CHAPTER 1

COMPANY PROFILE

1.1 Overview of the Organization

GLOBOSE we introduce ourselves as leading manufacturer in all type
of electrical and instrumentation control panels for various applications,
automation. Our specialization in PLC based electrical control panels, fixed and
drawn out type MCC/PCC panels, instrumental panels, SCADA, automatic power
factor control panels. We have manufacturing plant at Vijayapura and Bangalore
(India). The plant is equipment’s, like in house facility as fabrication
manufacturing, testing, erection and commissioning of panels.

GLOBOSE Panel manufacturing system has been designed from the

outset based on customer requirements. The result is a panel product that offers
unrivalled flexibility and user safety ,backed up by comprehensive testing and
support for many specific applications. We can also do SITC of CPRI approved
Tested Panels and IEC – 61439 Panels. GLOBOSE Electrical Company is one of
the few Electrical Contractors with full capabilities in both Electrical Engineering
and Construction.

GLOBOSE has established one of top systems Integrator in

Ventilation System Integrator in South India [Basement+ Staircase+ STP]
GLOBOSE has established one of top systems car parking ventilation system of
covered car parks to comply with current with current building regulation and also
meeting the NBC standard.

GLOBOSE we work with building developers and owners to

optimize the ongoing value of investment. We work the building managers and
HVAC, electrical, fire, and CCTV contactors to deliver robust, easy-to-use
systems with built-in troubleshooting BMS. We work consulting engineers to
design high performing future proof building management systems for the state-
of-the-art buildings.

1
1.2 Vision and Mission of the Organization

Vision:

 Be the best service provider for customers, covering Supplying and

Supporting engineering functions.

Mission:

 GLOBOSE provide user- friendly, safe and secure SOLUTION to

customer needs. Provides user friendly SYSTEMS to Implement.
SUPPORT the Systems for the life Cycle.

2
1.3 Organization Structure
The organizational structure of our manufacturing company, based on the
functional structure:

1. Top level management

 Managing Director –Gopinath Ramachandra Somayaji
 Director–Vidya Gopinath Somayaji
 Executive Director sales –Sudhir Udupa

2. Operation department
 Production manager
 Quality control manager
 Maintenance manager
 Materials manager

3. Sales Department
 Sales manager
 Sales representatives

4. Finance department
 Chief financial office
 Accountant Financial analyst

5. Information Technology Department

 IT Manager
 Network Administrator
 System Administrator

3
 Each department is responsible for its own set of functions and reports
to the top-level management. The production department is responsible for the
manufacturing process, while the quality control department is responsible for
ensuring the quality of the products. The maintenance department is responsible
for the upkeep of the machinery and equipment used in production. The materials
department is responsible for the procurement and management of raw materials.
The sales department is responsible for the sale and distribution of the company's
products. The finance department is responsible for managing the company's
finances, including budgeting, accounting, and financial analysis. The IT
department is responsible for managing the company's information technology,
including network administration, system administration, help desk support, and
IT service management.

4
1.4 Roles and Responsibilities of Personnel in the
Organization
1. Managing Director

 Provides strategic direction for the company

 Develops and implements policies and procedures
 Oversees the financial performance of the company
 Builds relationships with key stakeholders and industry leaders

2. Directors

 Oversees the manufacturing process and production operations

 Implements process improvements to increase efficiency and reduce cost
 Ensures compliance with safety and environmental regulations
 Works with other departments to ensure timely delivery of products

4. Chief Information Officer

 Develops and implements IT policies and procedures

 Oversees IT service management processes
 Ensures data security and privacy
 Implements new technology solutions to increase efficiency

5. Production Manager

 Oversees the manufacturing process and production schedule

 Ensures compliance with safety and environmental regulations
 Monitors and manages production costs
 Implements process improvements to increase efficiency

6. Quality Control Manager

 Oversees quality control processes to ensure product quality

 Develops and implements quality control procedures
 Manages quality control staff and provides training
 Implements process improvements to increase product quality

5
7. Sales Representatives

 Builds relationships with customers and identifies new sales opportunities

 Provides product information and demos to customers
 Responds to customer inquiries and provides customer support
 Collaborates with other departments to ensure customer satisfaction

8. Network Administrator

 Oversees network infrastructure and security

 Installs and configures network equipment and software
 Monitors network performance and troubleshoots issues
 Implements network improvements to increase efficiency and security

6
1.5 Products and Market Performance
We as Panel Manufacture continuously and sincerely put efforts to enhance our
technical knowledge through excellent industrial interaction which has developed
a unique dimension to our product and final system execution. We have built a
well established infrastructure that is spread out over a wide land area and assist
us in production of panels.

In order to work in a smooth way, Furthermore, we regularly upgrade our

infrastructure according to the advanced market developments to carry out
flawless production process.

