Electrical panel boards- Engineering training report

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HIGHER NATIONAL DIPLOMA IN

ENGINEERING

ADVANCED TECHNOLOGICAL INSTITUTE

COLOMBO 15

NAME

:

: G.K.T.PRE

G.K.T.PREMARATHN

MARATHNA

A

FIELD

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PREFACE

Industrial training is an important experience in the learning procedure of an Engineering student Industrial training is an important experience in the learning procedure of an Engineering student which provides an opportunity to utilize the knowledge in a real working environment under the which provides an opportunity to utilize the knowledge in a real working environment under the guidance of competent engineers.

guidance of competent engineers.

Higher National Diploma in Engineering six months Industrial Training is coordinated by Higher National Diploma in Engineering six months Industrial Training is coordinated by National

National Apprentice Apprentice and and Industrial Industrial Training Training Authority Authority (NAITA) (NAITA) in in association association with with IndustrialIndustrial training division of the Higher National Diploma in Engineering in Advanced Technological training division of the Higher National Diploma in Engineering in Advanced Technological Institute. I tried my best to keep to the guidelines stipulated by NAITA. This is succeeded by my Institute. I tried my best to keep to the guidelines stipulated by NAITA. This is succeeded by my own training experience, which is detailed to

own training experience, which is detailed to the most possible extent.the most possible extent.

This report presents the experiences and knowledge I have gathered during the first 3 months This report presents the experiences and knowledge I have gathered during the first 3 months training period starting from 10

training period starting from 10thth February 2014 to 09 February 2014 to 09thth May 2014 at Orange Electric of OREL May 2014 at Orange Electric of OREL Corporation (Pvt) Limited.

Corporation (Pvt) Limited.

Chapter one reviews information about the training organization, its main functions, Chapter one reviews information about the training organization, its main functions, organizational structure, business products, welfare and safety practices. The experience and 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. 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 Information about the work shop I visited, duties and functions performed during the training period is

period is included. included. Problems encountered Problems encountered during training during training and solutions and solutions found are found are also discussedalso discussed in the second chapter. In the third chapter, gives a conclusion of training and of this report.

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ACKNOWLEDGEMENT

I would like to offer my sincere gratitude to the Advanced Technological Institute (ATI) 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 Colombo 15, National Apprentice and Industrial Training Authority (NAITA) and OREL Corporation (Pvt) Limited for offering this training opportunity.

Corporation (Pvt) Limited for offering this training opportunity.

Further I must extend my deepest gratitude to Mrs. Anodya Ariyarathna, Director of ATI 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 Mattakkuliya. In addition, Mr. Yogaganeshan, Head of Department Electrical Engineering and all academic staff of my Institute who guides me at

all academic staff of my Institute who guides me at all the times.all the times.

I am grateful to Factory Manager of OREL Corporation (Pvt) Limited. for giving us this 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 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 Orange Electric. I would be grateful to thanks Production Manager Mr. Gervin Sugath, who gave

me the guidance for a better training. My special gratitude‟s al

so offered to all the Engineers andso offered to all the Engineers and other officers. My sincere thanks also belong to Head of Department and supervisor in the 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 Electrical department. Also I would like to thank all the other Electricians and Operators who helped me in many ways during this training period.

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 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 support. Finally I wish to convey my gratitude to everyone that I may have forgotten to mention above, who supported me to

above, who supported me to complete my In-plant Training successfully.complete my In-plant Training successfully.

G.K.T.Premarathna, G.K.T.Premarathna, Student of HNDE, Student of HNDE,

Department of Electrical Engineering, Department of Electrical Engineering, Advanced Technological Institute, Advanced Technological Institute, Colombo 15.

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…...

... 10... 10 1.1.2. Vision

1.1.2. Vision

………

..

……….…

... 11... 11 1.1.3. Mission

1.1.3. Mission

………

..

…

..

………. 1

11 1.1.4. Businesses together with OREL Corporation

1.1.4. Businesses together with OREL Corporation

…………

..

………

..

………. .1

11 1.1.5. Products Range of Orange Electric Factory

1.1.5. Products Range of Orange Electric Factory

………

....

……

..

………….1

22 1.1.6. Quality Assurance

1.1.6. Quality Assurance

………

………....…..

………....….. 11

33 1.1.7. Organization

1.1.7. Organization

………

..

……….. 1

33 1.1.8. Employee Facilities & welfare

1.1.8. Employee Facilities & welfare

………

....

………. 1

44

1.2. Safety Practices

………...…...

15 15

2.0. CHAPTER 02

–

TRAINING EXPERIENCE TRAINING EXPERIENCE

2.1. Orange Industrial Electrical workshop

………

1717 2.1.1. Panel assembling procedure

2.1.1. Panel assembling procedure

……….…………

.. 18.. 18 2.1.2. Power circuit wiring procedure

2.1.2. Power circuit wiring procedure

……….……

..

…

19 19 2.1.3. Control circuit wiring procedure

2.1.3. Control circuit wiring procedure

………

....

…..

19 19

2.2. Tools & Machines used in workshop

……….………..…….

. 20. 20 2.2.1. Basic tools

2.2.1. Basic tools

………

..

….

20 20 2.2.2. Machineries

2.2.2. Machineries

………

…… 21

21

2.2.3. Nuts and bolts

………

..

……

..

…..

22 22 2.2.4. Panel accessories used in workshop

2.2.4. Panel accessories used in workshop

………..………

22 22

2.3. Electrical Protective Devises Used in the Panels

………....

... 24... 24 2.3.1. Fuses

2.3.1. Fuses

………..

2424 2.3.2. Miniature Circuit Breakers (MCB)

2.3.2. Miniature Circuit Breakers (MCB)

………

..

…...

25 25 2.3.2.1. Standard dimensions of MCBs

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2.3.2.2. MCB Distribution Box designing

………

..

……..

26 26 2.3.3. Residual Current Circuit Breaker (RCCB)

2.3.3. Residual Current Circuit Breaker (RCCB)

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.. 26.. 26 2.3.4. Moulded case circuit breakers (MCCB)

2.3.4. Moulded case circuit breakers (MCCB)

………

.... 27.... 27 2.3.4.1. The Shunt trip coil and Under Voltage Tripping Coil

2.3.4.1. The Shunt trip coil and Under Voltage Tripping Coil

……

....

…..

29 29 2.3.4.2. Auxiliary contacts

2.3.4.2. Auxiliary contacts

………

...

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29 29 2.3.4.3. Installation process of MCCB internal accessories

2.3.4.3. Installation process of MCCB internal accessories

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30 30 2.3.5. The Surge Protection Device

2.3.5. The Surge Protection Device

………

..

