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ENGINEERING
NAME
: G.K.T.PREMARATHNA
FIELD
PREFACE
This report presents the experiences and knowledge I have gathered during the first 3 months
training period starting from 10th February 2014 to 09th May 2014 at Orange Electric of OREL
Corporation (Pvt) Limited.
Chapter one reviews information about the training organization, its main functions,
organizational structure, business products, welfare and safety practices. The experience and
knowledge gained within the period of industrial training are presented in the second chapter.
Information about the work shop I visited, duties and functions performed during the training
period is included. Problems encountered during training and solutions found are also discussed
in the second chapter. In the third chapter, gives a conclusion of training and of this report.
Kasun Premarathna
ACKNOWLEDGEMENT
I would like to offer my sincere gratitude to the Advanced Technological Institute (ATI)
Colombo 15, National Apprentice and Industrial Training Authority (NAITA) and OREL
Corporation (Pvt) Limited for offering this training opportunity.
Further I must extend my deepest gratitude to Mrs. Anodya Ariyarathna, Director of ATI
Mattakkuliya. In addition, Mr. Yogaganeshan, Head of Department Electrical Engineering and
all academic staff of my Institute who guides me at all the times.
I am grateful to Factory Manager of OREL Corporation (Pvt) Limited. for giving us this
opportunity. I also appreciate the cooperation from Mr. Ekanayaka the training coordinator of
Orange Electric. I would be grateful to thanks Production Manager Mr. Gervin Sugath, who gave
me the guidance for a better training. My special gratitudes also offered to all the Engineers and
other officers. My sincere thanks also belong to Head of Department and supervisor in the
Electrical department. Also I would like to thank all the other Electricians and Operators who
helped me in many ways during this training period.
Above all the things, it is the efforts of my parents and the family members gave me strength and
support. Finally I wish to convey my gratitude to everyone that I may have forgotten to mention
above, who supported me to complete my In-plant Training successfully.
G.K.T.Premarathna,
Student of HNDE,
Department of Electrical Engineering,
Advanced Technological Institute,
Colombo 15.
Kasun Premarathna
CONTENTS
Title
Page
Kasun Premarathna
2.6. Cables .. 41
2.6.1. Cable Insulation Materials . 41
2.6.2. Cable Lug ... 41
2.6.3. Cable Numbering Tube .. 42
Kasun Premarathna
3.1. Conclusion .. 67
3.2. Abbreviations . 68
Kasun Premarathna
LIST OF FIGURES
Figure 1.1
10
Figure 1.1.4
11
Figure 1.1.5
12
Figure 1.2.1
15
Figure 2.1
18
Figure 2.2.1
Tool box
20
Figure 2.2.1.1
Cable Cutter
20
Figure 2.2.1.2
Crimping Tool
20
Figure 2.2.2.1
Jig Saw
21
Figure 2.2.2.2
Electric Drill
21
Figure 2.2.2.3
21
Figure 2.2.2.4
Industrial Heater
21
Figure 2.2.3
22
Figure 2.2.4.1
Din rails
23
Figure 2.2.4.2
Insulator mounts
23
Figure 2.2.4.3
Cable ducts
23
Figure 2.2.4.4
23
Figure 2.3.1
Cartridge Fuse
24
Figure 2.3.2
24
Figure 2.3.2
MCBs
25
Figure 2.3.2.1
25
Figure 2.3.2.2
26
Figure 2.3.3.1
26
Figure 2.3.3.2
27
Figure 2.3.4
28
Figure 2.3.4
I - Thermal adjustment
28
Figure 2.3.4
II - Magnetic adjustment
28
Figure 2.3.4.2
29
Figure 2.3.4.3
30
Kasun Premarathna
Figure 2.3.5.1
SPD device
31
Figure 2.3.5.2
31
Figure 2.3.6
31
Figure 2.3.7
32
Figure 2.3.8.2
DELAB ELR
32
Figure 2.3.8.2
connection of ELR
32
Figure 2.3.9
33
Figure 2.4.1.1
Types of CTs
34
Figure 2.4.1.2
Working principle of CT
34
Figure 2.4.1.3
CT connection
35
Figure 2.4.2
35
Figure 2.4.3
36
Figure 2.4.4
37
Figure 2.5.1
38
Figure 2.5.2.1
ABB contactor
39
Figure 2.5.2.2
Auxiliary components
39
Figure 2.5.3.1
Timers
39
Figure 2.5.3.2
39
Figure 2.5.4
40
Figure 2.6
41
Figure 2.6.2
Cable Lugs
41
Figure 2.6.3
42
Figure 2.7
Bus bars
43
Figure 2.8.1
44
Figure 2.8.2
45
Figure 2.8.3
45
Figure 2.9.2
47
Figure 2.9.3
48
Figure 2.10.1
50
Figure 2.10.2.1
51
Figure 2.10.2.2
51