1.5.1 Industrial and building based products

 VCB Panels
 PCC Panels
 Main LT Panels
 MCC Panels
 PDB Based Panels
 SDB Panels o Intelligent PCC Panels
 Intelligent MCC Panels
 Intelligent DB, PDB, Panels
 Metering Panels
 DG Sync Panels
 APFC Panels
 Metering Panels
 AMF Panels

1.5.2 HVAC panels

 Chiller Control Panels

 Damper Control Panels
 AHU Control Panels
 VFD Panels o Heater Bank Control Panels
 Compressor, Fan, AHU Control Panels

7
1.5.3 Automation panels

 PLC Based Panels

 RIO Panels
 HMI Panels
 DDC Panels
 VFD Panels
 SCADA Systems
 DCS RIO Panels
 Process Automation Panels

1.6 Company Details

 Works Area :15000 Sq. Feet
 Group Office:2500 SQ. Feet
 Group Establishment ; 2010
 Total Manpower : 60 members
 Management Team : 4 members
 Executive Team : 6 members
 Group Turnover : 300 Million Rupees
 Branch Office : 3 Branch Office
 Certification : An ISO-9001-2015
 CPRI Tested : Up to 65 KA for panels
 GSSPL Can Supply : IEC- 61439 Panels
 Branch Office : Chennai/Hyderabad/Vijayapura
 Factory : Vijayapura/ Bangalore
 CIN No : U36912KA2013PTC068211
 PAN No : AAFCG1207P
 GST No: 29AAFCG1207P1ZD
 UDYAM No: KR03A0070587
 P.F. NO : PYPNY1601895000
 E.S.I. No: 49000331290000699
 MSME No: 29020111943

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 CHAPTER 2

OJT1- CONTROL PANEL MANUFACTURNG AND

DESGINING

2.1 Introduction
To design a low tension or low voltage panel, the procedure for the
designing a panel is designing the system as per customer requirement the
enclosure shall be designed by using proprietary software Z CAD. Other details
like SLD (single line diagram) and control schemes shall be prepared by using
AUTOCAD. Bill of quantities can be done by using excel program. After
receiving all the material they assemble of enclosure can be done. After
assembling switch gear and control gear shall be integrated into the enclosure and
starts wiring/ inter connecting as per the designs. And then continued by testing
and finally dispatching of a panel

2.2 Manufacturing Steps

2.2.1 Panel designing

Figure 2.1: Panel designing using CAD software

It is anchored to the right side of the AutoCAD window by default.

Selecting only the control panels that you will use will minimize the clutter and
give you only the tools that you need to work with.

9
2.2.2 Cutting and welding

Figure 2.2: Panel cutting and welding process

 We will use a cutting machine to cut the panel board.

 We sweep and weld spare parts using gas or weld rod for welding. Cut
the marking area that we have marked earlier and weld all
the parts together.

2.2.3 Fabrication with grinding finish

Figure 2.3:Panel fabrication with grindng finish

Surface grinding is a finishing process that uses a rotating abrasive

wheel to smooth the flat surface of metallic or nonmetallic materials to give them
a more refined look by removing the oxide layer and impurities on work piece
surfaces. This will also attain a desired surface for a functional purpose.
10
2.2.4 Test and inspection of panel fabrication

Figure 2.4: Test and inspection of panel fabrication

Inspection is needed for maintaining quality in a construction project.

Different aspects of quality are to be considered. Different types of inspection and
quality control procedures may apply to different materials. An engineer should be
conversant with all these procedures.

2.2.5. Painting

Figure 2.5: Panel painting

After finishing all the testing we will paint the panels. Very large panels
are machine painted,It is most commonly used for protection purpose, paint can
be made in many colors, we can mostly used colors are greay7032.

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2.2.6. Powder coating and heating process

Figure 2.6: Panel Powder coating and heating process

A panel Paint Curing Oven cures dries the paint through the heated air
that is re circulated in the Oven. This is generally done by having a heating
chamber where air is heated and the heated air is circulated inside the Paint
Curing Oven chambers by means of fans.

2.2.7. Door and mounting sheet fittings

Figure 2.7: Panel Door and mounting sheet Fittings

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2.3 LT Panel Designing Steps
2.3.1 DOL starter designing

Figure 2.8: Control & Power circuit of DOL starter

Direct On Line start is probably the simplest and traditional type of start
and it is to connect the motor directly to the power supply performing therefore a
full-voltage start-up.

13
2.3.2 GA diagram

Figure 2.9: General arrangement diagram of LT panel

2.3.3 Single line diagram

Figure 2.10: SLD

2.3.4 Materials arrangements

14
 Figure 2.11: Materials arrangement

2.3.5 Wiring

Figure 2.12: Panel wiring

Electri
c al
panel
wiring
diagrams are used to outline each device, as well as the connection between the
devices found within an electrical panel.

2.3.6 Testing

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 Figure 2.13: Testing of panel

Infrared thermography is a test that can be utilized to identify unbalanced

loads, poor connections, deteriorated insulation or any other issues in energized
electrical panels or components without dismantling the components.

2.3.7 Panel cleaning using air blower machine

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 Air blower machine is a simple and effective electrical device used in
homes and industries to blow away dust from every nook and corner.

