Report on Vocational Training(Summer)2011

KHAN ELECTRICAL ENGINEERING CENTRE

(PALAN INDUSTRIAL ESTATE,BANERJEEPARA,MAHESTALA.KOL-141)
Under : KHAN ELECTRICAL ENGINEERING CENTRE
Reference-Prof. Subhasis Bandopadhyay
Submitted By: Aniruddha Koley
Roll no. :08156028025
Stream: Electrical & Electronics Engineering
College: Pailan College of Management & Technology



Submitted on: ___________________________
1
st
August 2011 (ANIRUDDHA KOLEY)
CONTENTS

1. Introduction to Electrical Engg. Centre
2. Operations at Khan Electrical Engg. Centre
3. Manufacture of Electrical Panel
4.Assembling of various parts
5.Fuses description
6.Various types of Breaker
7. Current Transformer
8. Various types of feeder
9.Busbars
10.Voltmeter & Ammeter
11.Digital Panel Meter
12.Insulation testing
13.Load testing
14.VVVF Operation
15.Safety Measurement
16.Conclusion






Introduction to Electrical Engg. Centre


An Electrical Engg. Centre is a hub where graduates from Electrical Engg. Departments are
familiarized with various electrical components such as :
Electrical Panels
Electrical drives
Transformers
Relays
Protection of various components
Safety measures to be taken


Operations at Khan Electrical Engineering Centre:-


The various operations at Khan Electrical Engg. Center are :-
Machine Design
Assembling of various modules
Manufacture of Design components & Electrical Panels
Testing & final delivery of the manufactured products




Manufacture of Electrical Panel:


The basic operation for manufacturing panels is Lathe Operation.
Lathe Operation:
Metals are brought in and various operations are done like:
Cutting
Drilling
Bending
Welding
Painting/Galvanizing
Insulation
Lathe Lathe Machining Lathe Bore

Lathe trial Lathe Painting-using-the-lathe
Assembling of Panel Components:
The basic components used for panel assembling are :-
1>FUSES:- In electrical and electronics engineering, a fuse is a type of low
resistance resistor that acts as a sacrificial device to provide over current protection, of either
the load or source circuit. Its essential component is a metal wire or strip that melts when too
much current flows, which interrupts the circuit in which it is connected. Short circuit,
overloading, mismatched loads or device failure are the prime reasons for excessive current.

A fuse interrupts excessive current (blows) so that further damage by overheating or fire is
prevented. Wiring regulations often define a maximum fuse current rating for particular
circuits. Over current protection devices are essential in electrical systems to limit threats to
human life and property damage. Fuses are selected to allow passage of normal current plus a
marginal percentage and to allow excessive current only for short periods. Slow blow fuses are
designed to allow higher currents for a modest amount of time longer, and such considerations
are and were commonly necessary when electronics devices or systems had electronic
tube tech or a large number of incandescent lights were being powered such as in a large hall,
theater or stadium. Tubes and incandescent lights each have reduced current needs as they
heat up to operating temperatures for their internal resistance grows as they are heated the
same physics principle causes the fuse material to melt, disconnecting the circuit from power.

A fuse consists of a metal strip or wire fuse element, of small cross-section compared to the
circuit conductors, mounted between a pair of electrical terminals, and (usually) enclosed by a
non-conducting and non-combustible housing. The fuse is arranged in series to carry all the
current passing through the protected circuit. The resistance of the element generates heat due
to the current flow. The size and construction of the element is (empirically) determined so that
the heat produced for a normal current does not cause the element to attain a high
temperature. If too high a current flows, the element rises to a higher temperature and either
directly melts, or else melts a soldered joint within the fuse, opening the circuit

The fuse element is made of zinc, copper, silver, aluminum, or alloys to provide stable and
predictable characteristics. The fuse ideally would carry its rated current indefinitely, and melt
quickly on a small excess. The element must not be damaged by minor harmless surges of
current, and must not oxidize or change its behavior after possibly years of service.
2>CIRCUIT BREAKER:- Mainly four types of circuit breaker are used in panel, i.e.
i)ACB(Air-blast Circuit Breaker)
ii)VCB(Vacuum Circuit Breaker)
iii)MCB(Miniature Circuit Breaker)
iv)MCCB(Molded Case Circuit Breaker)
v)RCCB
i)ACB:- Air circuit breakers can be used both as circuit-breakers for general protection (of
plants, of user complexes, of electric lines) and as protection circuit breakers of electrical
machines (generators, motors, transformers, capacitors).