Kasun Premarathna
Figure 2.10.3
53
Figure 2.10.4
55
Figure 2.10.4.1
56
Figure 2.11
57
Figure 2.11.1
Capacitor Bank
57
Figure 2.11.1.1
Power capacitor
58
Figure 2.11.1.2
58
Figure 2.11.1.2
58
Figure 2.11.2
60
Figure 2.11.3
61
Figure 2.12.1.1
Test Lamps
62
Figure 2.12.1.2
Clamp meter
62
Figure 2.12.1.3
Continuity tester
63
Figure 2.12.1.4
Megger tester
63
Figure 2.12.2.1
64
Figure 2.12.2.2
65
Figure 2.12.2.3
66
LIST OF TABLES
Table 2.4.1
34
Table 2.6.4
42
Table 2.7.1
43
Kasun Premarathna
10
Kasun Premarathna
Orange Electric was launched as the companys main brand in 2004. With the increase of their
product portfolio the company has five major factories in Maharagama, Boralesgamuwa,
Ratmalana, Meegoda and Ranala. In these five factories they manufacture more than one million
items for a month. Under the proficient headship of Mr. Kushan Kodituwakku, our respected
MD, the Orange brand became an overnight success, securing market leadership within a short
period in the field of manufacturing, exporting and importing of Electrical Products.
1.1.2. Vision
"To create a billion dollar global electrical brand"
1.1.3. Mission
"To add more to life with electricity"
Kasun Premarathna
I was mainly involved with the Orange Electric of OREL Corporation during the period of
industrial training, which is situated at Megoda, Padukka. This factory manufactures electrical
components to the highest quality and most stringent international standards.
Low Voltage Switchgear which Designed for a flawless performance, the Low Voltage
Switchgear available with us is largely used in varied industrial applications for providing
isolation switching and earth leakage protection of electrical circuits.
.
Electrical Accessories
Bulbs
CFL Lamps are created a strong foothold in the business of manufacturing and exporting world
class CFL Lamps. Tube lights and LEDs also produced in orange
Cables
The Electrical Cables are specially manufactured using the best grade raw materials. Thus, these
Electrical Cables are the best choice that is available in the markets all across the world.
Moreover, the clients can access this enviable range of Electrical Cables in varied specifications
that too at very reasonable rates.
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Kasun Premarathna
One of the major Manufacturers and Exporters is Power Distribution Panel. These Power
Distribution Panels are trusted for Safety Reliability and Quality in LV Power
Distribution.
o
Steel Enclosure
The Steel Enclosures for Power Distribution Panels is fabricated using the finest grade raw
materials.
1.1.7. Organization
Orange electrical is very highly organized company and It has very complicate organization
system. The total number of employees at Orange electric is about 1000. This is main
organization structure of orange electric.
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Kasun Premarathna
Board of Directors
Chairmen
Managing Director
Other Director
Welfare
Orange Electric, a company who places great emphasis on the welfare of its employees has
recently implemented several distinctive programs, giving new meaning to work life balance
whilst taking their Healthy Employee concept to an altogether higher plain. The Company has
devised some interesting and special programs that greatly contribute.
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Kasun Premarathna
Transport service.
Welfare shop.
We got the assistance from supervisor, before testing the experiment with electrical
supply.
Proper testing and checking instruments were used to find the live parts.
We used only tools and equipment with non-conducting handles when working on
electrical devices.
We kept in mind to never handled electrical equipment when hands, feet, or when
standing on a wet floor.
We kept the workplace dry and free from oil, water and grease.
The power source was disconnected before servicing or repairing electrical equipment.
We kept in mind to use the equipment in a range of the rated voltage and current shown
on the name plate.