2.3.8 Packing
Bubble Wrap or air bubble packing is a transparent plastic packaging
material that is mainly used to pack fragile or easily breakable items. The bubbles
have regularly spaced protruding air-filled hemispheres which function as the
cushioning agent for sensitive and easily breakable objects.

2.3.9 Panel dispatch

It means the seller has packaged the product, organized all the necessary
information, and handed it over to the delivery company.

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2.4 Interns Ability To Apply The Skill And Technical
Knowledge On OJT-1
2.4.1 Overview of the control panel

Globose panel manufacturing system has been designed from the outset
based on customer requirements. The result is a panel product that offers
unrivalled flexibility and user safety, backed up by comprehensive testing and
support for many specific applications.

2.4.2 Designing of control panel

An enclosure that contains different type of switchgears, control and

power units to perform the desired operation.

Globose prides itself on the reputation that it has built while providing
electrical design, electrical installation and electrical maintenance for a wide
range of facilities. Our 100% commitment to customer satisfaction ensures that
our customers have a competitive advantage on all of their electrical project.

2.4.3 Control panel

A cabinet which contains a collection of electrical components designed

to control and protect the motors and equipments.

The selection of components for a control panel is mainly based on

1. Power rating of the equipments.

2. Incoming supply
3. Explosion proof category
4. Application of the equipment.

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2.4.4 The main components of a control panel
2.4.4.1 Enclosure
 The main visible part of a control panel.
 The purpose of an enclosure is to hold and protect the components from
environment & to prevent electrical shock to equipment users.
The selection of an enclosure is based on
 Dimension of the switch gear items inside in it
 Material of construction
 Area of location of the panel.

2.4.4.2 Incomer with handle and shaft.

 Isolator is an off load device, used to control, protect and isolate the
equipment in case of over current or short circuit conditions.
 De energize the equipment to allow the maintenance in order to clear the
faults.

2.4.4.3 Switch gear components

 Combination of electrical components like MCCB, MCB, contactor, Over

load relay, fuses, are used to control, protect and isolate electrical
equipment.
 The main function of these switch gear components are to protect the
electrical equipments in case of any faults occurred in the system.
2.4.4.4 MCCB(Molded case circuit breaker)
 Provide protection to connected devices against both over load and
short circuit
 The molded case provides an insulating breaker components.
 The position of the handle indicates the status of the contact whether
they are closed, open or tripped, so faulted circuit can be identified
easily.
 MCCBs are inbuite of are extinguisher and trip unit.

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2.4.4.5 Trip unit

In the event of a short circuit or prolonged over current, the trip unit trip
the operating mechanismnwith the help of a temperature sensitive device and a
current sensitive electro magnetic device.

2.4.4.6 MCB(Miniature circuit breaker)

 MCBs are automatically operated electrical switch used to protect
an electrical circuit from damage caused by over current or over
load.
 Basic function is to interrupt a current flow after protective rellays
detect a fault.
 A fuse will operates once and then must bereplaced, but a curcuite
breaker can be reset to resume its normal operation
 MCBs can be operate only up to a rated current of 100A , whereas
MCCBs can be operated up to a rated current of 1000A
 During the condition of the short circuit , the electromagnet
attached with the MCB strikes the trip lever and causes an
immediate release of the contacts of the MCB
 POrovides protection to the electrical equipment as well as the user
who operates the electrical equipment.
2.4.4.7 Contactor
 A contactor is a control device, used to pass/switch current to an electric
equipment.
 Electric equipments can be protected from the over current damage
through the use of over load heaters which is associated with the contacts
of the contractor,
 If any over currents detector changes from NC to NO, thus protects the
equipment.

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2.4.4.8 Over load relay
 Protects the circuit from over load condition with the help of bimetallic
strip which the help of bimetllic strip which is attached with the trip
mechanism.
 The rating of an overload relay is always expressed in a range.
2.4.4.9 Phase sequence relay
 Continuously monitors all the phases and detects phase sequence ,
phase unbalance, phase failure and loss in three phase systems.
 If phase sequence relay detects any fault in the system , if
automatically trip the system and protects the electrical equipment.

2.4.4.10 Indicators

 Indicator lamps show the current status of the equipments.

 Red : R PHASE OFF
 Yellow: Y PHASE,TRIP
 Blue: B PHASE
 Green: ON

2.4.4.11 Push buttons

 Push button are used to on/off the electrical equipment.

 Green:Start
 Red: Stop
 Black: Emergency stop

2.4.4.12 Matering devices

 Control panel are also equipped with matering devices like

voltameter, ammeter and hour run meters in order to find voltage,
current and speec of the equipment respectively.

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2.5 Interns Performance On OJT-1
The performance of interns during an internship can vary greatly
depending on a number of factors, including the level of support provided by the
internship supervisor and the organization.

In general, interns are expected to be motivated and eager to learn, and to

take initiative in their work. They should be able to follow instructions and work
independently as well as part of a team. Communication skills are also important ,
as interns will need to be able to communicate effectively with their supervisor,
colleagues, and any clients or stakeholders they interact with.

