These methods shall only be used where blast cleaning is impractical.
Manufacturer to clearly explain such areas in his technical offer.

17
 Figure 3.13 Cleaning and Surface Preparation

2.16.3 Protective Coating

As soon as all items have been cleaned and within four hours of the subsequent drying, they shall
be given suitable anti-corrosion protection.

Figure 3.14 Protective Coating

2.16.4 Paint Material

Following are the types of paint which may be suitably used for the items to be painted at shop
and supply of matching paint to site: Heat resistant paint (Hot oil proof) for inside surface For

18
external surfaces one coat of thermos setting powder paint or one coat of epoxy primer followed
by two coats of synthetic enamel/polyurethane base paint. These paints can be either air drying
or stoving. For highly polluted areas, chemical atmosphere or for places very near to the sea
coast, paint as above with one coat of high build Micaceous iron oxide (MIO) as an intermediate
coat may be used.

2.16.5 Painting Procedure

All prepared steel surfaces should be primed before visible re-rusting occurs or within 4 hours,
whichever is sooner. Chemical treated steel surfaces shall be primed as soon as the surface is dry
and while the surface is still warm. Where the quality of film is impaired by excess film
thickness (wrinkling, mud cracking or general softness) the supplier shall remove the
unsatisfactory paint coating and apply another coating. As a general rule, dry film thickness
should not exceed the specified minimum dry film thickens by more than 25%.

2.16.6 Damaged Paintwork

Any damage occurring to any part of a painting scheme shall be made good to the same standard
of corrosion protection and appearance as that was originally applied. Any damaged paint work
shall be made good as follows:

The damaged area, together with an area extending 25 mm around its boundary, shall be cleaned
down to bare metal. A priming coat shall be immediately applied, followed by a full paint finish
equal to that originally applied and extending 50 mm around the perimeter of the original
damage. The repainted surface shall present a smooth surface. This shall be obtained by carefully
chamfering the paint edges before and after priming.

2.16.7 Dry Film Thickness

To the maximum extent practicable the coats shall be applied as a continuous film of uniform
thickness and free of pores. Overspray, skips, runs, sags and drips should be avoided. The
different coats may or may not be of the same color.

Each coat of paint shall be allowed to harden before the next is applied as per manufacturer’s
recommendation. Particular attention must be paid to full film thickness at the edges.

19
 Figure 3.15 Dry film thickness

2.16.8 Tests For Painted Surface

The painted surface shall be tested for paint thickness. The painted surface shall pass the cross-
hatch adhesion test and impact test as acceptance tests and Salt spray test and Hardness test as
type test as per the relevant ASTM standards. Supplier shall guarantee the painting performance
requirement for a period of not less than 5 years.

Figure 3.16 Complete paint body ready

2.17 Cable connection in transformer

Please calculate the primary and secondary side currents of your transformer. Once you have
these values, multiply by factor of 1.25. Whatever value you get, use that Amp value to derive
cable size, based on laying conditions of cable. By laying conditions, we mean ambient temp,
method of laying cable (underground/aboveground), grouping of cables in trefoil or single layer
etc. If it’s a small indoor Transformer, it’s pretty straightforward. But more info like Transformer
rating, Voltage ratio etc. is required.

20
 Figure 3.17 Transformer cable connection

2.18 Terminal Markings

High voltage phase windings shall be marked both in the terminal boards inside the tank and on
the outside with capital letter 1U, 1V, 1W and low voltage winding for the same phase marked
by corresponding small letter 2u, 2v, 2w. The neutral point terminal shall be indicated by the
letter 2n. Neutral terminal is to be brought out and connected to local grounding terminal by an
earthing strip.

2.19 Lightning Arrestors

9 kV, 5 kA metal oxide lightning arrestors Distribution class type of reputed make as per
relevant standard, one number per phase shall be provided to be fitted under the HV bushing
with GI earth strip 25x4 mm connected to the body of the transformer with necessary clamping
arrangement.

2.20 Methods of Transformers Testing

Testing Transformers Testing transformers is more important than many people realize, and
whenever CT or PT testing is conducted, it’s important to ensure that technicians use the correct

21
transformer testing equipment to ensure that all electrical, mechanical, and thermal standards are
being met.

2.20.1 Turns Ratio Test

Turns ratio transformer testing is commonly used to ensure that the winding ratio between the
primary and secondary coils are aligned to recommended specifications. This type of transformer
testing also ensures the transformer will provide either step-up or step-down voltage. A step-
down transformer, for instance, comprised of 100 primary turns and 10 secondary turns will
work to reduce the voltage by a factor of 10 — corresponding to the secondary coil — while
multiplying the current by 10 as well.

2.20.2 Insulation Resistance Test

Insulation resistance transformer testing, also known as the Megger test, is used to determine the
quality of insulation within the transformer itself. These tests are conducted with a
megohmmeter, one of the necessary transformer test instruments, that operates similar to a multi-
meter. In order to pass the test, the insulation of a transformer must be determined to have a
greater resistance than defined by international standards for that transformer type. If it measures
any lower it could signify an issue with the insulation which may require replacement.

2.20.3 Resistance Test

This type of transformer testing once a transformer has been left to settle at the same temperature
of the surrounding air. The reason for this is to check for any differences between the opens and
windings within the transformer. This helps ensure that all the circuits are still wired and
connected correctly. This test is conducted using an ohmmeter.

Overall, there are eight types of transformer testing; however, these are four of the most
common. All of these tests are critical for maintaining the integrity of the transformer and
without them, the operation can be severely hindered.