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31 31 2.3.6. Phase Failure Relay (PFR)

2.3.6. Phase Failure Relay (PFR)

……….

31 31 2.3.7. Overload Relay

2.3.7. Overload Relay

………

..

…….

32 32 2.3.8. Earth Leakage Relay (ELR)

2.3.8. Earth Leakage Relay (ELR)

………

..

……..

32 32 2.3.9. Earth Fault Relay (EFR)

2.3.9. Earth Fault Relay (EFR)

………

……… 33

33

2.3.9.1. Characteristic settings procedure of Earth Leakage Relay ...

…

.. 33.. 33

2.4. Measuring Devises Used in the Panels

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..

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34 34

2.4.1. Current transformer

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...

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34 34 2.4.2. Core Balance Current Transformer

2.4.2. Core Balance Current Transformer

………

………… 35

35

2.4.3. Indicator

………

....

……36

2.4.4. Ammeter

………

....

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36 36 2.4.4.1. Connecting process an Ammeter

2.4.4.1. Connecting process an Ammeter

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36 36 2.4.5. Voltmeter

2.4.5. Voltmeter

………

....

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37 37 2.4.6. KWh Meter (Energy meter)

2.4.6. KWh Meter (Energy meter)

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....

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37 37 2.4.7. Digital Power Analyzer

2.4.7. Digital Power Analyzer

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..

………….

37 37

2.5. Switching Devises Used in the Panels

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38 38 2.5.1. Relay 2.5.1. Relay

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3838 2.5.2. Contactor 2.5.2. Contactor

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3838 2.5.3. Timer Relay 2.5.3. Timer Relay

………...…

………

..

………

… 39

2.5.4. Push B

uttons

uttons ………

………

..

………. 40

2.5.5. Selector Switches

………

...

…………

40 40

2.6. Cables

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41 41 2.6.1. Cable Insulation Materials

2.6.1. Cable Insulation Materials

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41 41 2.6.2. Cable Lug

2.6.2. Cable Lug

………

....

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41 41 2.6.3. Cable Numbering Tube

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2.6.4. Current ratings of single core PVC insulated

2.6.4. Current ratings of single core PVC insulated cablecable

………

....

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42 42

2.7. Bus bars

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43 43 2.7.1. Bus bar sizes and current capacity

2.7.1. Bus bar sizes and current capacity

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..

……… 43

2.8. Distribution Panels

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44 44 2.8.1. Main Distribution Panel

2.8.1. Main Distribution Panel

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....

………

....

……… 44

2.8.2. Sub Distribution Panel

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...

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44 44 2.8.3. The pump house

2.8.3. The pump house distribution panel wiring proceduredistribution panel wiring procedure

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..

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45 45

2.9. Changeover Panels

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47 47 2.9.1. Manual Changeover Panel

2.9.1. Manual Changeover Panel

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...

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47 47 2.9.2. Automatic Changeover Panel (ATS panel)

2.9.2. Automatic Changeover Panel (ATS panel)

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47 47 2.9.3. Automatic Changeover Panel wiring

2.9.3. Automatic Changeover Panel wiring

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...

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48 48

2.10. Motor Control panels

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50 50 2.10.1. Direct Online Starter (DOL) panel

2.10.1. Direct Online Starter (DOL) panel

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50 50 2.10.2 Cooling tower panel wiring

2.10.2 Cooling tower panel wiring

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51 51 2.10.3. Star-Delta Starter panel

2.10.3. Star-Delta Starter panel

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53 53 2.10.4. Fire pump panel wiring

2.10.4. Fire pump panel wiring

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...

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54 54

2.11. Power Factor Correction Capacitor Bank

………

……… 5

……… 577

2.11.1. Components Used in Capacitor Bank

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58 58 2.11.2.

2.11.2. 6 steps 6 steps Capacitor Bank Capacitor Bank Panel wiringPanel wiring

……….……….

59 59

2.12. Electrical Panel testing

……….……..

....6262 2.12.1. Testing equipment

2.12.1. Testing equipment

………...……….

62 62 2.12.2. Panel tests

2.12.2. Panel tests

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..

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64 64 2.12.2.1. Visual inspection procedure

2.12.2.1. Visual inspection procedure

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64 64 2.12.2.2. Insulation resistance testing procedure

2.12.2.2. Insulation resistance testing procedure

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....

….

65 65 2.12.2.3. Functional test 2.12.2.3. Functional test

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66 66 3.0. CHAPTER 03 - CONCLUSION 3.0. CHAPTER 03 - CONCLUSION 3.1. Conclusion 3.1. Conclusion

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....

……… 67

3.2. 3.2. Abbreviations Abbreviations

……….………

……….……

………

… 68

68

3.3. References 3.3. References

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..

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69 69

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LIST OF FIGURES

Figure

Figure 1.1 1.1 Orange Orange Electric Electric factory factory 1010 Figure

Figure 1.1.4 1.1.4 OREL OREL Corporation Corporation businesses businesses 1111 Figure

Figure 1.1.5 1.1.5 Orange Orange Electric Electric Logo Logo 1212 Figure

Figure 1.2.1 1.2.1 Electrical Safety Electrical Safety Signs Signs 1515 Figure

Figure 2.1 2.1 Standard Standard Panel Panel Design Design 1818 Figure

Figure 2.2.1 2.2.1 Tool Tool box box 2020

Figure

Figure 2.2.1.1 2.2.1.1 Cable Cable Cutter Cutter 2020

Figure

Figure 2.2.1.2 2.2.1.2 Crimping Crimping Tool Tool 2020

Figure

Figure 2.2.2.1 2.2.2.1 Jig Jig Saw Saw 2121

Figure

Figure 2.2.2.2 2.2.2.2 Electric Electric Drill Drill 2121 Figure

Figure 2.2.2.3 2.2.2.3 Pneumatic Pneumatic Pop-Rivet Pop-Rivet Gun Gun 2121 Figure

Figure 2.2.2.4 2.2.2.4 Industrial Industrial Heater Heater 2121 Figure

Figure 2.2.3 2.2.3 Nuts Nuts and and bolts bolts 2222

Figure

Figure 2.2.4.1 2.2.4.1 Din Din rails rails 2323

Figure

Figure 2.2.4.2 2.2.4.2 Insulator Insulator mounts mounts 2323 Figure

Figure 2.2.4.3 2.2.4.3 Cable Cable ducts ducts 2323

Figure

Figure 2.2.4.4 2.2.4.4 Wire Wire End End Caps Caps 2323

Figure

Figure 2.3.1 2.3.1 Cartridge Fuse Cartridge Fuse 2424

Figure

Figure 2.3.2 2.3.2 HRC HRC Fuse Fuse with with holder holder 2424 Figure

Figure 2.3.2 2.3.2 MCBs MCBs 2525

Figure

Figure 2.3.2.1 2.3.2.1 Standard Standard dimensions dimensions of of MCBs MCBs 2525 Figure