To maximize their performance , interns should take advantage of the

learning opportunities provided by the internship , such as attending training
sessions, seeking feedback from their supervisor, and asking questions to clarify
their tasks. They should also be willing to take on additional responsibilities and
go above and beyond what is ecpected of them.

Ultimately , the success of an internship depends on both the intern and the
organization. If both parties are committed to making the internship a positive and
productive expenses , the intern is likely to perform well and gain valuable skills
and experience that will benefit their future career.

As an AI language model, I don’t have access to specific information on

individual interns performance in a particular manufacturing company , however ,
I can provide some general advice on how interns can perdorm well in the
manufacturing of control panel for basement ventilation system.

Understand the manufacturing process: Interns should take the time to

learn and understand the manufacturing process for electrical control panel. This
includes the different stages involved in the process. The tools and equipment
used , and the safety measures that must be followed..

22
Time management: Manufacturing processes often involve tight deadlines and
schedules. Interns should learn to manage their time effectively and prioritize
tasks and ensure that they meet the production targets.

Team work: Manufacturing processes often require collaboration and

teamwork.Internsshould be willing to work as part of a team,follow
instruction,and communicate effectively with their colleagues.

23
2.6 Extent Of Interns Ability To Add Value To The
Organization Through Internship
Internship is a significant tool for intern’s development.Internship has
assumed great importance because of exceptional rate of change in the internal
and external organizational environment.The importance/benefits of trained
personnel towards organizational development are as follow-

 Trained intern’s do not require tight control and supervision as they are
well aware of how to perform a job.
 Trained intern’s can show higher performance by making optimum and
best utilization of the material,tools,equipments and other resources
provided to them.
 Trained intern’s minimize wastages of resourses in the organization and
work both efficiently and effectively.
 Training makes intern’s more commited to an organization as the
employees are provided with groeth,advancement and learning
opportunities.
 Training develops a line of proficient and skilled managers as it prepares
intern’s for complex and higher level tasks.
 Trained intern’s produce quality and quantity output.
 Trained intern’s enable the organization to face competation from rival
firms.
 Trained intern’s can respond and adapt to the changing technology well.

24
 CHAPTER 3
OJT-2 : 500 KVAR APFC PANEL WIRING
3.1 Introduction
Power factor is the ratio between the KW and the KVA drawn
by an electrical load where the KW is the actual load power and the KVA is
the apparent load power. It is a measure of how effectively the current is being
converted into useful work output and more particularly is a good indicator of
the effect of the load current on the efficiency of the supply system .In
industry most of the load is inductive in nature which results in lagging power
factor that is why there is loss and wastage of energy which results in high
power bills and heavy penalties from electricity boards. If the load is uneven it
is very difficult to maintain unity power factor. To overcome this difficulty
APFC panel is used which maintains unity power factor. So industries require
automatic power factor correction system. APFC or Automatic Power Factor
Control Panels are mainly used for the improvement of Power Factor. Power
Factor can be explained as ratio of active power to apparent power and it is a
key factor in measuring electrical consumption. Everyone knows that
how costly electricity has become in present time. Therefore it becomes
utmost important to cut down on electrical consumption for reducing
expenditure. APFC Panels come real handy in the achievement of this purpose
Use of these control panels becomes indispensable in those industries where
electrical installations are meant to supply to large electrical load. A dip in
Power Factor can attract operational losses and a penalty from electricity board,
responsible for electricity supply. APFC Panels can effectively and
automatically manage quickly changing and scattered loads along with the
retention of high Power Factor. We are renowned manufacturers of APFC
Panels symbolized with quality and reliability. These are available in different
current ratings to cater to distinct applications.

25
3.2 Objectives Of APFC Panel
 To conduct an electrical survey of the existing system in an opencast mine
to study the system configuration and load patterns, variation of power
factor during the mine operation hours and analyze power factor correction
facility, if any.
 Design a microcontroller based correction equipment to improve the
power factor of the system to desired value of greater than 0.95.
 Implement the system and monitor different electrical load models and
diverse load patterns to verify the result.
 To carry out economic analysis for power factor improvement.

3.3 Power Factor

The power factor (PF) of an AC electrical power system is the real
power flowing power is the capacity of the circuit for performing work in a
particular time. Apparent power is the product of the current and voltage of the
circuit. Due to energy stored in the load and returned to the source, or due to a
non-linear load that distorts the wave shape of the current drawn from the source,
the apparent power will be greater than the real power. It is schematically shown
in Figure 3.1.

Figure 3.1: Schematic Diagram for Power Factor

A load with a power factor of 1.0 result in the most efficient loading of
the supply and a load with a power factor of 0.5 will result in much higher losses
in the supply system. poor power factor can be the result of either a significant
26
phase difference between the voltage and current at the load terminals, or it can be
due to a high harmonic content or distorted/ discontinuous current waveform.
Poor load current phase angle is generally the result of an inductive load such as
an induction motor, power transformer, lighting ballasts, welder or induction
furnace. A poor power factor due to an inductive load can be improved by the
addition of power factor correction, but, a poor power factor due to a distorted
current waveform requires a change in equipment design or expensive harmonic
filters to gain an appreciable improvement. To have an efficient system the power
factor should be maintained near to 1. Utilities typically charge additional costs to
commercial customers who have a power factor below some limit, which is
typically 0.9 to 0.95.