2.21 Reasons for testing

All the equipment offered shall be fully type tested by the bidder or his collaborator as per the
relevant standards including the additional type tests. The type test must have been conducted on
a transformer of same design during the last five years at the time of bidding. The bidder shall
furnish four sets of type test reports along with the offer. In case, the offered transformer is not

22
type tested, the bidder will conduct the type test as per the relevant standards including the
additional type tests at his own cost in CPRI/ NABL accredited laboratory in the presence of
employer’s representative(s) without any financial liability to employer in the event of order
placed on him. Special tests other than type and routine tests, as agreed between purchaser and
bidder shall also be carried out as per the relevant standards. The requirements of site tests are
also given in this clause. The test certificates for all routine and type tests for the transformers
and also for the bushings and transformer oil shall be submitted with the bid. The procedure for
testing shall be in accordance with IS1180 (Part-1) :2014 /2026 as the case may be except for
temperature rise test. Before dispatch each of the completely assembled transformers shall be
subjected to the routine tests at the manufacturer’s works.

2.22 Routine Tests

1. Ratio, polarity, phase sequence and vector group.
2. No Load current and losses at service voltage and normal frequency.
3. Load losses at rated current and normal frequency.
4. Impedance voltage test.
5. Resistance of windings at each tap, cold (at or near the test bed temperature).
6. Insulation resistance.
7. Induced over voltage withstand test.
8. Separate source voltage withstand test.
9. Neutral current measurement-The value of zero sequence current in the neutral of the star
winding shall not be more than 2% of the full load current.
10. Oil samples (one sample per lot) to comply with IS 1866.
11. Measurement of no-load losses and magnetizing current at rated frequency and 90%, 100%
and 110% rated voltage.
12. Pressure and vacuum test for checking the deflection.

2.23 Type Tests to Be Conducted on One Unit

2.23.1 Acceptance Tests
At least 10% transformers of the offered lot (minimum of one) shall be subjected to the
following routine/ acceptance test in presence of purchaser’s representative at the place of
manufacture before dispatch without any extra charges. The testing shall be carried out in

23
accordance with IS:1180 (Part-1): 2014 and IS:2026. Checking of weights, dimensions, fitting
and accessories, tank sheet thickness, oil quality,

material, finish and workmanship as per GTP and contract drawings. Physical verification of
core coil assembly and measurement of flux density of one unit of each rating, in every
inspection with reference to short circuit test report Temperature rise test on one unit of the total
ordered quantity.

2.23.2 Tests At Site

The purchaser reserves the right to conduct all tests on transformer after arrival at site and the
manufacturer shall guarantee test certificate figures under actual service conditions.

2.23.3 Inspection
In respect of raw material such as core stampings, winding conductors, insulating paper and oil,
supplier shall use materials manufactured/supplied by standard manufacturers and furnish the
manufacturers‟ test certificate as well as the proof of purchase from these manufacturers (excise
gate pass) for information of the purchaser. The bidder shall furnish following documents along
with their offer in respect of the raw materials:

i. Invoice of supplier.

ii. Mill’s certificate.

iii. Packing list.

iv. Bill of landing.

v. Bill of entry certificate by custom.

2.24 Documentation
The bidder shall furnish along with the bid the dimensional drawings of the items offered
indicating all the fittings.

Dimensional tolerances.

Weight of individual components and total weight.

24
An outline drawing front (both primary and secondary sides) and end-elevation and plan of the
tank and terminal gear, wherein the principal dimensions shall be given.

Typical general arrangement drawings of the windings with the details of the insulation at

each point and core construction of transformer.

Typical general arrangement drawing showing both primary and secondary sides and end
elevation and plan of the transformer.

2.25 Packing And Forwarding

The packing shall be done as per the manufacturer’s standard practice. However, it should be
ensured that the packing is such that, the material would not get damaged during transit by Rail /
Road / Sea. The marking on each package shall be as per the relevant IS.

2.26 Guarantee
The manufacturers of the transformer shall provide a guarantee of 24 months from the date of
receipt at the stores of the Utility or 18 months from the date of commissioning, whichever is
earlier. In case the distribution transformer fails within the guarantee period the purchaser will
immediately inform the supplier who shall take back the failed DT within 15 days from the date
of the intimation at his own cost and replace/repair the transformer within forty-five days of date
of intimation with a roll over guarantee.

The outage period i.e., period from the date of failure till unit is repaired/ replaced shall not be
counted for arriving at the guarantee period.

In the event of the supplier’s inability to adhere to the aforesaid provisions, suitable penal action
will be taken against the supplier which may inter alia include blacklisting of the firm for future
business with the purchaser for a certain period.

25
3 Chapter – 4 Medium Voltage Switchgear
3.1 Introduction
From 3 KV to 36 KV switchgear system is categorized as medium voltage switchgear or
MV switchgear. These switchgears are of many types. They may metal enclosed indoor type
switchgear, metal enclosed outdoor type switchgear, outdoor type switchgear without metal
enclosure, etc. The interruption medium of this switchgear may be insulating oil, SF6 gas or
vacuum. The main requirement of power network is to interrupt current during faulty condition
irrespective of what type of CB is used in the MV switchgear system. Although it may be
capable of functioning in other conditions also.

26
The main focus of circuit breaker design is to that all circuit breakers should be capable of
interrupting short circuit current with a high degree of reliability and safety. The number of
faulty tripping occurred during the total lifespan of a circuit breaker mainly depends upon the
location of the system, the quality of the system and environment conditions. If the number of
tripping is much high, the best choice is vacuum circuit breaker as it may not require any
maintenance up to 100 faulty tripping with short circuit current up to 25 KA. Whereas, other
circuit breakers require maintenance after 15 to 20 faulty tripping with same short circuit current
of CB. The substations reunited in rural areas are generally of an outdoor type, and most of them
are the unattended type. Hence for this type of applications maintenance free outdoor type,
medium voltage switchgear is most suitable. Porcelain clad vacuum circuit breaker meets
this demand against the conventional indoor kiosks.