Figure 2.3.2.2 2.3.2.2 MCB MCB Distribution Distribution Box Box wiring wiring diagram diagram 2626 Figure

Figure 2.3.3.1 2.3.3.1 Internal Internal connection connection of of RCCB RCCB 2626 Figure

Figure 2.3.3.2 2.3.3.2 2 2 poles poles and and 4 4 poles poles RCCB RCCB 2727 Figure

Figure 2.3.4 2.3.4 MCCB MCCB and and its its auxiliary auxiliary components components 2828 Figure

Figure 2.3.4 2.3.4 I I - - Thermal Thermal adjustment adjustment 2828 Figure

Figure 2.3.4 2.3.4 II II - - Magnetic Magnetic adjustment adjustment 2828 Figure

Figure 2.3.4.2 2.3.4.2 Auxiliary Auxiliary contacts contacts and and Tripping Tripping Coil Coil arrangement arrangement 2929 Figure

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Figure

Figure 2.3.5.1 2.3.5.1 SPD SPD device device 3131

Figure 2.3.5.2

wiring diagram of “OBO” SPD

device device 3131 Figure 2.3.6

Figure 2.3.6

“ANLY” PFR and its connection diagram

3131 Figure 2.3.7

Figure 2.3.7

“LS” Overload relay and symbol

3232 Figure 2.3.8.2

Figure 2.3.8.2

“DELAB” ELR

3232

Figure

Figure 2.3.8.2 2.3.8.2 connection connection of of ELR ELR 3232 Figure 2.3.9

Figure 2.3.9

“DELAB” EFR

and and its its connection connection 3333 Figure

Figure 2.4.1.1 2.4.1.1 Types Types of of CTs CTs 3434

Figure

Figure 2.4.1.2 2.4.1.2 Working Working principle principle of of CT CT 3434 Figure

Figure 2.4.1.3 2.4.1.3 CT CT connection connection 3535

Figure

Figure 2.4.2 2.4.2 Core Core Balance Balance Current Current Transformer Transformer 3535 Figure

Figure 2.4.3 2.4.3 Connecting diagram Connecting diagram of of an an Ammeter Ammeter 3636 Figure

Figure 2.4.4 2.4.4 Voltmeter and Voltmeter and selector selector 3737 Figure

Figure 2.5.1 2.5.1 Relay Relay and and relay relay base base 3838 Figure 2.5.2.1

Figure 2.5.2.1

“ABB” contactor

3939

Figure

Figure 2.5.2.2 2.5.2.2 Auxiliary Auxiliary components components 3939 Figure

Figure 2.5.3.1 2.5.3.1 Timers Timers 3939

Figure

Figure 2.5.3.2 2.5.3.2 Analog Analog timer timer internal internal connection connection 3939 Figure

Figure 2.5.4 2.5.4 Push Push button button and and emergency emergency button button 4040 Figure

Figure 2.6 2.6 PVC PVC insulated insulated cable cable 4141 Figure

Figure 2.6.2 2.6.2 Cable Cable Lugs Lugs 4141

Figure

Figure 2.6.3 2.6.3 Cable Cable Numbering Numbering Tube Tube 4242 Figure

Figure 2.7 2.7 Bus Bus bars bars 4343

Figure

Figure 2.8.1 2.8.1 Main Main Distribution Distribution panel panel 4444 Figure

Figure 2.8.2 2.8.2 Sub Sub Distribution Distribution panel panel 4545 Figure

Figure 2.8.3 2.8.3 The The pump pump house house distribution distribution panel panel wiring wiring diagram diagram 4545 Figure

Figure 2.9.2 2.9.2 Automatic Changeover Automatic Changeover Panel Panel 4747 Figure

Figure 2.9.3 2.9.3 Automatic Changeover Automatic Changeover Panel Panel control control wiring wiring diagram diagram 4848 Figure

Figure 2.10.1 2.10.1 Power Power circuit circuit and and control control circuit circuit of of DOL DOL panel panel 5050 Figure

Figure 2.10.2.1 2.10.2.1 Power Power circuit circuit of of cooling cooling tower tower panel panel 5151 Figure

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Figure

Figure 2.10.3 2.10.3 Power Power circuit circuit and and Control Control circuit circuit of of star star delta delta panel panel 5353 Figure

Figure 2.10.4 2.10.4 Control Control circuit circuit of of Fire Fire pump pump panel panel 5555 Figure

Figure 2.10.4.1 2.10.4.1 Timer Timer connection connection of of fire fire pump pump panel panel 5656 Figure

Figure 2.11 2.11 Power factor Power factor triangle triangle 5757 Figure

Figure 2.11.1 2.11.1 Capacitor Capacitor Bank Bank 5757

Figure

Figure 2.11.1.1 2.11.1.1 Power Power capacitor capacitor 5858 Figure

Figure 2.11.1.2 2.11.1.2 Capacitor Capacitor switching switching contactors contactors 5858 Figure

Figure 2.11.1.2 2.11.1.2 Automatic power Automatic power factor factor controller controller 5858 Figure

Figure 2.11.2 2.11.2 Capacitor Capacitor Bank Bank power power circuit circuit drawing drawing 6060 Figure

Figure 2.11.3 2.11.3 Capacitor Capacitor Bank Bank control control circuit circuit drawing drawing 6161 Figure

Figure 2.12.1.1 2.12.1.1 Test Test Lamps Lamps 6262

Figure

Figure 2.12.1.2 2.12.1.2 Clamp Clamp meter meter 6262

Figure

Figure 2.12.1.3 2.12.1.3 Continuity Continuity tester tester 6363 Figure 2.12.1.4

Figure 2.12.1.4 Megger testeMegger tester r 6363

Figure

Figure 2.12.2.1 2.12.2.1 Visual Visual inspection inspection test test report report 6464 Figure

Figure 2.12.2.2 2.12.2.2 Insulation Resistance Insulation Resistance test test report report 6565 Figure

Figure 2.12.2.3 2.12.2.3 Functional Functional tests tests reports reports 6666

LIST OF TABLES

Table

Table 2.4.1 2.4.1 Metering Metering Accuracy Accuracy Classes Classes of of CTs CTs 3434 Table

Table 2.6.4 2.6.4 Current Current ratings ratings of of single single core core PVC PVC insulated insulated cable cable 4242 Table

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1.0. 1.0. CHAPTER 01- INTRODUCTION

CHAPTER 01- INTRODUCTION

1.1. 1.1. Introduction of OREL Corporation Private Li

Introduction of OREL Corporation Private Limited

mited

OREL Corporation Private Limited (Orange Electric Corporation) is the biggest electric OREL Corporation Private Limited (Orange Electric Corporation) is the biggest electric company, which is manufacturing, exporting and importing world class Electrical Products based company, which is manufacturing, exporting and importing world class Electrical Products based in Sri Lanka.

in Sri Lanka.