These can be used both as circuit-breakers for general protection (of plants, of user complexes,
of electric lines) and as protection circuit-breakers of electrical machines (generators, motors,
transformers, capacitors). They are used in all types of plants (civil, industrial, and in the service
sector) as well as in the equipment on-board ships, in mines, in prefabricated substations, and
for primary and secondary distribution in general.
ii)VCB:- Vacuum interrupters mounted vertically within the circuit breaker frame, perform
the circuit breaker interruption.

Consisting of a pair of butt contacts, one movable and one fixed, interrupters require only a
short contact gap for circuit interruption. The resulting high-speed operation allows the entire
operating sequence, from fault to clear, to be consistently performed in three cycles or less.

Never use the primary disconnects as handles when maneuvering the
breaker.
iii)MCB:- Our miniature circuit breakers provide efficient and trustworthy protection for cables
and systems in severe industrial environments and in service installations in buildings.


It possesses three different tripping characteristics to provide the perfect solution for all kinds
of application from cable production up to the protection & control. Our manufacturers have
manufactured these with facilities for quick, easy and safe field application of supporting
contacts and shunt trip release mechanisms. We also offer facilities such as mechanism locking
and sealing wire are provided wherever needed.
iv)MCCB:-Our MCCB conforms to the standards of GB14048.2 and IEC947-2. Molded case
circuit breaker (MCCB) is mainly used in electric power system with rated frequency of AC50Hz,
rated voltage up to 690V and rated current up to 800A to distribute electric power.

Moreover, these are also used to protect the line and equipment from being damaged due to
overload, short circuit and under voltage.
v)RCCB:- These are in compliance with the standards of IEC1008-1 and GB16916.1-1997.

Applied to the circuit of AC 50/60Hz, 1P 240V, 3P4 15V, these are mainly used for preventing
electric fire and personal casual accidents caused by personal electric shock or leakage. They
act as current-operated and fast leakage protectors.

3>CURRENT TRANSFORMER: - In electrical engineering, a Current Transformer (CT) is used
for measurement of electric currents. Current transformers, together with Voltage
Transformers (VT) (potential transformers (PT)), are known as Instrument Transformers. When
current in a circuit is too high to directly apply to measuring instruments, a current transformer
produces a reduced current accurately proportional to the current in the circuit, which can be
conveniently connected to measuring and recording instruments. A current transformer also
isolates the measuring instruments from what may be very high voltage in the monitored
circuit. Current transformers are commonly used in metering and protective relays in the
electrical power industry.

Like any other transformer, a current transformer has a primary winding, a magnetic
core, and a secondary winding. The alternating current flowing in the primary produces a
magnetic field in the core, which then induces a current in the secondary winding circuit. A
primary objective of current transformer design is to ensure that the primary and secondary
circuits are efficiently coupled, so that the secondary current bears an accurate relationship to
the primary current.
The most common design of CT consists of a length of wire wrapped many times around
a silicon steel ring passed over the circuit being measured. The primary winding may be a
permanent part of the current transformer, with a heavy copper bar to carry current through
the magnetic core. Window-type current transformers are also common, which can have circuit
cables run through the middle of an opening in the core to provide a single-turn primary
winding. When conductors passing through a CT are not centered in the circular (or oval)
opening, slight inaccuracies may occur.
The rated secondary current in CT is commonly standardized at 1 or 5 amperes. For
example, a 4000:5 CT would provide an output current of 5 amperes when the primary was
passing 4000 amperes. The secondary winding can be single ratio or multi ratio, with five taps
being common for multi ratio CTs. The load, or burden, of the CT should be of low resistance. If
the voltage time integral area is higher than the core's design rating, the core goes into
saturation towards the end of each cycle, distorting the waveform and affecting accuracy.
4>FEEDER: Feeders are conductors which carry electric power from the service equipment (or
generator switchboard) to the over current devices for groups of branch circuits or load centers
supplying various loads.
Feeder Rating:- 200A 800A
Feeder Description:- 100comu Machine Repair Shop FDR1
Cable:- Bus Truncking 5*(3*185+1*95)AYFY
Sub feeders originate at a distribution center other than the service equipment or generator
switchboard and supply one or more other distribution panel boards, branch circuit panel
boards, or branch circuits. Code rules on feeders also apply to sub feeders.