Kasun Premarathna
Fallowing safety methods were used to prevent from hazards while machinery works in
workshop.
We used personal protective equipment such as Safety shoes, Gloves, Ear Plugs,
Mufflers, Safety Goggles and etc.
We followed out to wear suitable cloth, not too tight and not too loose.
After the work was finished, cleaned the surface and electrical switch off the machineries
power supply.
We kept the floor of workplace free from oil, water and grease.
The company has a response for all electrical work, systems and equipment under their control.
They must ensure that and are given sufficient information of any known hazards or risks to
health and safety to enable them to work safely;
Installed suitable equipment for perform and the environment within which it will be
expected to work.
Danger signs, Warning information and other safety procedures were presented in
working place.
16
First aid facilities and sick room was arranged in the company.
Kasun Premarathna
Distribution panels
o Main distribution panels
o Sub distribution panels
Changeover panels
o Manual Changeover Panels
o Automatic Changeover Panels (ATS panel)
Steel enclosures
The Power Electrical Panels consist of metering devices, protective devices, switching devices,
conductors, bus bar chambers, indicators, circuit breakers, capacitors and many other types of
equipment.
Before designing electric panel the following details should be incorporated into it.
17
Type of insulation.
IEC regulation
Kasun Premarathna
First of all, the panel box, cover plates, panel door, mounting plate and benches were
selected according to the given drawing.
Door arrangement was fixed by using Panel hinge according to general arrangement.
The door Beading and panel key mount was attached to the door.
The cover plate bracket was prepared by using drill machine, tap cutting tool, flat screw
driver.
Switch gear benches and din rails were arranged on the mounting plate according to
drawing.
Mark holes position to fix the benches, din rail bracket, profile using pencil and drilled all
holes using drilling machine.
Arrange bus bars, bus bar insulators, neutral link, neutral bar, earth bar, earth link as
general arrangement using bus bar bend machine.
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Kasun Premarathna
Made the holes to fix bus bar insulators, earth link, and neutral link etc. on mounting
plate and all holes were taped.
All items were fixed according to general arrangement using proper tools.
The door arrangement of indicators and other equipments was prepared according to
drawing by using drill machine and Jig saw.
All electrical equipments were fixed in to the proper place and mounting plate was fixed
in to the panel box.
The cable ducts was cut in to suitable size and fixed in to the panel box.
The relevant wire size was selected according to current rating chart.
The cable length was defined and cut the wires using wire cutter.
The Lug was fixed to the wires using lug cramping tool and End cap was fixed in to the
cable according to phase colour.
Wiring was done according to the wiring diagram, Allen key, Phillips and flat screw
drive.
The cable length was defined and cut the wire using side cutter, wire striper.
The control side was wired by including numbers, Phillips and flat screw drive were
used.
19
The control line was neatly arranged by using spirals and cable ties.
Kasun Premarathna
Hammer
Screwdriver (Slot-head)
Phillips Screwdriver
Pliers
Hacksaw
Allen Keys
Side Cutter
Measuring Tape
Cable Cutters
Cable cutters are useful to cut cables. Gilbow cutter (heavy-duty cable cutters) cuts the large
size cables & common bas bar.
Crimping Tool
A crimping tool is a tool designed to crimp or connect a connector or lug to the end of a
cable. To use this crimping tool, each wire is first placed into the correct position. The
hydraulic crimping tool crimps high gauge wire easily with steady hydraulic power.
20
Kasun Premarathna
2.2.2. Machineries
Jig Saw
A Jig Saw is a useful in cutting shapes, curves and removing parts from the panels.
Electric Drill
A Drill is a driving tool attachment, usually a drill bit. It is used for drilling, tapping and
boring holes in various materials. Some electric drills drown with rechargeable batteries.
A pneumatic pop rivet gun is designed to fix the rivet nuts together without too much effort
from the person handling the gun. The pneumatic pop rivet gun used compressed air hoses.
Industrial Heater
Industrial Heater is used to plastic welding, bending, bus bar insulation and many other
purposes.
Kasun Premarathna
Nail
Screw
Flat washer
Spring washer
Bolt
Allen Bolt
Nuts
Stud nuts
22
Panel plate
Beading
Panel hook
Cables ties
Panel holder
Earth bar
Panel key
Kasun Premarathna
Din rail
Din rail is a metal rail of a standard type widely used for mounting circuit breakers and
industrial control equipment inside panel.