With their customer oriented approach, all the business policies are based on high ethical values. With their customer oriented approach, all the business policies are based on high ethical values. They endeavor to maintain complete transparency in all the business procedures. All the 1000 They endeavor to maintain complete transparency in all the business procedures. All the 1000

employees of the company stand by the company‟s vision of attaining complete client

satisfaction. They have earned the confidence of many eminent clients from countries like India, satisfaction. They have earned the confidence of many eminent clients from countries like India, England, Australia, Austria, Maldives, Bangladesh, Pakistan, Singapore, Korea, Japan, Taiwan, England, Australia, Austria, Maldives, Bangladesh, Pakistan, Singapore, Korea, Japan, Taiwan, Cypress, Nepal, Dubai, and Uganda.

Cypress, Nepal, Dubai, and Uganda.

The Orange Electric was started in 1978. It started as an Australian Sri Lankan joint venture with The Orange Electric was started in 1978. It started as an Australian Sri Lankan joint venture with Clipsal, with a simple assembly line producing a limited range of switches and sockets. From Clipsal, with a simple assembly line producing a limited range of switches and sockets. From then on, the company experienced phenomenal growth and market leadership, manufacturing a then on, the company experienced phenomenal growth and market leadership, manufacturing a complete range of electrical products. The sale of Clipsal Australia to the French multinational complete range of electrical products. The sale of Clipsal Australia to the French multinational company Schneider Electric was a turning point in the history of the company, as this twist of company Schneider Electric was a turning point in the history of the company, as this twist of fortune led to the foundation of Orange Electric. At this critical juncture it was decided to resist fortune led to the foundation of Orange Electric. At this critical juncture it was decided to resist against the sale of the company to a multinational.

against the sale of the company to a multinational.

Figure 1.1- Orange Electric factory Figure 1.1- Orange Electric factory

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Orange Electric was launched as the company‟s main brand in 2004. With the increase of their

product

product portfolio portfolio the the company company has has five five major major factories factories in in Maharagama, Maharagama, Boralesgamuwa,Boralesgamuwa, Ratmalana, Meegoda and Ranala. In these five factories they manufacture more than one million 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 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 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.

period in the field of manufacturing, exporting and importing of Electrical Products.

1.1.2. Vision

"To create a billion dollar global electrical brand" "To create a billion dollar global electrical brand"

1.1.3. Mission

"To add more to life with electricity" "To add more to life with electricity"

1.1.4. 1.1.4. Businesses together with OREL Corporation

Businesses together with OREL Corporation

OREL Corporation is converged 16 businesses OREL Corporation is converged 16 businesses

Figure 1.1.4 - OREL Corporation b

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I was mainly involved with the

“Orange Electric” of “OREL Corporation‟

during the period of during the period of industrial training, which is situated at Megoda, Padukka. This factory manufactures electrical industrial training, which is situated at Megoda, Padukka. This factory manufactures electrical components to the highest quality and

components to the highest quality and most stringent international standards.most stringent international standards.

1.1.5. Products Range of Orange Electric Factory



 Low Voltage SwitchgearLow Voltage Switchgear

Low Voltage Switchgear which Designed for a flawless performance, the Low Voltage 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 Switchgear available with us is largely used in varied industrial applications for providing isolation switching and earth leakage protection of electrical circuits.

isolation switching and earth leakage protection of electrical circuits. ..



 Electrical AccessoriesElectrical Accessories

Electrical Accessories is assorted variety of Electrical Accessories includes Electrical Mounting Electrical Accessories is assorted variety of Electrical Accessories includes Electrical Mounting Boxes, Electrical Plug Top, Electric Lamp Holder, and Electrical Ceiling Rose.. Designed to Boxes, Electrical Plug Top, Electric Lamp Holder, and Electrical Ceiling Rose.. Designed to perfection, the Electrical Accessories provided by them comply with the set industrial st

perfection, the Electrical Accessories provided by them comply with the set industrial standards.andards.



 BulbsBulbs

CFL Lamps are created a strong foothold in the business of manufacturing and exporting world 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

class CFL Lamps. Tube lights and LEDs also produced in orange



 CablesCables

The Electrical Cables are specially manufactured using the best grade raw materials. Thus, these 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. 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 Moreover, the clients can access this enviable range of Electrical Cables in varied specifications that too at very reasonable rates.

that too at very reasonable rates.

Figure 1.1.5 - Orange Electric Logo Figure 1.1.5 - Orange Electric Logo

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

 Industrial Electrical ApplicationIndustrial Electrical Application

They have made a mark in the field of manufacturing and exporting products for Industrial They have made a mark in the field of manufacturing and exporting products for Industrial Application. These products are specially manufactured using premium grade raw materials and Application. These products are specially manufactured using premium grade raw materials and electronic components.

electronic components.

o

o Power Distribution PanelPower Distribution Panel

One of the major Manufacturers and Exporters is Power Distribution Panel. These Power 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 Panels are trusted for Safety Reliability and Quality in LV Power Distribution.

Distribution.

o

o Steel EnclosureSteel Enclosure

The Steel Enclosures for Power Distribution Panels is fabricated using the

The Steel Enclosures for Power Distribution Panels is fabricated using the finest grade rawfinest grade raw materials.

materials.

1.1.6. Quality Assurance

We are a quality oriented organization and so we make regular up gradations of the Electrical We are a quality oriented organization and so we make regular up gradations of the Electrical Products that are also inspected on varied parameters in compliance to our policies. Further, to Products that are also inspected on varied parameters in compliance to our policies. Further, to add credibility to our name, we have been Awarded ISO-9002 in 1994 and ISO-9001 in 2000 for add credibility to our name, we have been Awarded ISO-9002 in 1994 and ISO-9001 in 2000 for quality management system in the manufacture of electrical accessories. Also super brand status quality management system in the manufacture of electrical accessories. Also super brand status for the superior quality Electrical Products offered by us.

for the superior quality Electrical Products offered by us.