27
3.3.1 Reasons of low power factor

 Mercury vapour lamps or lamps operated with chokes Power and

distribution Transformers.
 A complete unloaded transformer is very inductive and has a very low
power factor.
 Induction motors (Load and unload condition)
The inductive load equipment causing low power factor in the mines
includes Hoists, Shovel, Drill, Pump, Shearer, Conveyors etc.

3.4 Power Factor Correction

Power factor correction (PFC) is a technique of counteracting the
undesirable effects of electric loads that create a power factor (PF) that is less than
1. Power factor correction may be applied either by an electrical power
transmission utility to improve the stability and efficiency of the transmission
network or, correction may be installed by individual electrical customers to
reduce the costs charged to them by their electricity supplier.

Capacitive Power Factor correction is applied to circuits which

include induction motors as a means of reducing the inductive component of the
current and thereby reduce the losses in the supply. Capacitors connected at each
starter and controlled by each starter are known as "Static Power Factor
Correction".

3.4.1 Power factor improvement methods

There are classified into 3 types of Improvement methods

 Static Capacitor
 Synchronous Condenser
 Phase Advancer

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3.4.1.1 Static Capacitor:

 Static Capacitor are connected in parallel with those equipment’s which

work on lagging or low power factor
 These Static Capacitors provides leading current or delivers reactive
power which neutralize or compensate the lagging inductive current of the
system.
 Hence the power factor of the load circuit is improved with the help of
these Capacitors

Advantages:

 Losses are low in Static Capacitors hence more efficient.

 It require less maintenance.
 It is light weight so it can be easy to installed as compare to other

Disadvantages:

 Life of Static Capacitor is about 8-10 years.

 Once the Capacitors is damaged then we need to replace with new.
 Switching of Capacitors requires special breaker or arrangement.

3.4.1.2 Synchronous Condenser:

 A Synchronous motor running without any mechanical load and it’s field
winding in over exited mode then this type of Synchronous motor is called
Synchronous Condenser.
 At this condition this motor behaves like Capacitors.
 Synchronous Condensers are generally used at major supply substations or
large industries for power factor improvement methods
 When it is connected in parallel with the supply, it provides a leading
current or reactive power to the system which neutralizes the lagging
reactive component of the load.

29
Advantages:

 Life of synchronous Condensers is about 25 years

 The fault can be removed easily
 By varying the field excitation, we can control the required level of power
factor.

Disadvantages:

 It is expensive and maintenance costs is also high

 It produces noise
 It has no self starting torque so it required auxiliary device.

30
3.4.1.3 Phase Advance:

 Specially phase advancer is use to improve the power factor of induction

motors only
 The phase advancer is mounted on the same shaft as the induction motor
and it’s supply is connected in the rotor circuit of the motor through the
slip ring
 It provides exciting ampere turns to the rotor circuit at slip frequency, By
providing more ampere turns than required, hence improves the power
factor of the induction motor.

3.4.2 Benefits of power factor correction

 Reduction in KVA R Demand.
 Reduction in KVA Demand
 Reduction in Line Current
 Avoid Power Factor penalties
 Reduction in Transformer Rating
 Reduction in Line loss
 Reduction in Switchgear rating

3.5 Block Diagram Of APFC Panel

31
 Figure 3.2: Block Diagram of APFC Panel

3.5.1 Algorithm

Step-1: Take input for voltage and current in the circuit.

Step-2: Measure the phase lag and calculate the power factor.

Step-3: Differentiate from the targeted power factor and calculate the reactive
power requirement.

Step-4: Switch ON or OFF appropriate number of capacitors from capacitor bank

depending on reactive power supplied by each step.

Step-5: Again compare the power factor with targeted PF and continue from step-
1

3.5.2 Flowchart

32
 Figure 3.3:Flowchart of APFC Panel

3.6 Interns Ability To Apply The Skill And Technical

Knowledge On OJT-2

3.6.1 Overview of the APFC panel

Varying power demand on the supply system, Power factor also

varies as a function of the load requirements, Difficult to maintain a
consistent power factor by use of Fixed Compensation i.e. fixed capacitors,
Leading power factor under light load conditions (fixed compensation), No
manual intervention is needed, As under leading power factor under light
load conditions which results in over voltages, saturation of transformers,
mal-operation of diesel generating sets and penalties by electric supply
authorities, APFC prevent leading power factor also.