Insulator Mounts
Bus Bar Insulator mounts are used for connecting line and neutral bar with panel mounting
board and connecting bus bar with panel board.
Cable Duct
Cable duct is wire and cable management product for routing and concealing electrical
wiring in control panels. Available in many sizes
The wire end caps are used for easily identified wire. These end caps can be obtained various
colour according to electrical colour code.
Kasun Premarathna
2.3.1. Fuses
A fuse is a type of protection device in electrical applications. Fuses are designed to open circuits
the filament when excessive currents are present due to overloads or faults and to prevent further
damage to the system. Short circuit, system overload, other device failures, lightning, static
electricity or system overload are some common results in blown fuses.
Cartridge Fuse
In cartridge fuse the fuse wire is enclosed in a transparent glass tube or bulb, the whole unit is
sealed off. In case the fuse blows, it is to be replaced by new one as the cartridge fuse can not be
rewired due to its sealing. In cartridge type fuses have many other sub types as MCB type, screw
type, etc.
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Kasun Premarathna
Every circuit breaker has a voltage rating that designates the maximum voltage it can handle and
a continuous current rating, which is the maximum continuous current carry without tripping.
The value of the kA rating, determines how much current the circuit breaker can withstand under
fault conditions. When we consider MCBs we can see various MCBs with different ampere
ranges and internal situations (Tripping). MCBs are classified according to the ampere.
Type B - operate 3-5 times rated current and suitable for lighting loads
Type C - operate 5-10 times rated current and suitable for lighting and motor loads.
Type D - operate 10-20 times rated current and suitable for heavy units, welding plants
My experience
2.3.2.1. Standard dimensions of MCBs
I was able to measure the standard size (in mm) of the MCB and RCCB. It was very
important for the panel designing and arranging the panel box.
Kasun Premarathna
I designed fallowing Distribution Boxes for the 300 houses in the housing apartment. This
was designed for single phase 30A house.
I have been used 30A isolator switch, 30A RCCB, four MCBs of 10A and six MCBs of 6A
according to the requirement. All were Orange production.
4mm2 CU/PVC insulated wire was used for the wiring and single phase common bus bar was
used to connect the MCBs.
Kasun Premarathna
RCCB works on the principle that in an electrical circuit the incoming current is the same as out
going current. RCCB incorporates a core balance. The primary winding lies in series with the
supply mains and load. Secondary winding is connected to a very sensitive relay. During flow of
leakage current in the circuit an imbalance is created in the circuit which gives rise to leakage
flux in the core. This leakage flux generates an electrical signal that is sensed by the relay and it
trips the Mechanism thereby disconnecting the supply. When pressing the TEST button 'T', a
fault is simulated via the Test resistance & RCCB trips.
27
Accessories such as shunt trip, under-voltage trip, Rotary Operators, motorized kit units,
mechanical-electrical interlock, auxiliary contacts are available.
Kasun Premarathna
2.3.4.1. The Shunt trip coil and Under Voltage Tripping Coil (UVT)
Shunt and UVT coils are used for remote opening of circuit breaker. The Shunt trip coil consists
of an electro-magnetic trip coil that is connected in series with an external field wired switch.
When energized the shunt coil, causing the breakers mechanical latch to move to the open
position. Shunt coil supply is connected normally open (NO) contact point of the component.
Usually EFR, ELR are connected with the shunt coil
UVT coil is energized and activated to close the breaker when the coil supply voltage dips below
85% of the rated voltage. When we use the UVT coil with MCCBs we connect coil supply
through the normally close (NC) contact point of the component. At a fault condition, it stops the
supply flown through the UVT coil and then the UVT coil trips the breaker. So when a UVT coil
is used in a circuit, the MCCB cannot be switched on if there is no current supply.
Kasun Premarathna
My experience
2.3.4.3. Installation process of MCCB internal accessories
I was able to identify the procedure of installation
procedure of the Auxiliary contact, Alarm switch,
Shunt trip coil or Under voltage trip coil.
30
Kasun Premarathna
either a fixed 30mA or 300mA instantaneous trip point or with a user adjustable trip point and
time delay both adjustable.