1.1.7. Organization

Orange electrical is very highly organized company and It has very complicate 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 system. The total number of employees at Orange electric is about 1000. This is main organization structure of orange electric.

organization structure of orange electric.



 Board of DirectorsBoard of Directors 

 ChairmenChairmen 

 Managing DirectorManaging Director 

 Other DirectorOther Director 

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1.1.8. Employee Facilities &

1.1.8. Employee Facilities & welfare

welfare



 Employees Trust Fund (ETF) and Employees Provided Fund (EPF)Employees Trust Fund (ETF) and Employees Provided Fund (EPF)

EPF is required Employee‟s contribution

is 8% of the total monthly earnings (To be deducted is 8% of the total monthly earnings (To be deducted

from the Employee‟s Salary) and Employer‟s contribution is minimum of 1

2% of the total salary2% of the total salary of the employee monthly.

of the employee monthly.

ETF is required Employee‟s contribution of 3% percentage of the earning of an employee.



 Working hours and LeavesWorking hours and Leaves

The normal working hours of the Orange Electric Factory are 7.30 am to 5.00 pm. Excess of The normal working hours of the Orange Electric Factory are 7.30 am to 5.00 pm. Excess of normal working hours to be treated as overtime. The transport service is gone on according to the normal working hours to be treated as overtime. The transport service is gone on according to the working times.

working times.

An office employee shall be granted 14 days annual leave with pay in respect of the second and An office employee shall be granted 14 days annual leave with pay in respect of the second and any subsequent year if he has been continuously in employment during the year.

any subsequent year if he has been continuously in employment during the year.



 WelfareWelfare

Orange Electric, a company who places great emphasis on the welfare of its employees has Orange Electric, a company who places great emphasis on the welfare of its employees has recently implemented

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. devised some interesting and special programs that greatly contribute.



 Yoga and Karate sessions.Yoga and Karate sessions. 

 Meditation programs and First Aid facility.Meditation programs and First Aid facility. 

 Changing Room and Lockers.Changing Room and Lockers. 

 Meals, Tea & Washing facilities.Meals, Tea & Washing facilities. 

 Annual cricket match, New Year festival and annAnnual cricket match, New Year festival and ann ual trip.ual trip. 

 Bonus and Loans.Bonus and Loans. 

 Transport service.Transport service. 

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1.2.

1.2. Safety Practices

Safety Practices

In the Orange Electric workshop, we used safety methods, because of electrocution is mainly due In the Orange Electric workshop, we used safety methods, because of electrocution is mainly due to serious injury. The operation of tools and machineries also cause to hazards. We considered to serious injury. The operation of tools and machineries also cause to hazards. We considered about personal safety, human health and equipment safety.

about personal safety, human health and equipment safety.

Below

Belowsafetysafety instructions were followed in workshop for the prevent instructions were followed in workshop for the prevent from electrical hazards,from electrical hazards,



 Before installation, wiring, operation, maintenance and inspection of the panel,Before installation, wiring, operation, maintenance and inspection of the panel,

instructions or the catalogue were studied carefully to ensure proper o

instructions or the catalogue were studied carefully to ensure proper o perations.perations.



 We got the assistance from supervisor, before testing the experiment with electricalWe got the assistance from supervisor, before testing the experiment with electrical

supply. supply.



 Proper testing and checking instruments were used to Proper testing and checking instruments were used to find the live parts.find the live parts. 

 We used only tools and equipment with non-conducting handles when working onWe used only tools and equipment with non-conducting handles when working on

electrical devices. electrical devices.



 We kept in mind to never handled electrical equipment when hands, feet, or whenWe kept in mind to never handled electrical equipment when hands, feet, or when

standing on a wet floor. standing on a wet floor.



 We kept the workplace dry and free from oil, water and grease.We kept the workplace dry and free from oil, water and grease. 

 The power source was disconnected before The power source was disconnected before servicing or repairing electrical equipment.servicing or repairing electrical equipment. 

 We kept in mind to use the equipment in a range of the rated voltage and current shownWe kept in mind to use the equipment in a range of the rated voltage and current shown

on the name plate. on the name plate.

Figure 1.2.1 - Electrical Safety Signs Figure 1.2.1 - Electrical Safety Signs

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Fallowing

Fallowing safety methods weresafety methods were used to prevent from hazards while machinery works in used to prevent from hazards while machinery works in workshop.

workshop.



 We used personal protective equipment such as Safety shoes, Gloves, Ear Plugs,We used personal protective equipment such as Safety shoes, Gloves, Ear Plugs,

Mufflers, Safety Goggles and etc. Mufflers, Safety Goggles and etc.



 Used appropriate tools and equipment for work.Used appropriate tools and equipment for work. 

 Before done the work, instruction was read properlBefore done the work, instruction was read properl y.y. 

 We followed out to wear suitable cloth, not We followed out to wear suitable cloth, not too tight and not too loose.too tight and not too loose. 

 After the work was finished, cleaned the surface and electrical switch off the machineriesAfter the work was finished, cleaned the surface and electrical switch off the machineries

power supply. power supply.



 We kept the floor of workplace free from oil, watWe kept the floor of workplace free from oil, wat er and grease.er and grease. 

 Used cleaners for the clean the body.Used cleaners for the clean the body.

The company has a response for all electrical work, systems and equipment under their control. 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 They must ensure that and are given sufficient information of any known hazards or risks to health and safety to enable

health and safety to enable them to work safely;them to work safely;



 Suitable control measures are in place and followed.Suitable control measures are in place and followed. 

 Installed suitable equipment for perform and the environment within which it will beInstalled suitable equipment for perform and the environment within which it will be

expected to work. expected to work.



 Equipments were calibrated correctly.Equipments were calibrated correctly. 

 Danger signs, Warning information and other safety procedures were presented inDanger signs, Warning information and other safety procedures were presented in

working place. working place.



 First aid facilities and sick room was arranged in the companFirst aid facilities and sick room was arranged in the compan y.y. 

 Safety equipment and cleaners were provided in the workshop.Safety equipment and cleaners were provided in the workshop. 