3.6.2 Designing of APFC panel steps

3.6.2.1 Calculation of capacitor size

33
 Figure 3.4: Calculation of capacitor size
3.6.2.2 GA diagram

Figure 3.5: APFC panel GA diagram

34
3.6.2.3 Metering circuit diagram

Figure 3.6: Metering circuit

35
3.6.2.4 Control circuit

Figure 3.7:Control circuit of APFC panel

36
3.6.2.5 APFC panel wiring images

Figure 3.8: APFC panel wiring images

37
3.6.3 500kvar APFC panel materials required list

SL.NO MA QTY
TERIALS

1 MCCB-800A(TP+N) 1NO
2 VOLTMETER 1NO
3 AMMETER 1NO
4 PHASE INDICATION LAMP 3NO
5 AUTO/OFF/MANUAL SWITCH 1NO
6 CURRENT TRANSFORMER 3NO
APFC RELAY(16 STAGE MICROPROCESSOR 1NO
7 BASED RELAY)

8 COOLING FAN(8INCH WITH HOOD) 3NO

9 CTTB 8NO
10 INDICATION LAMP As
Required
11 PUSHBUTTONS As Required

12 CAPACITOR DUTY CONTACTOR As Required

13 TIMER 1NO
14 FOR 10 KVAr @415V 2NO
14.1 MCB(25A TP 10KA,C-CURVE) 2NO
14.2 CAPACITOR DUTY CONTACTOR(5KVAr,TP) 2NO
14.3 10 KVAr CAPACITOR BANK 2NO

15 FOR 15 KVAr @415V 2NO

15.1 MCB(32A TP 10KA,C-CURVE) 2NO
15.2 CAPACITOR DUTY CONTACTOR(10KVAr,TP) 2NO
15.3 15 KVAr CAPACITOR BANK 2NO

16 FOR 25 KVAr @415V 6NO

16.1 MCB(63A TP 10KA,C-CURVE) 6NO
16.2 CAPACITOR DUTY CONTACTOR(25KVAr,TP) 6NO
16.3 25 KVAr CAPACITOR BANK 6NO

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 17 FOR 50 KVAr @415V 6NO
17.1 MCCB (125A TP 16KA,C-CURVE) 6NO
17.2 CAPACITOR DUTY CONTACTOR(50KVAr,TP) 6NO
17.3 50 KVAr CAPACITOR BANK 6NO

18 CABLES
1.5,4,6,16,35 Sq.mm PVC.FLEXIBLE ,Cu cable As Required

Table 3.1: 500kvar APFC panel materials required list

3.6.4 Tools used list

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 SL. No TOOLS
1 LUG Crimpping Tool
2 WIRE Cutter
3 Ferrule Typing Machine
4 Connector
5 Cutting Machine
6 Truff Cutter
7 Tester
8 Drilling Machine
9 Busbar Cutting machine
10 Measurement Tape

Table 3.2: Tools used list

3.6.5 Maintenance of APFC panel

 Check the current of capacitor and cable connection.

 Tighten the connections if termination is found loose. Clean
the area around the capacitor.
 Check the capacitance of capacitor once in three month.
 Disconnect capacitor drawing over 30% current than rated.
Contact us on help line for further action.
 Disconnect the capacitor having leakage problem and replace.

1
Relay not functioning Check the connection of CT

40
 2 Relay not energizing Check that the supply is
available at the terminal A, L2
& L3.

3 Check that the supply is as per

Relay indicating wrong requirement of capacitor rating.
power factor

4 Capacitor drawing low current Check that the supply is as per

requirement of capacitor rating

5 Capacitor drawing high current It may be due to harmonics report to

L&T Immediately
6 Sleeves of bus bar melting Check for loose connection, tighten
all
the bus bar and switchgear
terminals.
7 Switchgear problem
Report to L&T office

8 Abnormal heating of enclosure Report to Meher / L&T immediately

with correct location of heating area
and measured temperature if
possible. Check and clean and filter.
Check for the proper function of the
fans if provided.

9 Check whether the current drawn

Abnormal heating of by the capacitor is in excess of its
capacitor terminals rated value. Check for loose
terminal connection and re- solder /
tighten as applicable.

3.6.6 Trouble shooting of APFC panel

SL. No Problem Suggested Remedy

3.7 Interns Role And Responsibilities On OJT-2

41
 Interpreting assembly drawings and instruction.
 Understanding the clients requirements and specifications.
 Developing prototype if needed.
 Cutting and drill the Din rails
 Developing layouts and design plans.
 Preparing a sequences of operations to accomplished the task.
 Follow the safety precaution by using electric machinery
 Coordinating with the designing team.
 Maintaining the electric tools and equipments such as Drill machine,
Cutting machine, Blade, Bits Etc.
 Preparing a reports of the work completed.
 Keep your work area safe from hazards
 Ability to work for long periods of time if required.
 Excellent knowledge and experience in Panel designing.
 Ability to operate different types of tools.
 Understand and read the electrical drawings
 Ability to solve complex problems efficiently.
 Employ should report to work on time.
 Read the work place safety and health poster at the job site.
 Make sure employees have and use safety tools and equipments.
 Maintaining discipline at the working area.
 Attentions should be during works.
 Knowledge about panel wiring

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3.7.1 Skill development

 Increase efficiency of trainees.