Figure 4.18 Metering penal

3.2 Range of MV Switch Gears

1. Wapda Grid Panel
2. Wapda Metering Panel
3. Consumer Protection Panel
4. Incoming/Outgoing Panel
5. Generator Panel
6. Changeover Panel
7. Bus Coupler Panel

27
8. Load Break Switches (LBS)
9. Ring Main Units

3.3 Features
Some features of switchgear are listed below
1. Complete Reliable
2. Absolutely Certain discrimination
3. Quick Operation
4. Provision for Manual Control
5. Provision for Equipment

3.4 MV Switchgear Components

1. Circuit Breaker
2. Ct (Current transformer)
3. Pt (Potential transformer)
4. Busbars
5. Load Break Switch
6. Protection Relay
7. Energy Meter
8. Surge Arrester

3.5 MV Switchgear working

Electrical switchgear refers to a collection of circuit protection devices (circuit breakers, fuses or
switches) mounted in a common, metal enclosure. The circuit protection devices distribute power
to various sections of a facility and the electrical loads within those sections. They also provide
protection to individuals and equipment throughout the facility by limiting the current flow
through the system to safe levels.

3.6 MV Switchgear Safety

It is important when operating on medium voltage switchgear that we follow the safety rules and
operating regulations in order to be safe. This article covers general safe operations on medium
voltage switchgear and looks at the aspects of Switching, Isolating, Testing, and Earthing, as
well as various types of Medium Voltage testers and their usage.

28
3.7 Electrical Hazards
There are five types of hazards associated with the operation of medium voltage switchgear:

3.8 Electrical Shock

There is no way to tell if an electrical conductor or terminal is alive just by looking at it, it should
be tested using an appropriate approved tester. Thereafter it should be made safe in such a
manner that it cannot be energized by someone else whilst it is being worked on.

3.9 Electrical Burns

With medium voltage it is not necessary to touch a conductor or terminal in order to get burned.
Air does not normally conduct electricity however, when a person gets too close to an electrical
wire that is not properly insulated, the air can break down and form a conducting path between
them to earth.

3.10 Fire and Explosion

There is great danger of fire and explosion when working with medium voltage equipment, due
to the large fault currents that can flow in the system. Oil circuit breakers (OCBs) and oil mini
sub stations (MSS) and ring main panels (RMPs) pose a particular threat.

3.11 Heat Built Up

Heat can build up in wires. A lightweight extension lead gets hot when used for heavy duty
service.

3.12 Mechanical Hazards

Electricity is often used to run machinery, rotating machinery and moving parts are always a
source of danger, always ensure that guards are in place.

3.13 MV Circuit Breaker

Circuit breakers are critical links in a fault-clearing situation. When a fault occurs on the
electrical system, the associated current must be interrupted quickly and reliably to prevent
catastrophic damage to equipment and nearby personnel.

All circuit breakers have contacts, and when the contacts separate during a fault clearing
operation, they draw an arc. The electric arc forms between the contacts and is drawn out in
length as the contacts open.

29
For this reason, circuit breakers require a device to control or remove the arc. The Three
common mediums used to extinguish an arc during breaker contact separation are Oil, Gas, and
opening in a Vacuum.

3.14 Vacuum Circuit Breaker

Vacuum circuit breakers are the most popular type of medium-voltage breaker for industrial
environments due to their compact size and improved reliability compared to air circuit breakers.

Vacuum circuit breakers are similar to air circuit breakers with the main difference being that the
contact assembly is housed in a vacuum bottle. The moveable contact assembly is comprised of a
stem, having the enclosed contact at one end, and a driving mechanism at the other end located
outside the vacuum bottle.

Compression springs are provided in connection with the contact assembly in order to separate
the moveable contact from the fixed contact and to apply the force necessary to keep the contacts
from opening unintentionally.

As with air circuit breakers, the actuator may be operated manually or electrically by trip and
close coils, triggered by a protective relay. Like air circuit breakers, medium-voltage vacuum
breakers in an industrial environment are typically a draw-out type.

Figure 4.19 Vacuum interrupter

Vacuum circuit breakers offer many advantages compared to other types, including:

30
1. Relatively long life due to contact erosion being controlled within the vacuum bottle.
2. Maintenance-free operation - contacts are enclosed within a hermetically sealed housing.
3. Superior reliability thanks to the use of hard contact materials.
4. Virtually no atmospheric contact contamination, which reduces contact oxides and
corrosion.
5. Quiet operation due to containment of arcing within the vacuum bottle.
6. Little or no environmental effects.
7. low current chop, resulting in reduced transient voltage spikes during interruption, lowering
the likelihood of needing surge suppressors.

3.15 Oil Circuit Breaker

Oil circuit breakers, which are typically located outdoors, were common place in the past but are
becoming scarcer in the industrial environment as they are mostly being replaced with vacuum
circuit breakers.

Figure 4.20 Oil Circuit Breaker in switchyard

All contacts and mechanism assemblies are housed within an oil-filled tank, which provides both
an insulation and arc-quenching means. A medium-voltage oil circuit breaker in an industrial
environment is typically a stand-alone type and requires that Oil be drained and the breaker de-
tanked to perform maintenance.

A typical oil circuit breaker includes the same operational characteristics as an air circuit
breaker.

3.16 Gas Circuit Breaker

Gas circuit breakers, which are almost exclusively used in outdoor applications, are increasingly
favored over oil circuit breakers because of their lower maintenance costs. The arc generated in

31
this style of breaker is extinguished in a chamber filled with pressurized Sulfur hexafluoride
(SF6) gas, an inorganic, non-flammable gas that is an excellent electrical insulator.

SF6 Circuit breakers are similar to vacuum circuit breakers with the main difference being that
the contact assembly is housed in a pressurized bottle. During operation, this highly compressed
gas is released through the arc in breaker, collected into a relatively low-pressure reservoir and
then pumped back into the high-pressure reservoir for to be reused.

Figure 4.21 Gas circuit breaker

One distinct advantage gas breaker has over vacuum breakers is if the gas bottle loses pressure,
the residual SF6 gas can be enough to allow the breaker to open safely under a normal load. The
main disadvantage of SF6 is its negative effects on the atmosphere as a potent greenhouse gas.