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2.0. CHAPTER 02

–

TRAINING EXPERIENCE

2.1. Orange

2.1. Orange Industria

Industrial Electrical

l Electrical workshop

workshop

In Orange Industrial Electrical workshop, Power Electrical Panels were designed as per the IEC In Orange Industrial Electrical workshop, Power Electrical Panels were designed as per the IEC standards. These power electrical panels were trusted for Safety Reliability and Quality in Low standards. These power electrical panels were trusted for Safety Reliability and Quality in Low Voltage Power Distribution. Power Electrical Panels made available in various specifications in Voltage Power Distribution. Power Electrical Panels made available in various specifications in Industrial Electrical workshop,

Industrial Electrical workshop,



 Distribution panelsDistribution panels

o

o Main distribution panelsMain distribution panels o

o Sub distribution panelsSub distribution panels



 Changeover panelsChangeover panels

o

o Manual Changeover PanelsManual Changeover Panels o

o Automatic Changeover Panels (ATS panel)Automatic Changeover Panels (ATS panel)



 Motor control panelsMotor control panels 

 Capacitor Bank panelsCapacitor Bank panels 

 Steel enclosuresSteel enclosures

The Power Electrical Panels consist of metering devices, protective devices, switching devices, 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 conductors, bus bar chambers, indicators, circuit breakers, capacitors and many other types of equipment.

equipment.

Before designing electric panel the following details should

Before designing electric panel the following details should be incorporated into it.be incorporated into it.



 Location and dimension of the panelLocation and dimension of the panel 

 Load description, Amperage, Voltage requiredLoad description, Amperage, Voltage required 

 Cable size and conduit sizeCable size and conduit size 

 Type of insulation.Type of insulation. 

 Ventilation, temperature and space arrangement in the panelVentilation, temperature and space arrangement in the panel 

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18

18 Kasun Kasun Premarathna Premarathna Higher Higher National National Diploma Diploma in in Engineering Engineering [HNDE]- [HNDE]- Electrical Electrical 23-batch23-batch

I was able to practice the process of panel assembling and panel wiring in Orange Electric I was able to practice the process of panel assembling and panel wiring in Orange Electric workshop.

workshop.

2.1.1. Panel

2.1.1. Panel assembling procedureassembling procedure 

 First of all, the panel box, cover plates, panel door, mounting plate and benches wereFirst of all, the panel box, cover plates, panel door, mounting plate and benches were

selected according to the given drawing. selected according to the given drawing.



 Door arrangement was fixed by using Panel hinge according to general arrangement.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 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 screwThe cover plate bracket was prepared by using drill machine, tap cutting tool, flat screw

driver. driver.



 Switch gear benches and din rails were arranged on the mounting plate according toSwitch gear benches and din rails were arranged on the mounting plate according to

drawing. drawing.



 Mark holes position to fix the benches, din rail bracket, profile using pencil and drilled allMark holes position to fix the benches, din rail bracket, profile using pencil and drilled all

holes using drilling machine. holes using drilling machine.



 Taped all holes using tap cutting tool.Taped all holes using tap cutting tool.



 Din rails and benches were fixed bDin rails and benches were fixed by using flat screw.y using flat screw.



 Arrange bus bars, bus bar insulators, neutral link, neutral bar, earth bar, earth link asArrange bus bars, bus bar insulators, neutral link, neutral bar, earth bar, earth link as

general arrangement using bus bar bend machine. general arrangement using bus bar bend machine.

Figure 2.1

(19)



 Made the holes to fix bus bar insulators, earth link, and neutral link etc. on mountingMade the holes to fix bus bar insulators, earth link, and neutral link etc. on mounting

plate and all holes were taped. plate and all holes were taped.



 All items were fixed according to general arrangement uAll items were fixed according to general arrangement u sing proper tools.sing proper tools. 

 The door arrangement of indicators and other equipments was prepared according toThe door arrangement of indicators and other equipments was prepared according to

drawing by using drill machine and Jig saw. drawing by using drill machine and Jig saw.



 All electrical equipments were fixed in to the proper pAll electrical equipments were fixed in to the proper p lace and mounting plate was fixedlace and mounting plate was fixed

in to the panel box. in to the panel box.

2.1.2. Power circuit wiring

2.1.2. Power circuit wiring procedure

procedure



 The cable ducts was cut in to suitable size and 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 The relevant wire size was selected according to current rating chart.to current rating chart. 

 The cable length was defined The cable length was defined and cut the wires using wire cutter.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 theThe Lug was fixed to the wires using lug cramping tool and End cap was fixed in to the

cable according to phase colour. cable according to phase colour.



 Wiring was done according to the wiring diagram, Allen key, Phillips and flat screwWiring was done according to the wiring diagram, Allen key, Phillips and flat screw

drive. drive.



 Marked the tighten nut using permanent maker pen.Marked the tighten nut using permanent maker pen. 

 Checked the wire connection, cable size and connection.Checked the wire connection, cable size and connection.

2.1.3. Control circuit wiring procedure



 Auto cable was used to wire the Auto cable was used to wire the control circuit.control circuit. 

 The cable length was defined The cable length was defined and cut the wire using side cutter, wire striper.and cut the wire using side cutter, wire striper. 

 Print the tube number using ferrule print machine.Print the tube number using ferrule print machine. 

 Lugs were fixed to cable using cramping tool.Lugs were fixed to cable using cramping tool. 

 The control side was wired by including numbers, Phillips and flat screw drive wereThe control side was wired by including numbers, Phillips and flat screw drive were

used. used.



 Wire combines between control side and power side.Wire combines between control side and power side. 

 The control line was neatly arranged bThe control line was neatly arranged b y using spirals and cable ties.y using spirals and cable ties. 

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2.2. Tools & Machines used in

2.2. Tools & Machines used in workshop

workshop

When I was assembling the panels in the workshop, Fallowing tools and machineries were used. When I was assembling the panels in the workshop, Fallowing tools and machineries were used. Before I used these tools and machineries safety rules and operating instruction were fallowed Before I used these tools and machineries safety rules and operating instruction were fallowed correctly. correctly.

2.2.1. Basic tools

  HammerHammer 

 Screwdriver (Slot-head)Screwdriver (Slot-head) 

 Phillips ScrewdriverPhillips Screwdriver 

 PliersPliers 

 HacksawHacksaw 

 Allen KeysAllen Keys 

 Side CutterSide Cutter 

 Wrench (Box-End Wrench, Socket Wrench, Pneumatic Wrench, Open-end Wrench)Wrench (Box-End Wrench, Socket Wrench, Pneumatic Wrench, Open-end Wrench) 

 Measuring TapeMeasuring Tape



 Cable CuttersCable Cutters

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

size cables & common bas bar.