My experience
2.3.9.1. Characteristic settings procedure of Earth Fault Relay
I was able to perform the set fault current and trip time of DELAB Earth Fault Relay
Press [Select] once to enter mode (it will show the existing value Range 0.03 ~ 30 A)
Set the desired Fault current using the [Up / (+) or Down / (-)] button.
Press [ Select ] until mode is displayed.(it will show the existing value Range 0.05 ~ 20s)
Set the desired trip time using the [Up / (+) or Down / (-)] button.
33 Kasun Premarathna
The current transformer should never be open-circuited or operated with no-load attached when
the main primary current is flowing. If the ammeter is to be removed, a short circuit should be
placed across the secondary terminals first. This is because when the secondary is open-circuited
it will produce a large secondary voltage. Current transformers are available in Ring type,
Bushing type, square type, bar type and etc.
Accuracy decreases with increased burden (load) or low line current. Accuracy Class of
Metering CTs:
Class
0.1 To 0.5
1
3
5
Metering Class CT
Applications
Precision measurements or protection
General industrial measurements more sensitive
General industrial measurements
Approximate measurements
Table 2.4.1 - Metering Accuracy Classes of CTs
34 Kasun Premarathna
My Experience
When I was connecting the CT, the ratio of the CT was not matched to the panel current
value.
The CT ratio was 150/5A. But the panel MCCB was 63A.
So I used the double turns for reduce the CT ratio as explain below.
Increasing the number of primary turns can decrease the turns ratio. A current transformer with
a 300 to 5 turns ratio can be changed to a 150 to 5 turns ratio by passing the primary twice
through the window. Also the turns ratio can be either increased or decreased by wrapping wire
from the secondary through the window of the current transformer.
35 Kasun Premarathna
2.4.3. Indicator
Indicators are used to get information about states of equipment such as ON (Green), OFF (red),
TRIP (Orange). Indicators are available in read yellow blue and orange and 12V to 230V.
2.4.4. Ammeter
An ammeter is a measuring instrument used to measure the electric current in a circuit. Current
transformers and ammeters are used together as a matched pair in which the design of the current
transformer is such as to provide a maximum secondary current corresponding to a full-scale
deflection on the ammeter. For most current transformers the primary and secondary currents are
expressed as a ratio such as rated current : 5A.
In 3 phase system, 3 position selector switch was used to select the 3 phases R, Y or B.
The selector switch was connected with the Ammeter A1 and A2.
36 Kasun Premarathna
2.4.5. Voltmeter
A voltmeter is an instrument used for measuring electrical potential difference between two
points in an electric circuit. Analog voltmeters move a pointer across a scale in proportion to the
voltage of the circuit. The voltmeter selector switch is used to select the two phases or phaseneutral in 3 phase system.
37 Kasun Premarathna
2.5.1 Relay
A relay is a switching device. Relays are used where it is necessary to control a circuit by a lowpower signal with complete electrical isolation between control and controlled circuits or where
several circuits must be controlled by one signal.
Relay consists with coil, normally open and normally closed contact points. When current starts
flowing through the control coil, the electromagnet starts energizing and contact points are
changed their position.
Coil voltage can be 12V to 230V AC or DC. Also contact current rating is important factor.
According to the contact pin arrangement, relays are categorized as 8 pins, 11 pins, 14 pins and
etc. relay is fixed with its base.
2.5.2. Contactor
I was able to identify the contactor construction and usages, because contactor was used in every
motor control panel. It was used for the high power application switching on power circuit. Also
I connected timers, auxiliary contact points (side and top), timers and mechanical interlock to the
contactors according to the requirement. In Orange Electric workshop I had used ABB,
Schneider and LS brands contactors.
Contactor is also a type of relay. The contactor consists with normally Open contacts and also
auxiliary contact points. Also it can connect auxiliary contact points (side and top), timers and
mechanical interlock.
38 Kasun Premarathna
A contactor consists of mainly 2 parts-Fixed and movable jaws. the fixed jaws are firmly
connected with the circuit and is a provided with a coil having movable jaw as soon as current is
allowed to flow from the circuit the coil gets charged and due to electromagnetic effect it attracts
the movable metal jaw, thus the circuit is complete with the contact provided by the movable
jaw. This is the functioning of contactor. When current through the coil loss, coils demagnetize
and open the contacts. The coil consist with shaded pole core, because of avoiding the current
zero position of the AC supply.