5>BUS BARS(Aluminum & Coppers):- In electrical power distribution, a bus bar is a strip
of copper or aluminum that conducts electricity within a switchboard, distribution
board, substation or other electrical apparatus.

Bus bars are typically either flat strips or hollow tubes as these shapes allow heat to dissipate
more efficiently due to their high surface area to cross-sectional area ratio. The skin
effect makes 5060 Hz AC bus bars more than about 8 mm (1/3 in) thick inefficient, so hollow
or flat shapes are prevalent in higher current applications. A hollow section has higher stiffness
than a solid rod of equivalent current-carrying capacity, which allows a greater span between
busbar supports in outdoor switchyards.

A bus bar may either be supported on insulators, or else insulation may completely surround it.
Bus bars are protected from accidental contact either by a metal earthed enclosure or by
elevation out of normal reach. Neutral bus bars may also be insulated. Earth bus bars are
typically bolted directly onto any metal chassis of their enclosure. Busbars may be enclosed in a
metal housing, in the form of bus duct or busway, segregated-phase bus, or isolated-phase bus.
Bus bars may be connected to each other and to electrical apparatus by bolted, clamp, or
welded connections.
6>VOLTMETER/AMMETER(Moving coil galvanometer):- AC electromechanical meter
movements come in two basic arrangements: those based on DC movement designs, those
engineered specifically for AC use. Permanent-magnet moving coil (PMMC) meter movements
will not work correctly if directly connected to alternating current, because the direction of
needle movement will change with each half-cycle of the AC.

In order to use a DC-style meter movement such as the D'Arsonval design, the alternating
current must be rectified into DC. This is most easily accomplished through the use of devices
called diodes.
here is a voltage current meter panel from a three-phase AC system. The three donut current
transformers can be seen in the rear of the panel. Three AC ammeters on the front of the panel
indicate current through each conductor going through a CT. As this panel has been removed
from service, there are no current-carrying conductors threaded through the center of the CT
donuts anymore.

Because of the expense of instrument transformers, they are not used to scale AC meters for
any applications other than high voltage and high current. For scaling a milliamp or micro amp
movement to a range of 120 volts or 5 amps, normal precision resistors are used, just as with
DC.
7>DIGITAL PANEL METER:- Based on the feedback received from its valued customer base,
MECO has now launched Digital Panel Meters (DPMs) in DIN72, DIN96 and DIN144 sizes in
compact reinforced molded plastic cases. With these additions, MECO offers DPMs in all
popular sizes suitable for every application. This helps the user to select the correct instrument
and add value to their equipment or the panel.

The DPMs in 3, 3.5, 4.5 and 5 digit, with LED and LCD display are suitable to measure all
electrical parameters like V,A,W,VAR, PF and Hz in electrical networks of 1Phase, 3Phase 3Wire
and 3Phase 4Wire for balanced as well as unbalanced loads. These meters can also be scaled
for displaying process parameters like kmph, RPM, %, CPS, Ft/s, psi etc against an input of 4-
20mA or 1-5V. A choice of AC and DC auxiliary power supply is also available. A range of over
100 models of DPMs is available in sizes of 144x144mm, 96x96mm, 72x72mm, 48x96mm,
50x85mm and 71x46mm. The DPMs are available with a choice of built-in as well as external
transducers.
Insulation Testing/meggaring:-
A regular program of testing insulation resistance is strongly recommended to prevent
electrical shocks, assure safety of personal & to reduce or eliminate down time.