3.17 Current Transformer

A CT is an instrument transformer in which the secondary current is substantially proportional to
primary current and differs in phase from it by ideally zero degree. Case of CT primary current is
the system current and this primary current or system current transformer to the CT secondary,
hence secondary current or burden current depends upon primary current of the current
transformer.

32
 Figure 4.22 Current transformer

3.17.1 Rated Primary Current

The primary current rating of a CT must be greater than the expected maximum operating
current it is monitoring. Standard values for Ipr are: 10, 12.5, 15, 20, 25, 30, 40, 50, 60, 75 A,
and decimal multiples of these values (source: IEC 60044-1)

3.17.2 Rated Secondary Current

The secondary current rating of a CT is either 1A or 5A. CTs with a 5 A secondary rating are
becoming less common as more CT driven equipment becomes digital. For long secondary cable
runs, CTs with 1 A secondary windings can minimize the transformer and secondary cable size.

3.18 Potential Transformer

The potential transformer may be defined as an instrument transformer used for the
transformation of voltage from a higher value to the lower value. This transformer step down the
voltage to a safe limit value which can be easily measured by the ordinary low voltage
instrument like a voltmeter, wattmeter and watt-hour meters, etc.

33
 Figure 4.23 Potential transformer

3.18.1 Connection of Potential Transformer

The potential transformer is connected in parallel with the circuit. The primary windings of the
potential transformer are directly connected to the power circuit whose voltage is to be
measured. The secondary terminals of the potential transformer are connected to the measuring
instrument like the voltmeter, wattmeter, etc. The secondary windings of the potential
transformer are magnetically coupled through the magnetic circuit of the primary windings.

3.19 Busbars
In electric power distribution, a busbar (also bus bar) is a metallic strip or bar, typically housed
inside switchgear, panel boards, and busway enclosures for local high current power distribution.
They are also used to connect high voltage equipment at electrical switchyards, and low voltage
equipment in battery banks. They are generally uninsulated, and have sufficient stiffness to be
supported in air by insulated pillars. These features allow sufficient cooling of the conductors,
and the ability to tap in at various points without creating a new joint.

34
 Figure 4.24 Busbar

3.20 Load Break Switch

A load break switch is a disconnect switch that has been designed to provide making or breaking
of specified currents.
Load break switch, generally comes with the spring mechanism for switching ON & OFF the
supply, however, option with vacuum circuit breaker is also available. Of course, option with
Vacuum circuit breaker is costlier. Choice between these two totally depends on the customer.
Load break switch with vacuum circuit breaker is more reliable option.

Figure 4.25 Load break switch

35
Load break switch with spring mechanism is generally provided with Fuse protection. And
hence, every time a fault occurs, fuse needs to be replaced. On the other hand, if you are using
Load break switch with vacuum circuit breaker, we only need to Turn On the breaker.
Load break switch are also provided with the Earth Switch, which helps in grounding the
charges, which can be present even after the switch is turned off.

3.21 Protection Relay

A relay is a device which detects the fault and supplies information to the breaker for circuit
interruption. Fundamental requirements of control relays Fundamental function of relay is to
sense the fault current. A protective relay should have the following qualities
1. Selectivity
2. Speed
3. Sensitivity
4. Reliability
5. Simplicity
6. Economy
Most common relays which are used in panels Over Current Earth Fault Relay Over
current/Earth fault relays are the basic protection relays. Used for protection of transformers and
feeders from over current and earth faults. When excessive current flows in a circuit, it is
necessary to trip the circuit breaker protecting that circuit. Protection Functions
Protection function used in the relay are
1. Phase over current protection
2. Earth over current protection
3. Ground fault protection
4. Trip circuit supervision
5. Breaker failure

36
 Figure 4.26 Protection relay

3.22 DC Supervision Relay

This type of relay is used to supervise the DC current in the panels. DC supply is necessary to
maintain the digital components in operation. It does also indicate trip coil fault operation in CB
by indicating on trip coil faulty indicator.
DC supervision relay which is used in ZGL MV panels.

Figure 4.27 DC Supervision Relay

3.23 Energy Meter

This outdoor epoxy resin type combined Current transformer/Voltage transformer metering
instrument transformer, used in current transformer used in 11KV power system for measuring
energy, power line protection and control to be MV prepaid metering system.

37
 Figure 4.28 Energy meter

3.24 Surge Arrester

A surge arrester is a device to protect electrical equipment from over-voltage transients caused
by external (lightning) or internal (switching) events. Also called a surge protection device
(SPD) or transient voltage surge suppressor (TVSS), this class of device is used to protect
equipment in power transmission and distribution systems. (For consumer equipment protection,
different products called surge protectors are used.) The energy criterion for various insulation
material can be compared by impulse ratio. A surge arrester should have a low impulse ratio, so
that a surge incident on the surge arrester may be bypassed to the ground instead of passing
through the apparatus.
To protect a unit of equipment from transients occurring on an attached conductor, a surge
arrester is connected to the conductor just before it enters the equipment. The surge arrester is
also connected to ground and functions by routing energy from an over-voltage transient to
ground if one occurs, while isolating the conductor from ground at normal operating voltages.
This is usually achieved through use of a varistor, which has substantially different resistances at
different voltages.