The current rating of the contactor is depending on its category. The categories in standard are
described as:
39 Kasun Premarathna
The timers are divided into many categories according to their performance,
ON delay
Upon application of input voltage, the time delay begins. At the end of the time delay, the output
is energized. Input voltage must be removed to reset the time delay relay & de energized the
output.
OFF delay
Upon application of input voltage, the time delay relay is ready to accept a trigger. When the
trigger is applied, the output is energized. Upon removal of the trigger, the time delay begins. At
the end of the time delay, the output is de-energized..
According to the requirement, Timer relay characteristics are selected according to fallowing
parameters.
40 Kasun Premarathna
2.6. Cables
In panel wiring we used Orange Cable and Kalani Cable for requirements. I was able to refer
the cable current caring capacity table and selected the wires for panel wiring. In panel wiring
normally we used PVC insulated type single core copper wires.
The selection of cables for panel wiring was best done with reference to the latest and specific
manufacturers cable data and application guides with tables giving cable dimensional, and
current rating information.
The cross-sectional area of the conductors chosen should be of the optimum size to carry the
specified load current or short circuit short term current without overheating and should be
within the required limits for voltage drop.
PVC (Polyvinyl Chloride) is the most commonly used thermoplastic insulator for cables. It
is cheap, durable and widely available. PVC Normal operating temperatures are typically
between 750C and 1000C (depending on PVC type)
Nominal conductor
size
(mm)
1 phase Current
carrying capacity
(A)
3 phase Current
carrying capacity
(A)
1.0
1/1.13
13.8
12
1.5
1/1.38
18
16
1.5
7/0.50
18
14
2.5
7/0.67
24
21
7/0.85
32
28
7/1.04
41
37
10
7/1.35
57
51
16
7/1.70
76
70
25
19/1.35
104
90
35
19/1.53
128
113
50
19/1.78
151
138
70
19/2.14
192
175
95
37/1.78
232
210
120
37/2.03
269
245
150
37/2.35
300
260
185
37/2.52
351
305
240
61/2.25
412
360
300
61/2.52
472
410
400
61/2.85
562
468
500
61/3.20
595
520
42 Kasun Premarathna
width x height
3/4 x 1/4
239
161
1 x 1/4
320
1 x1/4
399
1 1/4 x 3/8
602
1 x 1/4
479
1 x 3/8
722
2 x 1/4
640
2 x 3/8
965
2 1/4 x 1/4
718
2 x 1/4
798
3 x 1/4
960
4 x 1/4
1280
43 Kasun Premarathna
44 Kasun Premarathna
My Experience
2.8.3. The pump house distribution panel wiring procedure
I was able to create an electrical design & wire the fallowing distribution panel in the orange
workshop
45 Kasun Premarathna
This distribution panel was designed for pump house. In this pump house all the pumps will
not operate at the same time, some pumps are using as the standby pumps.
ABB 4 poles 125A MCCB was used as the main breaker.
DELB ELR with shunt release coil was used as the protection device and HOBUT
200/5A core balance CT is used to get current inputs.
According to the customer requirement, emergency stop switch was connected with shunt
coil.
The 35mm2 copper PVC insulated wires (Kalani cables) were used to wire from main MCCB
to bus bar chamber. Thence 16mm2 for 63A, 10mm2 for 40A and 4mm2 for 16A wires were
used.
R, Y, B incoming indicators were attached to the panel door through the 2A fuse.
This panel box was designed 250x400x150 size. The 150mm was not enough for the
HOBUT 200/5A core balance CT. so that I had to cut the cover plate of the panel, before
the wired.
46 Kasun Premarathna
47 Kasun Premarathna
My Experience
2.9.3. Automatic Changeover Panel wiring
I was able to wire the below control circuit of Automatic Changeover panel. The panel consisted
with Telegarn ATS changeover with motorized kit.
This circuit was designed to get continues power supply from CEB or generator. According to
this panel circuit it can automatically switch on the generator when CEB power failure.
Important points
The Telegarn ATS changeover unit was used separate auxiliary supply from CEB side
(used pin no 01 and 02) and generator (used pin no 03 and 04).
There was two selector switches, one was used to Auto-Manual selector other one was used
to select CEB or Generator in manual mode.