It helps to detect deterioration of insulation in order to schedule repair work such as :
vacuum cleaning, steam cleaning, drying & rewinding. It also helpful when evaluating the
quality of the repairs before the equipment is put back into operation.
Necessary equipments for insulation test:-
Megohommeter with a timed test function
Temperature indicator
Humidity meter
Total current in the body of insulation is the sum of three components:-
Capacitance charging currents
Absorption current
Leakage or conductance current
Testing of Load(HV,LV):-
Full HV system consists of:-
10 SY1527 main power supply units
64 A876 boards
250 A877 boards
Most of the boards are at ISR waiting to be tested.3 SY1527 and some A876 and A877
are in use since more than 1 year to power several DTs.


Test setup consists of :-
1 SY1527 mainframe
8 A876 modules
32 A877 modules Location: end of
ISR test area.
Two racks with 1 SY1527 and crates for the A877 already in place. All HV and communication
cables needed for this setup are ready. 5 tests envisaged:
Min voltage and max current with resistive load
Max voltage and max current with resistive load
Transient test. Ramp-up/ramp-down tests with
RC load
Min voltage and min current
Measurement of output voltages before and
Resistive and RC loads with Radial connectors
Software. It will be adapted from the existing
PVSS project used at the ISR..Time required of the order of 6-8 months We should start as soon
as possible as some boards are going out of warranty.
LV system for magnet test is a great unknown! We should decide NOW what to do. So
far, at labs or at test beams, we have powered with LV at most 2 DTs at the time.
We need to go one order of magnitude
beyond. We will not be able to do this with
home made supplies.
We should decide now whether we want to
order some LV equipment for the magnet
test or whether we should abandon the idea
of reading out 12 chambers.
VVVF Operation:-

FEATURES
State of the art Micro Processor based design
Integrated User Interface for adjusting controller parameters, viewing status and
accessing Event and Statistical Information
Optically Isolated Inputs with Red Status LEDs Dry Contact Outputs with Green Status
LEDs
All Inputs & Outputs clearly labeled
Factory Wired Terminal Strip for ease of installation and maintenance Event Log with
Date/Time Stamp
Free Tech Support
Remote Monitoring
Factory Programmed Frequency Drive Unit
Simplex, Duplex or Triplex Selective Collective Operation
Top of Car TS-89 Tape Unit
The VVVF advantage:- Quickly installed, easily maintained and 100% factory tested
Suited for use with single or two speed, three phase, AC induction motors
Delivers level floor stops bringing your AC elevator up to accepted leveling standards
Provides zero-speed brake stops, which will reduce wear on the elevator machine and brake
Existing motor may be reused in modernizations
Excellent ride quality and dependable operations
Safety Measurement, Grounding, Earthing, Protection
of Transformer:-
TESTING OF TRANSFORMER:-
TESTING IS CARRIED OUT AS PER IS-2026.
ROUTINE , TYPE TESTS & SPECIAL TESTS
ROUTINE TESTS ( TO BE CARRIED OUT ON EACH JOB)
1.Measurement of winding resistance
2.Measurement of insulation resistance
3.Seperate source voltage withstand test (High Voltage tests on HV & LV)
4.Induced Over voltage Withstand test (DVDF test)
5.Measurement of voltage ratio
6.Measurement of NO LOAD LOSS & current.
7.Measurement of LOAD LOSS & IMPEDENCE.(EFFICIENCY &
REGULATION)
8.Vector Group Verification
9.Oil BDV test.
10.Tests on OLTC (if Attached)


Conclusion:-
Though being from Electrical & Electronics Engineering discipline, during the vocational training
period at KHAN ELECTRICAL ENGINEERING CENTRE, I have come to know about other details in
the process of running of a electrical engineering centre like lathe machine, transformer,
meggar, etc. which undoubtedly has been a very helpful & fruitful knowledge from this training.
I would like to be grateful to everyone of the KHAN ELECTRICAL ENGINEERING
CENTRE Family without whose valuable support this training would not have been a success. I
would specially like to thanks, Sr.Manager & Manager & the stuffs without whose valuable help
and guidance this training would have been impossible.
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