Figure 4.29 Surge arrester

38
3.25 Low Voltage Switchgear
3.25.1 Introduction
Generally, electrical switchgear rated up to 1KV is termed as low voltage switchgear. The term
LV Switchgear includes low voltage circuit breakers, switches, off load electrical isolators, HRC
fuses, earth leakage circuit breaker, miniature circuit breakers (MCB) and molded case circuit
breakers (MCCB) etc. i.e. all the accessories required to protect the LV system. The most
common use of LV switchgear is in LV distribution board. This system has the following parts
3.25.2 Incomer
The incomer feeds incoming electrical power to the incomer bus. The switchgear used in the
incomer should have a main switching device. The switchgear devices attached with incomer
should be capable of withstanding abnormal current for a short specific duration in order to allow
downstream devices to operate. But it should be cable of interrupting maximum value of the fault
current generated in the system. It must have an interlocking arrangement with downstream
devices. Generally, air circuit breakers are preferably used as interrupting device. Low voltage
air circuit breaker is preferable for this purpose because of the following features
1. Simplicity
2. Efficient performance
3. High normal current rating up to 600 A
4. High fault withstanding capacity up to 63 kA
Although air circuit breakers have long tripping time, big size, high cost but still they are most
suitable for low voltage switchgear for the above-mentioned features.
3.25.3 Sub Incomer
Next downstream part of the LV Distribution board is sub – incomer. These sub-incomers draw
power from main incomer bus and feed this power to feeder bus. The devices installed as parts of
a sub – incomer should have the following features
1. Ability to achieve economy without sacrificing protection and safety
2. Need for relatively a smaller number of interlocking since it cover limited are of network.
ACBs (Air Circuit Breakers) and switch fuse units are generally used as sub – incomers along
with molted case circuit breakers (MCCB)

39
3.25.4 Feeders
Different feeders are connected to the feeder bus to feeds different loads like, motor loads,
lighting loads, industrial machinery loads, air conditioner loads, transformer cooling system
loads etc. All feeders are primarily protected by switch fuse unit and in addition to that,
depending upon the types of loads connected to the feeders, the different switchgear devices are
chosen for different feeders.
In LV switchgear system, electrical appliances are protected against short circuit and overload
conditions by electrical fuses or electrical circuit breaker. However, the human operator is not
adequately protected against the faults occurs inside the appliances. The problem can be
overcome by using an earth leakage circuit breaker. This operates on low leakage current. The
earth leakage circuit breaker can detect leakage current as low as 100 mA and is capable of
disconnecting the appliance in less than 100 msec.
Low Voltage Switchgear Circuit Types
1. DOL Starter
2. Star-Delta Starter
3. Reverse Forward Circuit
4. Automatic Light Circuit
5. ACB Panel

3.26 DOL Starter

DOL Starter (Direct Online Starter) is also known as “across the line starter”. DOL starter is a
device consist of main contractor, protective devices and overload relay which is used for motor
starting operations. It is used for low rating usually below 5HP motors.
In direct online starter method of motor starting, the motor stator windings is directly connected
to the main supply where the DOL protect the motor circuit from high inrush current which may
damage the overall circuit as the initial current is much more higher than the full rated current.

40
 Figure 4.30 Dol starter

3.26.1 Over Current Protection

The condition that causes the flow of a faulty current in a large amount mostly due to a short
circuit or ground fault is called overcurrent.
The overcurrent condition can cause damage to the motor, power lines and can be a hazard for
operators. Such an amount of current is too dangerous for a brief moment. In the DOL starter,
we use a circuit breaker or fuses for protection against overcurrent. They open the circuit and
breaks the current flow in an instant until the problem in the system is resolved. The fuse or
circuit breaker is carefully selected with its rating kept in mind. Because we do not want the fuse
to break but to tolerate the starting current as well as the heavy load current. The overcurrent
breaker’s rating is kept a bit higher than the rated starting current of the motor.

3.26.2 Over Load Protection

The condition where the load connected to the motor increases beyond its limit and the motor
draws an excessive amount of current is called overload condition. During overload, the current
flow is beyond the safe limits which damage the wires as well as the motor windings. It melts the
windings and may cause fire hazards.

41
In order to protect the motor from overloading, we use an overload relay that trips the power
supply and protects the system from overheating. The overload relay monitors the current and
breaks the current flow when it exceeds a certain limit for a period of time. The tripping
mechanism may vary and depends on the application of motor.
3.26.3 Construction of DOL Starter
A DOL or Direct Online starter has simply two buttons; Green and Red, where the green button
is used for starting and the red is used for stopping the motor. The green button connects the
terminals and closes the circuit while the red button disconnects the terminals and breaks the
circuit. The DOL starter is made of a circuit breaker or MCCB or fuse, an overload relay and
contactor or coil. The circuit breaker is used for protection against short circuits while the
overload relay protects the motor from overloading. The contactor is used for starting and
stopping the motor where the green and red buttons are connected. The wiring for the start and
stop button is briefly explained in this article below.

3.27 Star-Delta Starter

In this tutorial, we will show the Star-Delta (Y-Δ) 3-phase induction AC Motor Starting Method
by Automatic star-delta starter with Timer with schematic, power, control and wiring diagram as
well as how star-delta starter works and their applications with advantages and disadvantages.
3.27.1 Operation and Working
1. from L1 The phase current flows to thermal overload contact through fuse, then OFF push
button, on push button Interlocking contact 2, and then C3. This way, the circuit is
completed, as a result;
2. Contactor coil C3 and timer coil (I1) is energized at once and the motor winding then
connected in Star. When C3 is energized, its auxiliary open links will be closed and vice
versa (i.e., close links would be open). Thus, C1 Contactor is also energized and Three Phase
Supply will reach to the motor. Since winding is connected in Star, hence each phase will get
√3 times less than the line voltage i.e., 230V. Hence Motor starts safely.
3. The close contact of C3 in the Delta line opens because of which there would be no chance of
activation of contactor 2 (C2).
4. After leaving the push button, Timer coil and coil 3 will receive a supply through Timer
contact (Ia), Holding contact 3 and the close contact 2 of C2.