Phase Failure Relay (PFR) was used to detect the supply conditions in CEB and generator.
48 Kasun Premarathna
R2 relay was used to give a CEB ON signal to the 11th pin of changeover motorized kit
through open point (NO) of R2 63.
R3 relay was used to give a Generator ON signal to the 10th pin of changeover motorized kit
through open point (NO) of R363.
T4 timer was used to avoid the sudden change from generator supply to the CEB supply, if
CEB supply is changing quickly due to voltage fluctuation, T4 will keep generator supply
continuously.
12th pin of the motorized kit was used to give OFF signal in to the changeover.
For interlock purpose R3 15 and R2 15 closed points were used in the circuit.
T4
1
4
and R173 closed points were used in generator starting control supply for avoid the
generator start manual or auto when the CEB supply is connected in manual or auto mode.
49 Kasun Premarathna
Typically, the contactor of the DOL circuit is controlled by separate start and stop push buttons.
When the start push button is pressed, the current flow through the control circuit and the
contactor coil which will energize the contactor coil and then the NO contactor contact get
closed and self holding. So the current is passed to the motor. When the stop button is pressed or
the over load coil is operated, the control circuit get broken and the contactor drops out.
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My Experience
2.10.2 Cooling tower panel wiring
I was able to wire the cooling tower panel according to the given details. This panel is consisting
with two 5.5kW pumps and a 1.5kW cooling fan motor. The two main motors are manually
selectable. All three motors are wired in DOL method.
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Calculations
Main pump and standby pump
o Full load current
V 3 Cos
o pump over load
5.5 * 103
8.6 A
2.3 A
415 * 3 * 0.8
= 8A to 12A
rating
= 16A
V 3 Cos
o over load
= 2A to 4A
o contactor
= 4A
o MCB
= 6A
rating
1.5 * 103
415 * 3 * 0.8
Important points
Run and trip indicators were used, trip indicators were connected through normally open
point (NO 97-98).
The main motor and standby motor only work after the cooling fan is on. For that purpose,
the control circuit supply for the main and standby pumps were connected through the
normally open point (NO) of the cooling fan motor contactor (KM3).
1 x 1/8 cupper tape bus bar chamber was designed for distribute the MCBs.
All the power circuit wirings were going on 4mm2 CU/PVC wires.
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When very large (< 5HP) motors are started by DOL, they cause a disturbance of voltage on the
supply lines due to large starting current surges. To limit the starting current surge, large
induction motors are started at reduced voltage and then have full supply voltage reconnected
when they run up to near rotated speed. Star-Delta starter is the reduced voltage starting method.
This type reduces phase voltage to about 58% of the running voltage, which reduce the current
and the motors torque.
Figure 2.10.3 Power circuit and Control circuit of star delta panel
The Star/Delta starter is manufactured from three contactors, an on delay timer and a thermal
overload. The currents through the winding are 1/ 3 of the current in the line.
There are two contactors that are close during run, often referred to as the main contractor and
the delta contactor. These are AC3 rated at 58% of the current rating of the motor. The third
contactor is the star contactor and that only carries star current while the motor is connected in
star. The current in star is one third of the current in delta, so this contactor can be AC3 rated at
1/3 (33%) of the motor rating.
In the star-delta starting method, firstly the motor starts as star after 80% of its full speed it can run as
delta. The one delay timer is sated that time of 80% of its full speed.
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P
V 3 Cos
Size of Main and Delta Contractor (K1 & K2)= full load current x 1/3
My Experience
2.10.4. Fire pump panel wiring
I was able to create electrical design & wire the fire pump panel.
Two main pumps of 37kW and a jockey pump of 2.2kW were used for the panel.
The 37kW pumps are connected as star-delta and 2.2kW pump as direct online
connection.
Calculation
For Main pumps
o Full load current
V 3 Cos
37 * 103
64.3 A
415 * 3 * 0.8
o Main & delta contactors = Full load current * 1/3 = 64.3 * 1/3 = 37.3 A
o Star contactor
= 30A to 42A
=100A
= 64.3* 1/3
= 21.4 A
V 3 Cos
2.2 * 103
3.8 A
415 * 3 * 0.8
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= 6A
Important points
The panel was designed with two pressure sensors, when sensor 1 will gives signal to the
panel, main pump1 will operates. If pump1 will overload, the pump 2 will operates. The
Pump 1 or pump 2 needs more power, sensor 2 will gives signal to jokey pump operation.