 Self confidence.
 Increased motivation levels.
 Group efforts.
 Develops future leaders.
 Improve the individuals level of awareness.
 Opportunity to identify weakness.
 Improve moral and job satisfaction
 Alignment with organizational goals.
 Expand knowledge sharing

3.8 How They Can Create Value To The Organization

Through Internship
An internship program offers benefits to the organization, to the students
and to your community. Students look for internship opportunities as a way to
develop their skills and apply the knowledge they are learning in their
coursework. Students also benefit from the "real world" experience they can gain,
which gives them professional experiences to remain competitive when seeking
employment after graduation. 

 Interns can complete project work and increase the organization’s

productivity. Interns are highly motivated to produce quality work.  They
want to make a meaningful contribution, and continue to develop their
professional skills.
 Begin training your organization’s future workforce.
 Interns can gain valuable experience working with installation teams and
helping to assemble the components
 Interns can also work with installation and maintenance teams to learn
about the practical aspects of panel installation and maintenance.
 Interns can assist in creating content for the organization's website, social
media platforms, and marketing materials.

43
 Interns can support the organization's technical team in helping, installing.
 Interns can assist with testing and evaluation of installing panel. They can
conduct performance tests, analyze data, and provide feedback to the
organization on how to improve their skills.

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 CHAPTER – 04
USE CASE - 01 AND USE CASE - 02

4.1 Use Case Questions Of Control Panel Manufacturing And

Designing

Q1. What are the quality standards for electrical control panels?

NEC
The National Electrical Code (NEC), or NFPA 70, is a widely-accepted
standard for the safe installation of electrical equipment and wiring. The NEC is
adopted by state or by region to standardize the enforcement of safe electrical
practices.
Article 409 covers industrial control panels and applies to panels
intended for general use at 600 volts or less, in ordinary locations. Industrial
Control Panel Design Regulatory Standards Article 409 specifies that industrial
control panels must be evaluated and marked for their Short Circuit Current
Rating (SCCR), which is established by evaluating each feeder individually as
well as all branch circuits.
The smallest kA value is used as the kA value for the panel as a whole.
The kA value must be greater than the kA value of the incoming source in order
for the panel to be installed.
NFPA 79
NFPA (National Fire Protection Association) 79 is a section of the NEC
that pertains to wiring standards for industrial machinery. The scope of this
standard encompasses electrical and electronic elements of all machinery that
operates at or below 600V, including injection molding machines, assembly
machinery, machine tools, and material handling machinery, among others, as
well as inspection and testing machinery.

45
 NFPA 79 provides safeguards for industrial machinery aimed at
protecting operators, equipment, facilities, and work-in-progress from fire and
electrical hazards.
Portions of NFPA 79 relate to control circuits and control functions,
operator interface and control devices, location, mounting, and enclosures for
control equipment, and other topics relevant to the design of industrial control
panels.

UL 508 and UL 60947-4-1

 UL 508 was one of the most important standards to recognize for many
years, but this standard has recently been phased out and has been replaced
by UL 60947-4-1.
Before January 26, 2012: listed control panels were evaluated to
standard UL 60947-4. If a customer specifically requested that a panel be
evaluated to UL-508, this was permissible.
From January 26, 2012 through January 26, 2017: new industrial control panels
were evaluated to UL 60947-4. However, evaluating revisions to existing control
panels to UL-508 was permissible if requested.
After January 27, 2017: all listed industrial control panels are required to meet UL
60947-4-1 specifications.

Q2. What is control panel manufacturing?

Control Panel and cabinet design is fundamental in allowing the user to interact
efficiently with the industrial process right on the front line. Industrial control
panels consist of power circuits or control circuits (or both) which provide signals
that direct the performance of machinery or equipment. Industrial control panels
don’t include the main power, nor do they include the controlled equipment;
rather, the panel is mounted on a back panel (or subpanel) or in an enclosure,
depending on the application.

46
Q3. What is the design of an electrical control panel?
 2D & 3D CAD Drawings
 Pre - Projects Planning
 Value Added Services
 Utility Service coordination
 Electrical Audits
 Installation and Maintenance
 Project Management
 Medium and Low Voltage Procurement
 Main Switchgear Installations
 Bus Duct & Riser Installation
 Power & Control Wiring for Processing & Manufacturing Equipment
 Power for Commercial and Industrial Project.

Q4. What are the different types of electrical control panels?

AUTOMATION PANELS
 PLC Based Panels
 RIO Panels
 Control Desk
 HMI Panels
 DDC Panels
 VFD Panels
 SCADA Systems
 DCS RIO Panels
 Process Automation Panels
 Customized Automation Panels

47
INDUSTRIAL AND BUILDING
 VCB Panels
 PCC Panels
 Main LT Panels
 MCC Panels
 PDB Based Panel
 SDB Panels
 Intelligent MCC Panels
 Intelligent PCC Panels
 Intelligent DB, PDB, Panels
 Metering Panels
 DG Sync Panels
 APFC Panels Metering Panels
 AMF Panels
 Busducts

HVAC PANELS
 Chiller Control Panels
 Damper Control Panels
 AHU Control Panels
 VFD Panels
 Heater Bank Control Panels
 Compressor, Fan, AHU Control Panels
 Auto Sequence Panels, Remote PB Panels
 Dehumidifier Control Panels

48
4.2 Use Case Questions Of APFC Panel.