42
5. When Contactor 1 (C1) is energized, then the two open contact in the line of C1 and C2 will
be closed.
6. For the specific time (generally 5-10 seconds) in which the motor will be connected in star,
after that the Timer contact (Ia) will be open (We may change by rotating the timer knob to
adjust the time again) and as a result;
7. Contactor 3 (C3) will be off, because of which the open link of C3 will be close (which is in
the line of C2) thus C2 will also energize. Similarly, When C3 off, then star connection of
winding will also open. And C2 will be closed. Therefore, the motor winding will be
connected in Delta. In addition, contact 2 (which is in the line C3) will open, by which, there
would not be any chance of activation of coil 3 (C3)
8. Since the motor is connected in Delta now, therefore, each phase of the motor will receive
full line voltage (400V) and the motor will start to run in full motion.

Figure 4.31 Star-delta starter

43
3.27.2 Application of Star-Delta Starter
As we know the main purpose of star delta starter is to start the three phase induction motor
in Star Connection while run in Delta Connection.
While keep in mind that Star Delta starter can only be used for low to medium voltage and light
starting torque induction motors. In case of direct on line (D.O.L) start, the receiving current at
motor is about 33% while the starting torque reduced about 25-30%. This way, Star Delta Starter
can be only used for light load during starting the motor. Otherwise, the heavy load motor won’t
start due to low torque which need to accelerate the motor to rated speed while converting to the
Delta connection.
3.27.3 Characteristics and Features of Star-Delta Starter
1. The starting current is 33% of full load current for star delta starter.
2. The peak starting torque is 33% of full load torque.
3. The peak starting current is 1.3 to 2.6 of full load current.
4. Star-Delta Starter can be used only for low to high power three phase induction motors.
5. It has reduced starting current and torque.
6. The 6 connection cables are needed for motor terminal box.
7. In Star Delta starter, Current peak and mechanical load on changeover from star delta.
3.27.4 Advantages
1. Simple Design and Operation
2. Comparatively cheaper than other voltage controlling methods
3. Torque and Current performance of the Star delta starter is well.
4. It draws two times starting current of the FLA (Full Load Ampere) of the connected motor.
5. It reduced the starting current to one-third (approximately) as compared to DOL (Direct On-
Line Starter)
3.27.5 Disadvantages
1. Starting Torque is also reduced to one-third because starter reduce the starting current to one-
third of the rated current [as Line voltage also reduced to 57% (1/√3)]
2. It required Six leads or terminals Motor (Delta Connected)
3. For Delta connection, the supply voltage must be same as the rated motor voltage.
4. We may not use star delta starter if the required (application or load) torque is more than
50% of the three phase induction motors rated torque

44
3.28 Forward Reverse Starter
As the name defines forward reverse starter is used to run the motor on both sides forward and
reverse. The figure given below shows the control and power diagram of the forward and reverse
starter diagram. These forward and reverse starters are dol type and not used above the 05 HP
motors. To run the motor of above 05 HP rating circuit has to made in star delta. These types of
starters are used in various applications e.g- mixing of materials, dying machines, etc.

Figure 4.32 Forward Reverse Starter

3.28.1 Working of Reverse Forward Starter

When we switch on the supply reaches through overload relay NC point and contactor NC point
to start push button. When any start button is pressed supply reaches the A1 point of the
contactor and also on the NO point of the contactor which takes continue the contactor in the
holding position. Now when pressed the forward start button forward contactor holds and the
motor starts running in the forward direction. This same action implies the reverse starting of the
motor.

45
3.28.2 Operation of Reverse Forward Starter
When start push button pressed contactor K1 ON for set time in timer 1 when timer 1 completes
its time contactor 2 will ON for set time in timer 2. This process will repeat again & again
automatically. To stop this process, press the stop button.

3.29 LDR
LDR is a device whose sensitivity depends upon the intensity of light falling on it. When the
strength of the light falling on LDR increases the LDR resistance decreases, while if the strength
of the light falls on LDR is decreased, its resistance increased.
In the time of darkness or when there is no light, the resistance of LDR is in the range of mega
ohms, while in the presence of light or in brightness in decrease by few hundred ohms.
3.29.1 Working
The working of circuit is very much easy to understand. In this circuit, we used IC LM358,
which is basically an operational amplifier. Pins 2 and 3 of these IC are used to compare the
voltage and give us an output as high or low depending on the voltages at the input pins.
In this circuit, LDR and 10KΩ Resistor form one potential divider pair, which is used to provide
a variable voltage at the non-inverting input (that is Pin 3). The second potential divider is built
around inverting input (Pin 2) with the help of 10KΩ Potentiometer, which will supply half of
the supply voltage to inverting pin.

3.30 Main Incomer ACB Panel

ACB panels are designed to prevent short circuit of an electrical circuit during voltage
fluctuations. We manufactured ACB panels using quality metal material and have suitable space
for reducing heat produced by Air Circuit Breaker (ACB). High quality ACB are used, make by
leading companies. We used ACB in different sizes according to the amount of voltage
fluctuation requirement.
Air Circuit Breaker is used to protect, control and monitor for low voltage distribution equipment
and that is more reliability for electrical distribution system safety and efficiently. Air Circuit
Breaker panel features as low voltage draw out or fixed power circuit breakers, circuit breaker
compartments, primary and secondary power connection, structures, bus-bar, self-standing type
and etc.

46
 Figure 4.33 Main incomer ACB panel

3.30.1
Features
1. Contribute to operation and maintenance of advanced electrical equipment
2. ACB panels supporting low-voltage and high-capacity and a control center are combined to
make an installation area smaller.
3. Equipped with compact and high-performance air circuit breakers (ACBs).

