SUMMER TRAINING REPORT TOPIC NAME: PANEL TRICOLITE ELECTRICAL INDUSTRY

(SAHIBABAD UNIT)

MADE BY:
SUBMITTED TO: MR. HEMANT HOD ELECTRICAL DEPARTMENT MRS.PRERNA DAHIYA SUBMITTED BY: MR. NEERAJ SAIN ELECTRICAL ENGG.

ELECTRICAL ENGINEERING

M.D POLYTECHNIC KHATIWAS (JHAJJAR) ROLL NO:10155090025

ABOUT TRICOLITE
TRICOLITE is a leading manufacturer of Custom Built Low & Medium Voltage Switchgears and Control gears in India.
Performing with a commitment to excellence since 1959

TRICOLITE

state-of-the-art Uttar Pradesh (Sahibabad) & Haryana (IMT Manesar). All the plants
is equipped with five manufacturing f a ci l i t i es in Delhi, are equipped with modern machinery, best of talent and know-how to cater to its esteemed customers with a wide spectrum of products. The company is empowered with modern communication facilities like Microsoft Navision, Enterprise Resource Planning systems, EDP centre with latest design and drawing peripherals and software like

Elecdes, PRO-E, SolidEdge, PRIMAVERA, AP100, Biloma & ESMS

LT SWITCHEAR AND CONTROL GEAR ASSEMBLIES

Switchgear and control gear assemblies are assemblies fitted with switching devices (breakers, switches, fuse switches and contactors etc. and control and measuring instruments, indicating, regulating and protective devices etc, to transform the assemblies into composite units, called control centers to perform a number of functions in the field of distribution and control of electric power. The basic idea of adapting to such control system is to broadly accomplish the following in normal operation. a! To have ease of operation or control a group of load or control points from one common location. b/ To monitor system operations for better coordination between the various feeders and rapid control of feeders.
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To provide a sequential operation when required between various feeders or to have an electrical interlocking scheme between them.

1)

Fixed Type Construction

1) Draw out Type Construction

Fixed-Type Construction
In a fixed type construction, all feeders in the switchboard, feeding the various load points, are securely mounted in the assembly and rigidly connected to the main bus. In case of a fault event in brie feeder on the bus side, a shut dm/An of entire switchboard may be-required. However, since this is the most cost effective, it is used commonly. A fixed type construction may be further classified as follows:

a)Industrial-type construction
In this construction there is a common bus bar that runs horizontally and is mounted on a vertical floor. The feeders are mounted above and below bus bar chamber. Require large floor space, are rugged and easy to handle.

a)

Cubicle-type construction

This is in form of sheet metal housing, compact in design and elegant in appearance. The feeders are mounted on one above another on a permissible height at which operator can easily operate. They can be further classified as follows:

Non-compartmentalized type: In this type a group of feeders are housed in one enclosure, and attending one would mean an exposure to others. Compartmentalized type: In this type each feeder is housed in a separate compartment of its own and attending one would limit the exposure to that unit.

CRCA AND GI SHEETS FOR ENCLOSURE:

Cold rolled cold annealed (CRCA) sheets are used to make outer body of panels like side covers, front covers and back covers. For these covers the thickness of CRCA sheets is usually 2 mm. But for load bearing member its thickness is generally 3-mni. Load bearing member are those on which some equipments (switchgears) are placed. That's why (lie CRCA sheets for load bearing members are chosen of more thickness, so that it can bear the load of switchgears properly. Galvanized iron (GI) sheets are used for partition in the panels. For partition purpose these sheets are usually of 1.6 mm thickness.
Some Standards followed in Panel:

> Length ofabay: 300 mm > Depth of panel: > Height of panel:

500

mm '> Length of cable alley: 400, 600, 900, 1100, 1350, 1450, 1600nim 2055, 2400 mm

BUS BAR:

Bus Bar (or bus in short) terin is used for a main bar or conductor carrying an electric current to which many connections may be made. Bus bars are mainly convenient means of connecting switch and other equipment into various arrangements. The usual arrangement of connection in most of the substations permits working on almost any piece of equipment without interruption of incoming or outgoing feeders. In some arrangement two buses are provided to which the incoming or outgoing feeders and the principal equipment may be connected. One bus usually called the "main" bus and the other "auxiliary" or "transfer" bus. The bus bars are usually of aluminum (less frequently of copper). The use of aluminum as electric conductor is made due to its numerous advantages over copper such as higher conductivity on weight basis, lower cost for equal current carrying cap. city; excellent corrosion resistance and ease of formability. For proper -eliable electrical connections aluminum buses are coated with silver.
Some important points on bus bar relating panels:

Number of bus bars in a panel depends upon the rating of panel i.e. rating of incomer and switchgears.

Generally bus bars are provided at the back of a panel. In case the panel is dead at the back i.e. not operational at the back, then they are provided in front of the panel. Also position of bus bars depends upon the customer.

There are both horizontal and vertical bus bars in a panel. Horizontal bus bar runs throughout the panel and is connected to the main supply. Horizontal bus bar is also connected to the vertical bus bars in each bay, hence feeding them with the main supply.