Q1. What are the features & uses of APFC Panel?

FEATURES
 Maintains high constant Power Factor
 High efficiency
 In-built independent fuses
 Protection from excess power in the system.
 Prevents leading Power Factor in low load conditions
 Obviously marked buttons and indicators
 Minimizes harmonic current
 Easy to use
 Corrosion-resistant
 Long lasting
 Electrical insulation
 Protects electrical equipments

USES
 Wind mills
 Monitoring current harmonics
 Process Controllers
 Micro Processors
 LT & HT Factories
 Electrical Installations
 Line Voltage analysis

49
Q2. Guide line for installation of capacitor?

 Use suitable size lugs for connecting the cable to the terminals of
capacitor..
 Ensure that there is no loose connection: As loose connection may lead to
failure of capacitor / insulation break down of cable.
 Use proper tools for connection / tightening.
 Ensure that the capacitor is mounted vertically.
 The earthing of capacitor should be done before charging.
 The applied voltage should not exceed more than 10%. Refer technical
specification of capacitor.
 The capacitor should be provided with the short circuit protection device
Do not connect higher rating protection device.

Q3. What is the use of capacitor in APFC Panel?

 The capacitor should be provided with suitable designed inrush current
limiting inductor coils or special capacitor duty contactors. Annexure d
point no d-7.1 of IS 13340-1993
 Once the capacitor is switched off it should not be switched on again
within 60 seconds so that the capacitor is completely discharged. The
switching time in the relay provided in the APFC panel should be set for
60 seconds for individual steps to discharge. Clause No-7.1 of IS 13340-
1993
 If the capacitor is switched manually or if you are switching capacitors
connected in parallel with each other then “ON” delay timer (60sec)
should be provided and in case of parallel operation once again point No 1
should be taken care. Clause No-7.1 of IS 13340-1993
 The capacitor mounted in the panel should have min gap of 25-30 mm
between the capacitor and 50 mm around the capacitor to the panel
enclosure.
 In case of banking a min gap of 25mm between the phase to phase and
19mm between the phase to earth should be maintained. Ensure that the

50
 banking bus bar is rated for 1.8 times rated current of bank.
 The panel should have provision for cross ventilation, the louver / fan can
be provided in the care Annexure d point No d-3.1 IS 13340-1993
 For use of reactor and filter in the panel fan should be provided for
cooling.
 Short circuit protection device (HRC fuse / MCCB) should not exceed 1.8
x rated current of capacitor.
 In case of detuned filter banks MCCB is recommended for short circuit
protection.

51
 RESUME
Darshan D.
E-mail : dd2aa2j@gmail.com

+91 6360971874

Career Objective:
To be associated with a professional organization for a challenging and
responsible opportunity to utilize and further build upon my strengths and
skills.

Education Qualification:
Course Institution Board/ Year of Percentag
University Passing e/ CGPA
Diploma in VISSJ.GOVT. Government of 2023 82.00%
Electrical Polytechnic. New Karnataka (Pursuing in
and Town Department of 6th semester)
Electronics Bhadravathi Technical
Education.
S.S.L.C National High School, K.S.E.E. Board 2020 87.62%
B R Project

Personal Details:
 Father Name : Dasu K.
 Nationality : Indian
 Sex : Male
 Marital Status :Single
 Languages Known : English, Kannada and Hindi
 Date of Birth : 15-08-2004
 Hobbies :Reading, Listening music, Tracking

52
 Workshops/ Internship / Conferences attended:

 Participated in the 15 days Internship on “Basic of PLC”

held on 20 September, 2022 Organized by GTTC in
Machenahalli Industrial Area Shivamogga.
 Attend the 15 hours Online Course of Internet of Things
(IOT) Organized by Infosys Springboard.
 Attend the 3 months Internship on “Electrical
Contracting and Panel Manufacturing” held on 28
February, 2023 Organized by GSSPL in Bangalore

SOFTWARE SKILL SET

 MS-OFFICE
 Auto CAD
 ESTIMATION
 BASIC OF MATLAB
 BASIC OF LOGO SOFT COMFORT

CERTIFICATION
 Basic of PLC
 IOT
 Communication Skills
 Electrical Control Panel Designing

Permanent Address Current Address

Shanthinagara Shanthinagara
B.R. Project Post, Bhadravathi Tq.
B.R. Project Post Bhadravathi Tq.
Mob. 6360971874
Mob. 6360971874
Email:dd2aa2j@gmail.com Email: dd2aa2j @gmail.com

53
 PHOTO GALLERY

I. Electrical Panel Designing

Figure i: Panel Designing Steps

54
II. Testing of Panels

Figure ii : Testing of Panels

55
III. Door Wiring of Panels

Figure iii : Door Wiring of Panels

56
VI. Panel Wiring

Figure iv : Panel Wiring

57
V. Internship Students in Factory

Figure v : Group Photo

58