3.31 LV Switchgear Components

3.31.1 Introduction
Electrical switchgear is very important part of any electrical distribution system. Switchgear are
used for many purposes like protection, isolation for live parts and switching operation. A
switchgear is the combination of electrical disconnect switches, fuses or circuit breakers used to
control, protect and isolate electrical equipment.
3.31.2 Components
1. Circuit Breakers
2. Magnetic Contactors
3. Ampere Meter
4. Volt Meter
5. Indication Lights

47
6. Selector Switch
7. Terminal Blocks
8. LDR
3.31.3 Circuit Breakers
An electrical circuit breaker is a switching device which can be operated manually and
automatically for controlling and protecting an electrical power system. As the modern power
system deals with huge currents, special attention should be given during designing of a circuit
breaker to ensure it is able to safely interrupt the arc produced during the closing of a circuit
breaker.
The circuit breaker mainly consists of fixed contacts and moving contacts. In normal “ON”
condition of the circuit breaker, these two contacts are physically connected to each other due to
applied mechanical pressure on the moving contacts. There is an arrangement stored potential
energy in the operating mechanism of circuit breaker which is released if the switching signal is
given to the breaker.
There are three main types of low voltage circuit breaker
1. MCB
2. MCCB
3. ACB
3.31.4 Operation
All circuit breaker systems have common features in their operation, but details vary
substantially depending on the voltage class, current rating and type of the circuit breaker.
The circuit breaker must first detect a fault condition. In small mains and low voltage circuit
breakers, this is usually done within the device itself. Typically, the heating or magnetic effects
of electric current are employed. Circuit breakers for large currents or high voltages are usually
arranged with protective relay pilot devices to sense a fault condition and to operate the opening
mechanism. These typically require a separate power source, such as a battery, although some
high-voltage circuit breakers are self-contained with current transformers, protective relays, and
an internal control power source.
Once a fault is detected, the circuit breaker contacts must open to interrupt the circuit; this is
commonly done using mechanically stored energy contained within the breaker, such as a spring
or compressed air to separate the contacts. Circuit breakers may also use the higher current

48
caused by the fault to separate the contacts, such as thermal expansion or a magnetic field. Small
circuit breakers typically have a manual control lever to switch off the load or reset a tripped
breaker, while larger units use solenoids to trip the mechanism, and electric motors to restore
energy to the springs.

3.32 MCB
An MCB or miniature circuit breaker is an electromagnetic device that embodies a complete
enclosure in a molded insulating material. The main function of an MCB is to switch the circuit,
i.e., to open the circuit (which has been connected to it) automatically when the current passing
through it (MCB) exceeds the value for which it is set. It can be manually switched ON and OFF
as similar to normal switch if necessary.
MCBs are time delay tripping devices, to which the magnitude of overcurrent controls the
operating time. This means, these get operated whenever overloads exist long enough to create a
danger to the circuit being protected.

Figure 4.34 MCB

3.32.1 Working
Under normal working conditions, MCB operates as a switch (manual one) to make the circuit
ON or OFF. Under overload or short circuit condition, it automatically operates or trips so that
current interruption takes place in the load circuit.
The visual indication of this trip can be observed by automatic movement of the operating knob
to OFF position. This automatic operation MCB can be obtained in two ways as we have seen in
MCB construction; those are magnetic tripping and thermal tripping.

49
Under overload conditions, the current through the bimetal causes it to raise the temperature of
it. The heat generated within the bimetal itself is enough to cause deflection due to thermal
expansion of metals. This deflection further releases the trip latch and hence contacts get
separated.
Under short circuit or heavy overload conditions, magnetic tripping arrangement comes into the
picture. Under normal working conditions, the slug is held in a position by a light spring because
the magnetic field generated by the coil is not sufficient to attract the latch.
When a fault current flows, the magnetic field generated by the coil is sufficient to overcome the
spring force holding the slug in position. And hence slug moves and then actuate the tripping
mechanism.

3.33 MCCB
A molded case circuit breaker (MCCB) is a type of electrical protection device that is used to
protect the electrical circuit from excessive current, which can cause overload or short circuit.
With a current rating of up to 2500A, MCCBs can be used for a wide range of voltages and
frequencies with adjustable trip settings. These breakers are used instead of miniature circuit
breakers (MCBs) in large scale PV systems for system isolation and protection purposes.

Figure 4.35 MCCB

50
3.33.1 MCCB Operates
The MCCB uses a temperature sensitive device (the thermal element) with a current sensitive
electromagnetic device (the magnetic element) to provide the trip mechanism for protection and
isolation purposes. This enables the MCCB to provide:

1. Overload Protection
2. Electrical Fault Protection against short circuit currents
3. Electrical Switch for disconnection.

3.34 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.
3.34.1 Working Principal
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:
1. 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.
2. By splitting the arc into a number of series will increases the arc voltage.
3. 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.
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
51
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 4.36 Air Circuit Breaker

3.34.2 Application and uses

1. It is used for protection of plants.
2. It is used for common protection of electrical machines.
3. It used for protection of transformers, capacitors and generators.
4. Also used in Low as well as High voltage and Currents applications.

3.35 Magnetic Contactor

Magnetic contactors are the same as the electrical relays which are used in a number of electric
motors. Magnetic contactors are used in the electric motors to balance the change in frequency of
the motor or the state of the motor which can be termed as the switching of the motor from ON
and OFF state. The change in frequency of the motor is due to the different parameters of the
power sources which are direct power sources and due to the high load of electrical motors.
Magnetic contactors act as a safeguard to protect the power supply and the motor. Magnetic
contactors are sometimes considered as circuit breakers due to their similarity of shape with the
circuit breakers but their functionality is different than that of circuit breakers. When the circuit
between the motor and the power source is in short state the connection is cut off to safeguard
the appliance. The magnetic contactors can be easily removed from the motors and the work on
the motor can be performed easily. With the removal of the magnetic contactor from the motor,
the possibility of live current passing to the motor is reduced to 0%. Relays and magnetic
contactors are taken as the same equipment at the industrial level but there are a lot of