 Crimping ToolCrimping Tool

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

hydraulic crimping tool crimps high gauge wire easily with steady hydraulic power.with steady hydraulic power. Figure 2.2.1 - Tool box

Figure 2.2.1 - Tool box

Figure 2.2.1.1- Cable Cutter Figure 2.2.1.1- Cable Cutter

Figure 2.2.1.2- Crimping Tool Figure 2.2.1.2- Crimping Tool

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2.2.2. Machineries



 Jig SawJig Saw

A Jig Saw is a useful in cu

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



 Electric DrillElectric Drill

A Drill is a driving tool attachment, usually a

A Drill is a driving tool attachment, usually a drill bit.drill bit. It is used for drilling, tapping and It is used for drilling, tapping and boring

boring holes in various materials. Some electric drills drown withholes in various materials. Some electric drills drown with rechargeable batteries. rechargeable batteries.



 Pneumatic Pop-Rivet GunPneumatic Pop-Rivet Gun

A pneumatic pop rivet gun is designed to fix the rivet nuts together without too much effort 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. from the person handling the gun. The pneumatic pop rivet gun used compressed air hoses.



 Industrial HeaterIndustrial Heater

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

purposes.

Figure 2.2.2.4 - Industrial Heater Figure 2.2.2.4 - Industrial Heater Figure 2.2.2.1 - Jig Saw

Figure 2.2.2.1 - Jig Saw

Figure 2.2.2.2 - Electric Drill Figure 2.2.2.2 - Electric Drill

Figure 2.2.2.3 - Pneumatic Pop-Rivet Gun Figure 2.2.2.3 - Pneumatic Pop-Rivet Gun

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2.2.3. Nuts and bolts

The fallowing nuts and bolts were used for the panel assembling and connecting devices in to the The fallowing nuts and bolts were used for the panel assembling and connecting devices in to the panel box by me.

panel box by me.



 Nail Nail 

 ScrewScrew 

 Flat washerFlat washer 

 Spring washerSpring washer 

 Bolt Bolt (CSK (CSK Bolt Bolt - - 4x10mm, 4x10mm, 4x12mm, 4x12mm, 5x10mm, 5x10mm, 5x12mm, 5x12mm, 5x16mm, 5x16mm, 5x20mm)5x20mm)

(PH

(PH Bolt Bolt - - 5x35mm, 5x35mm, 5x20mm, 5x20mm, 4x10mm, 4x10mm, 4x12mm)4x12mm) (Hex

(Hex Bolt Bolt --

8x30mm, 8x15mm, 6x8mm, 6‹12mm, 6‹15mm, 6‹20mm)



 Allen BoltAllen Bolt 

 Self tapping boltSelf tapping bolt 

 Nuts Nuts 

 Stud nutsStud nuts

2.2.4. Panel accessories used in workshop



 Panel platePanel plate 

 Panel hookPanel hook 

 Panel holderPanel holder 

 Panel hinge / Chrome hingePanel hinge / Chrome hinge 

 Panel keyPanel key



 BeadingBeading 

 Cables tiesCables ties 

 Name plates & danger stickers Name plates & danger stickers 

 Earth barEarth bar

Figure 2.2.3 - Nuts and bolts Figure 2.2.3 - Nuts and bolts

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

 Din railDin rail

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

industrial control equipment inside panel.



 Insulator MountsInsulator Mounts

Bus Bar Insulator mounts are used for connecting line and neutral bar with panel mounting Bus Bar Insulator mounts are used for connecting line and neutral bar with panel mounting board and connecting bus bar with panel board.

board and connecting bus bar with panel board.



 Cable DuctCable Duct

Cable duct is wire and cable management product for routing and concealing electrical Cable duct is wire and cable management product for routing and concealing electrical wiring in control panels. Available in man

wiring in control panels. Available in many sizesy sizes



 Wire End CapsWire End Caps

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

colour according to electrical colour code.

Figure 2.2.4.3 - Cable ducts Figure 2.2.4.3 - Cable ducts

Figure 2.2.4.4 - Wire End Caps Figure 2.2.4.4 - Wire End Caps Figure 2.2.4.2 - Insulator mounts Figure 2.2.4.2 - Insulator mounts Figure 2.2.4.1 - Din rails

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2.3. Electrical Protective Devises Used in the Panels

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

purpose, working principle, connection and testing of these protective devices.

2.3.1. Fuses

A fuse is a type of

A fuse is a type of protection device in electrical applications. Fuses are protection device in electrical applications. Fuses are designed to open designed to open circuitscircuits the filament when excessive currents are present due to overloads or faults and to prevent further 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 damage to the system. Short circuit, system overload, other device failures, lightning, static electricity or system overload are some common results in b

electricity or system overload are some common results in b lown fuses.lown fuses.



 Cartridge FuseCartridge Fuse

In cartridge fuse the fuse wire is enclosed in a transparent glass tube or bulb, the whole unit is 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 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 rewired due to its sealing. In cartridge type fuses have many other sub types as MCB type, screw type, etc.

type, etc.



 HRC Fuse (High Rupturing Capacity Fuse)HRC Fuse (High Rupturing Capacity Fuse)

HRC Fuse consists of highly heat resistant material (such as ceramic) body having metal-end HRC Fuse consists of highly heat resistant material (such as ceramic) body having metal-end caps, which is welded by silver current carrying element. HRC Fuse has high rupturing capacity. caps, which is welded by silver current carrying element. HRC Fuse has high rupturing capacity. It has constant fusing characteristics and operates fast.

It has constant fusing characteristics and operates fast.

Figure 2.3.1 - Cartridge Fuse

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2.3.2. Miniature Circuit Breakers (MCB)

In electrical panels, MCB was used as the

In electrical panels, MCB was used as the basic protective device.basic protective device.

MCBs are designed to automatically protect against MCBs are designed to automatically protect against overloads and short circuits, preventing damage to cables overloads and short circuits, preventing damage to cables and equipment. Trip characteristics normally can not and equipment. Trip characteristics normally can not adjustable. MCB has thermal-magnetic operation. Over adjustable. MCB has thermal-magnetic operation. Over current protection is got the system by the thermal trip current protection is got the system by the thermal trip unitunit of the breaker. Short circuit protection is got to system by of the breaker. Short circuit protection is got to system by the magnetic trip unit of the breaker.

the magnetic trip unit of the breaker.