Two position selector switches were used for auto manual selector and pump selector.
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The ABB contactor has only one external normally open (NO) contact point and no any
normally close (NC) contact point. I had to fallowed one of below way to solve this,
o Can connect auxiliary contact points to the contactor.(side contact or top contact)
o Can use mechanical interlock instead to the contact point interlock.
o Can connect another relay with parallel to the contactor.
I was able to connect auxiliary contact points. Other solutions are not suitable for this panel.
When the panel was being tested, the one timer didnt operate correctly.
o According to the 8 pin timer connection, point 1 and point 8 are act as common. If
point 1 is connected to the incoming side, the point 8 must be connected to the
incoming side. Otherwise timer will not operate correctly.
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Various industries and power system loads are inductive that take lagging current which decrease
the system power factor. The poor power factor increases the current flowing in conductor and
thus copper loss increases. Further high reactive power flows through the line, the apparent
power (KVA) and cost of electricity bill is high.
The power factor of a circuit may also be defined as the ratio of active power (KW) to the
apparent power (KVA). The lagging reactive power is responsible for the low power factor. It is
clear from the power triangle that smaller the reactive power component, the higher is the power
factor.
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Discharge resistor
Capacitors should be discharged to <10% of the rated voltage prior to being re-energized. For
this purpose, special discharge resistors are offered which can be selected in accordance with the
applied operating voltage and the desired discharge period. Standard IEC 831 requires a
discharge to 75V or less within 3 minutes.
My Experience
2.11.2. 6- steps Capacitor bank panel wiring
I was able to create electrical design & wire the capacitor bank according to the given details and
requirements.
Calculations
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7.5kVAR
25kVAR
Important points
Seven steps LOVATO DCRK7 Automatic power factor controller was used.
According to rated values power and control circuit drawings were designed.
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100A MCCB (ABB) was used as main breaker & 35mm2 wires are used.
1 x 1\8 copper bus bar chamber was used to distribute power to capacitors.
R1 relay was used in protection purpose, when generator will switched on, capacitors are
disconnected.
Temperature was one of the main stress factors for polypropylene type capacitors, an
average temperature of EPCOS PFC Capacitor is 45 C, so that two 230V cooling fans
are included in to the panel.
At the first power up, the unit in manual mode and press the MODE key and set CT
primary current, Smallest step kVAR, Rated capacitor voltage, required cos2 value.
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Clamp meter
Clamp meter is an electrical device having two jaws which open to allow clamping around an
electrical conductor. This allows properties of the electric current in the conductor to be
measured, without having to make physical contact with it, or to disconnect it for insertion
through the probe.
Continuity tester
A continuity tester is an electrical test equipment used to determine if an electrical path can be
established between two points that is if an electrical circuit can be made. The circuit under test
is completely de-energized prior to connecting the apparatus.
The tester consists of an indicator in series with a source of electrical power - normally a battery,
terminating in two test leads. If a complete circuit is established between the test-leads, the
indicator is activated.
Megger tester
The Megger tester is a method of testing making use of an insulation resistance meter that will
help to verify the condition of electrical insulation. The tester generates a high DC voltage of
around 500V to 5KV or more. In distribution panels, insulation resistance more than 5 M, it has
enough insulation resistance.
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The visual inspection of any installation was as important as any testing that was carried out
on an installation.
Before Visual Inspections was done, the relevant document of the testing panel was observed
by inspector.
The first part of a visual inspection was to ensure that the system was safe to test and that you
have enough information to be able to carry out the further test safely.
Followings were the main visual inspection area which aimed to check in the orange panel
testing process by us.
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Before I was doing the test, the panel power supply was disconnected.
The Megger tester test probe was connected to the live and neutral of the cable that requires
testing, then press the test button. Repeat the procedure between the live and earth, and the
neutral and earth. Voltage range of the tester voltage was 1000Vdc for 415V and 500Vdc for
230V.
The test was done according to the fallowing inspection test report requirements.
Neon lights will cause false readings, as will emergency or discharge lighting, so ensure
these are all disconnected prior to commencing tests. Also capacitors must disconnect from
the circuit.
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