 Current density of a bus bar depends upon its 1. Width 2. Depth

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SWITCHGEAR & MISCELLANEOUS

The term switchgear, used in association with the electric power system refers to the combination of electrical disconnects, fuses and/or circuit breakers used to iEolate electrical equipment. Switchgear is used both to de-energize equipment to allow work to be done and to clear faults downstream. This type of equipment is important because it is directly linked to the reliability of the electricity supply. Various type of switchgear used in Panels are ACB/MCB/FUSE/Contactor/Re1ays etc.. Panels also comprise of measuring instruments, indicating, regulating and protective devices

I) POWER CONTROL CENTRE (PCC)

2) MOTOR CONTROL CENTRE (MCC)

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3) AUTOMATIC POWER FACTOR CORRECTION PANEL (APFC)

POWER CONTROL CENTRE (PCC)

It is the main panel amongst all the panels. It is directly connected to grid (main) supply and in case main supply is failed it would be connected to DG (diesel generator). In other words we can say that it is dealing with bulk power. This panel does not feed the utility (requirement) dirctIy. It feeds the utility indirectly that is through sub panels. Sub panels like MCC, distribution panels, & other utility panels. orexkmp1e: In a large factory how the PCC and sub panels WORKS?

SUB PAII

PAINT SHOP

1 I

I SUBPANEL
WIRINODEPT

SUBPANEL
FABRICATION DEPT ASSEMBLY DEPT

J_SUBPANEL

In the above figure the PCC is feeding the sub panels and these sub panels further controls the different sections of factory.
MOTOR CONTROL CENTRE (MCC)

We usually term this panel as a sub panel i.e. after PCC. In this panel different types of motors are controlled. Anywhere the motors are to be controlled, a MCC is required. Some of these panels in different fields are: 1) Process panels 2) Utility panels 1) Plumbing panels 2) Fire panels etc.
PRODUCTION

Production activity is divided into multiple activities as under: Fabrication , Painting ,A ss embl y- --,,,,,W ir ing Quality

FABRICATION - Based on the approved GA drawing of the panel programming for

CRCA sheet for CNC Punching is done in AP 100 software. Once programming for sheet is done, CRCA sheet undergoes CNC punching and bending process. It is then followed by welding & grinding of these different parts of panel frame.

CNC Punching

Bending

Welding

DESIGNING Designing is one of the most important aspect in the manufacturing process of any product. This process begins with the receipt of design inputs from the Marketing department. Design process is sub divided into further steps. These steps are as follows: Client requirement Client specifies all the specification, which he wants in his product. These specifications must be introduced in the drawings. Legends and notes Legends and notes are general information on various symbols used in drawing. They give very general information about the panel. General arrangement It shows different views olihe panel ,These views are generally top view front view, front view without door. These views are just for the layout's dimensions and door mounted accessories Single line diagram Single line diagram are the simplified view of circuit diagram. Any numbers of phase line connections are shown in single line view for more compactness

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Bifl ofiriaterials It is simply a list of materials used in manufacturing of panel. It also consists of make, type, rating and quantity. It gives cluster view of all the material used. Schematic drawing Schematic drawings are the original drawings with many simplifications. They gives an over view of all the wiring, protection controlling diagram. Schematic drawing gives more information and description about panel then Single line diagram, also they are more complicated then Single line diagram. Approval of drawing After internal checking the drawing is handed over to the client for approval and corrections in the drawings. Once approval is received drawing is handed over to production department for manufacturing.

IN

Pre- Treatment

The bare metal being extremely susceptible to atmospheric corrosion should be applied with conversion coating Before painting, once the rust, oil and scale are cleaned, the bare metal is again exposed for oxidation. To avoid this, the material has to be coated with some type of conversion coating which prevents further oxidation before applying paint and also gives adhesion for paint. Therefore the frame received from fabrication shop undergoes Seven Tank pre treatment process which includes following stages: 1. Degreasing: Removal of oil and grease from the surface 2. Water rinse 3. Derusting: Removal of rust and light scale from the surface 4. Water rinse

5. Activation : This gives more compact and uniform coating ofzinc phosphate. 6. Phosphating : This forms coating ofzinc phosphate (4 to 6 microns) or iron phosphate (1 to 1.5 microns) on the clean surface of MS.

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7. Water rinse After a metal surface receives a conversion coating, the surface is water rinsed to remove un reacted conversion coating chemicals and a posttreatment is applied. Therpost-treatment can provide a two- to ten-fold increase in corrosion resistance and humidity resistance when compared to conversion coatings without final rinses. Powder Coating

Powder coating is an advanced method of applying a decorative and protective finish to a wide range of materials and products that are used by both industries and consumers. The powder used for the process is a mixture of finely ground particles of pigment and resin, which is sprayed onto a surface to be coated. The charged powder particles adhere to the electrically grounded surfaces until heated and fused into a smooth coating in a curing oven. The result is a uniform, durable, high-quality, and attractive finish

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ASSEMBLY

This activity calls for assembly of various parts of panel structure like Base Frame, Mounting Channel, Mounting Plates, Supports , Bus Bar fitting and Mounting of Switchgcar & control gear.

WIRING After assembly the power & control wiring as per the schematic drawing of the panel is being done.

QUALITY CHECK.

By this time the Panel is ready for quality check in terms of Fabrication. Assembly, Wiring, ' and Electrical Operation with respect to norins. Once Quality tested OK Panels are cleared for Customer inspection or dispatch.