52
differences between the relays and the magnetic contactors. Relay is used for loads up to 10A or
less than 10A whereas a magnetic contactor is used for loads greater than 10A. Relays are
typically used in single-phase appliances whereas a magnetic contactor is used in three-phase
appliances. Relay has a common contact for the connection to the appliance while the magnetic
contactor has 2 poles for its connection with an appliance.
3.35.1 Magnetic Contactor Parts
The magnetic contactor has three main parts/components. The current in the magnetic contactor
is carried out with the contacts. The contact includes different contacts like power contacts,
contact springs, and auxiliary contacts. The circuit of the magnetic contactor is enclosed in an
insulating material like Nylon 6, thermosetting plastics and Bakelite. The circuit is enclosed for
protection in case of touching. The electric arc which is the main part of the contactor is moved
by the blowout coils in case of a magnetic blowout. As an additional circuit, sometimes the
economizer circuits are also included in the circuit of the magnetic contactor. This economizer is
used to lower the power required by the magnetic contactor to reduce the coil current in the
closed state. Economizers are usually used in the dc contactors coils and on large ac contactor
coils.
3.35.2 Magnetic Contactor Functions
The magnetic field is generated by the electromagnet in the magnetic contractor when the
electricity starts flowing in the magnetic contractor. The magnetic field created is a strong
magnetic field that pulls the iron core of the magnetic contractor in the coil and as a result, an
electric arc is generated. The electricity is passed into the magnetic contractor in this manner. To
stop the functionality of the magnetic contractor it is simply pulled off from the device it is
attached with. When there is no electrical current in the magnetic contractor, the connection of
the core with the coil is also disconnected and the circuit connection is broken.

53
 Figure 4.37 Magnetic contactor

3.36 Ampere Meter

The meter uses for measuring the current is known as the ammeter. The current is the flow of
electrons whose unit is ampere. Hence the instrument which measures the flows of current in
ampere is known as ampere meter or ammeter.
The ideal ammeter has zero internal resistance. But practically the ammeter has small
internal resistance. The measuring range of the ammeter depends on the value of resistance.

Figure 4.38 Ampere meter

54
3.36.1 Connection of Amp Meter
The ammeter is connected in series with the circuit so that the whole electrons of measured
current passes through the ammeter. The power loss occurs in ammeter because of the measured
current and their internal resistance. The ammeter circuit has low resistance so that the small
voltage drop occurs in the circuit.

3.37 Volt Meter

Voltmeter which is also known as voltage meter is an instrument that measures the voltage or
potential difference among two points of an electronic or electrical circuit. Usually, the voltmeter
is used for Alternating Current (AC) circuits or Direct Current (DC) circuits. Alternatively,
Radio Frequency (RF) voltage can also be measured by specialized voltmeters.
A voltmeter measures voltages usually calibrated in volts, millivolts (0.001 volt), or kilovolts
(1,000 volts). In order to measure a device’s voltage, a voltmeter is connected in parallel to a
device. This setup is important as objects in parallel usually tend to experience the same potential
difference. It is connected in parallel with the circuit mainly because the same voltage drop
occurs across it.
A voltmeter also has high internal resistance. This is done mainly because it is used in measuring
the potential difference between the two points of the circuit. As such the current of the
measuring device remains the same. In other words, the high resistance of the voltmeter will
impede the flow of current through it. This allows the device to take correct readings of the
voltage.

Figure 4.39 Volt meter

55
3.38 Indication Lights
The indicator light is a panel-mounted lamp assembly consisting of the indicator housing, an
internal lamp, terminals, and a lens. The light source of indicator light is a high brightness pure
color LED or incandescent bulb.
As the name implies, indicator lights reveal the status (ON or OFF) of an electrical apparatus in
switchboards. In more sophisticated systems, the indicating lights may annunciate the cause of
the current interruption, such as line-to-ground fault, overload, and overcurrent condition.
Indicator lights include a colored lens such as red, green, blue, yellow/amber, clear, or white.
These colored lenses symbolize the condition of the machine or equipment to which the lights
are connected.

Figure 4.40 Indication lights

3.39 Selector Switch

A mechanical switch that can be rotated right, left, or center to open or close the electrical
contacts is known as a selector switch. The main function of this switch is to control devices and
also to switch between a minimum of two or above electrical circuits. This switch is applicable
where more than one control option is required; for instance, it needs to be activated for a fixed
time, or once activated it needs to be set on a particular option. These switches provide flexible
control options in less space to perform various functions. The selector switch symbol is shown
below.

56
 Figure 4.41 Selector Switch

The selector switch working principle is to control different currents circuits by turning the knob.
These switches include a simple selector switch on the front of the panel, and also combinations
of potential contacts inside of the switch.
The construction of a selector switch can be done by using different parts like a contact block,
holder, operator, and lamp block.

3.40 Terminal Blocks

A terminal block (also called as connection terminal or terminal connector) is a modular block
with an insulated frame that secures two or more wires together. It consists of a clamping
component and a conducting strip. A typical simplest terminal block is as shown in the image
below.

57
 Figure 4.42 Terminal blocks

The insulating body of a terminal block houses a current carrying element (a metal strip or
terminal bar). It also provides a base for clamping element. The body has a mounting
arrangement so that the block can be easily mounted on or unmounted from a PCB or a mounting
rail. Most terminal blocks are usually modular and mounted on DIN rail. That allows us to
increase the number of terminals according to the requirements. Terminal blocks keep
connections much more secure and wires well organized.

58
 3.41 Appendix A
VCB = Vacuum Circuit Breaker

ACB = Air Circuit Breaker

MCB = Miniature Circuit Breaker

MCCB = Molded Case Circuit Breaker

CB = Circuit Breaker

PF = Power Factor

HT = High Tension

LT = Low Tension

HV = High Voltage

LV = Low Voltage

LDR = Light Dependent Resistor

59
4 References

1. ZGL Introduction [Online] Available at:

[Link]

2. MV Switchgear Safety [Online] Available at:

[Link]
with-medium-voltage-switchgear/

3. Parts of MV Switchgear [Online] Available at:

[Link]

4. Working of MV Switchgears [Online] Available at:

[Link]

5. Low Voltage Switchgear Circuits [Online] Available at:

[Link]

6. LDR [Online] Available at:

[Link]

60