The MCBs‟ are in

single pole, double pole, try pole and four pole types. single pole, double pole, try pole and four pole types. Every circuit breaker has a voltage rating that designates the maximum voltage it can handle and 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. 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 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 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.

ranges and internal situations (Tripping). MCBs are classified according to the ampere. Type B - operate 3-5 times rated

Type B - operate 3-5 times rated current and suitable for lighting loadscurrent and suitable for lighting loads Type C - operate 5-10 times rated

Type C - operate 5-10 times rated current and suitable for lighting and motor loadcurrent and suitable for lighting and motor loads.s. Type D - operate 10-20 times rated cu

Type D - operate 10-20 times rated current and suitable for heavy units, weldrrent and suitable for heavy units, welding plantsing plants



My experience

2.3.2.1. Standard dimensions of

2.3.2.1. Standard dimensions of MCBs

MCBs



 I was able to measure the standard size (in mm) of the MCB and RCCB. It was veryI 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. important for the panel designing and arranging the panel box. Figure 2.3.2 - MCBs

Figure 2.3.2 - MCBs

Figure 2.3.2.1- Standard dimensions of MCBs Figure 2.3.2.1- Standard dimensions of MCBs

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2.3.2.2. MCB Distribution Box

2.3.2.2. MCB Distribution Box designing

designing



 I designed fallowing Distribution Boxes for the 300 houses in the housing apartment. ThisI designed fallowing Distribution Boxes for the 300 houses in the housing apartment. This

was designed for single phase 30A house. was designed for single phase 30A house.



 I have been used 30A isolator switch, 30A RCCB, four MCBs of 10A and six MCBs of 6AI have been used 30A isolator switch, 30A RCCB, four MCBs of 10A and six MCBs of 6A

according to the requirement. All were Orange p

according to the requirement. All were Orange production.roduction.



 4mm4mm22CU/PVC insulated wire was used for the wiring and single phase common bus bar wasCU/PVC insulated wire was used for the wiring and single phase common bus bar was

used to connect the MCBs. used to connect the MCBs.

2.3.3. Residual Current Circuit Breaker (RCCB)

The Residual Current Circuit breakers (RCCB or RCD) are the safest device to detect and trip The Residual Current Circuit breakers (RCCB or RCD) are the safest device to detect and trip against earth leakage currents, thus ensuring protection against electric shock caused by indirect against earth leakage currents, thus ensuring protection against electric shock caused by indirect contacts. These devices must be used in series with an MCB. RCCB Available in 2 Pole and 4 contacts. These devices must be used in series with an MCB. RCCB Available in 2 Pole and 4 Pole for domestic and Industrial application

Pole for domestic and Industrial application

1.

1.ElectromagnetElectromagnet

2.

2.Current transformer secondary windingCurrent transformer secondary winding

3.

3.Transformer coreTransformer core

4.

4.Test switchTest switch

L

-L -Live conductorLive conductor

N-N- Neutral conduct Neutral conductoror

Figure 2.3.2.2 - MCB Distribution Box

Figure 2.3.2.2 - MCB Distribution Box wiring diagramwiring diagram

Figure 2.3.3.1 - Internal connection of RCC Figure 2.3.3.1 - Internal connection of RCCBB

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RCCB works on the principle that in an electrical circuit the incoming current is the same as out 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 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 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 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 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 trips the Mechanism thereby disconnecting the supply. When pressing the TEST button 'T', a fault is simulated via the Test resistance & RCCB trips.

fault is simulated via the Test resistance & RCCB trips.

The RCCBs with a rated residual operating current (

I∆n

) of 30mA or less are used in place of) of 30mA or less are used in place of more conventional RCCBs with higher residual operating current ratings. The Rated current more conventional RCCBs with higher residual operating current ratings. The Rated current range varied 10mA to 1A.

range varied 10mA to 1A.

2.3.4. Moulded Case Circuit Breakers (MCCB)

In every panel which I wired MCCB was used as the main breaker. I was able to connect trip In every panel which I wired MCCB was used as the main breaker. I was able to connect trip coils, auxiliary contacts

coils, auxiliary contacts, inter lock and panel holders , inter lock and panel holders with MCCB. with MCCB. In Orange Electric worIn Orange Electric workshopkshop

I had used “ABB”, “Schneider”, “ATION”, and “Orange” brands‟ MCCBs.

The Moulded case circuit breakers have been developed for use in commercial and industrial The Moulded case circuit breakers have been developed for use in commercial and industrial protection.

protection. MCCB MCCB has has thermal-magnetic thermal-magnetic operation. operation. Trip Trip current current may may be be adjustable adjustable in in largerlarger ratings.

ratings.

I was able to identify the main features of a

I was able to identify the main features of a MCCB more than MCB,MCCB more than MCB,



 High short circuit current breaking capacity ( < High short circuit current breaking capacity ( < 20kV).20kV). 

 Used for high current ratings ( < 10000A )Used for high current ratings ( < 10000A ) 

 Adjustable current and tripping time rating.Adjustable current and tripping time rating.

Figure 2.3.3.2

(28)



 Simultaneous opening and closing of all poles.Simultaneous opening and closing of all poles. 

 Test button which allows periodic testing of the mechanical tripsTest button which allows periodic testing of the mechanical trips 

 Accessories such as shunt trip, under-voltage trip, Rotary Operators, motorized kit units,Accessories such as shunt trip, under-voltage trip, Rotary Operators, motorized kit units,

mechanical-electrical interlock, auxiliary contacts are available. mechanical-electrical interlock, auxiliary contacts are available.



 Thermal adjustment (overload)Thermal adjustment (overload)

MCCBs have a wide thermal adjustment range (long delay). The rated current current ( Ir ) it MCCBs have a wide thermal adjustment range (long delay). The rated current current ( Ir ) it continuously adjustable from 0.4 - 1 of

continuously adjustable from 0.4 - 1 of its nominal current (In)its nominal current (In)



 Magnetic Adjustment (short circuit)Magnetic Adjustment (short circuit)

Magnetic adjustment (short delay) is available on MCCBs. The magnetic setting (Im) is Magnetic adjustment (short delay) is available on MCCBs. The magnetic setting (Im) is continuously adjustable from 1

continuously adjustable from 1

–

10 of 10 of

it‟s In.

Figure 2.3.4 - MCCB and its auxiliary components Figure 2.3.4 - MCCB and its auxiliary components

Figure

Electrical panel boards- Engineering training report

HIGHER NATIONAL DIPLOMA IN

HIGHER NATIONAL DIPLOMA IN

ENGINEERING

ENGINEERING

ADVANCED TECHNOLOGICAL INSTITUTE

ADVANCED TECHNOLOGICAL INSTITUTE

COLOMBO 15

COLOMBO 15

NAME

NAME

:

: G.K.T.PRE

G.K.T.PREMARATHN

MARATHNA

A

FIELD

PREFACE

PREFACE

ACKNOWLEDGEMENT

ACKNOWLEDGEMENT

me the guidance for a better training. My special gratitude‟s al

me the guidance for a better training. My special gratitude‟s al

CONTENTS

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