Practicum Report

On

“Maintenance and Manufacturing of

Switchgear Equipment and PFI Plant”

Md. Imtiyaj Ahamed

ID: 16205013

Program: BSEEE

Department of Electrical and Electronic Engineering

IUBAT-International University of Business Agriculture and Technology

i
 Practicum Report
On

“Maintenance and Manufacturing of

Switchgear Equipment and PFI Plant”

Md. Imtiayaj Ahamed

ID: 16205013

Program: BSEEE

________________ __________________ __________________

Turiqul Islam Tonmoy Dr. Bishwajit Saha Dr. Md. Shariful Islam
Supervisor Coordinator Chairperson

Department of Electrical and Electronic Engineering

IUBAT-International University of Business Agriculture and Technology

ii
 Letter of Transmittal

1st May, 2020

Dr. Bishwajit Saha

Professor & Coordinator

IUBAT-International University of Business Agriculture and Technology

4, Embankment Drive Road, Uttara Model Town Sector 10, Uttara, Dhaka-1230,
Bangladesh.

Subject: Letter of Transmittal of the Practicum Report.

Sir,

With due respect, I would like to approach you that it is a great opportunity as well as
immense pleasure for me to submit this report titled “ Maintenance and Manufacturing
of Switchgear Equipment and PFI Plant” for the fulfillment of our practicum course.

It was undoubtedly a splendid opportunity for me to work on this project to actualize

my theoretical knowledge. Now I am looking forward for your kind appraisal
regarding this practicum report.

I hope you find this report satisfactory.

Sincerely Yours,

_____________

Md. Imtiayaj Ahamed

ID: 16205013

Program: BSEEE

iii
 Certificate

iv
 Student’s Declaration

This is to inform that the practicum report on “Maintenance and Manufacturing of

Switchgear Equipment and PFI Plant” has only been prepared as a partial
fulfillment of the Bachelor of Science in Electrical and Electronic Engineering
(BSEEE) Program. It has not been prepared for any other purpose reward or
presentation.

____________

Md. Imtiayaj Ahamed

ID# 16205013

Program: BSEEE

v
 Executive Summary

Powermann Bangladesh Limited (PBL) is the pioneer manufacturer of electrical

goods in Bangladesh. The company has always been contributing towards the
advancement and development of the engineering sector in Bangladesh by introducing
a range of quality electrical equipments, home appliances and by producing hundreds
of engineers, skilled workers and technicians through its apprenticeship schemes and
training programs. Recently, I have done my internship in Powermann Bangladesh
Limited. The internship basically revolved around the switchgear components,
manufacturing, panels design, and testing. The system, the style of working, and the
commitment of the employees in PBL is really exemplary. In this report, I have given
a brief view of what I have seen and learnt during my internship. I have organized the
practicum report according to the contents of my internship. This report will give its
reader knowledge about the PBL and power division specially about the switchgear
unit. I have all my practical efforts in the form of this report that is an asset for my
future career.

vi
 Acknowledgements

All praise is to the Supreme Being; creator and ruler of the universe, Almighty Allah,
whose mercy keeps us alive and to pursue my education in Bachelor of Science in
Electrical and Electronic Engineering and to complete the Practicum Report which is
entitled as “Maintenance and Manufacturing of Switchgear Equipment and PFI
Plant”. In the process of conducting this practicum report, I would like to express my
gratitude and respect to some generous persons for their immense help and enormous
cooperation.

At first, I would like to express my hearty reverence, profound adoration and devout
respect to our honorable Vice Chancellor, Professor Dr Abdur Rab for giving me
chance to study in this university.

I am really pleased and proud to express my deepest sense of gratitude, since

appreciation and profound respect to our reverend faculties, especially, Dr. Bishwajit
Saha, Professor and Coordinator, Department of Electrical and Electronic
Engineering, IUBAT for his scholastic guidance, constructive criticism and unwiring
efforts to execute this report. I also say my warmest thanks to Dr. Md Azizul Huq,
Professor, Department of Electrical and Electronic Engineering of IUBAT who had
taken my major course Switchgear and Protective Relays.

I will never forget my instructor, Turiqul Islam Tonmoy for his cooperative attitude
for my report and also for giving me courage to do this work.

Finally, I also feel it is important to acknowledge and thanks to Engineer S. M.

Mehedi Hasan, General Manager, who permitted to complete my internship program
at Powermann Bangladesh Limited.

vii
 Contents

Certificate..................................................................................................................................iv

Student’s Declaration.................................................................................................................v

Executive Summary..................................................................................................................vi

Acknowledgements..................................................................................................................vii

Chapter 1....................................................................................................................................1

Introduction................................................................................................................................1

1.1 Introduction....................................................................................................................3
1.2 Background.....................................................................................................................4
1.3 Learning Objectives.........................................................................................................5
1.4 Company Overview.........................................................................................................5
1.5. Management Philosophy..............................................................................................6

1.5.1 Quality Policy............................................................................................................6

1.5.2 Corporate Philosophy................................................................................................7

1.5.3 Mission.......................................................................................................................7

1.5.5 Spirits.........................................................................................................................7

1.5.6 Products Handling......................................................................................................7

Chapter-2....................................................................................................................................9

Switchgear Equipment...............................................................................................................9

2.1 Switchgear....................................................................................................................10
Essential Features of Switchgear........................................................................................11
Types of Switchgear:............................................................................................................12

2.1.1 Classification of Switchgear.......................................................................................12

2.1.2 Low Voltage (LV) Switchgear................................................................................13

2.1.3 Medium Voltage (MV) Switchgear.........................................................................13

2.1.4 High Voltage (HV) Switchgear...............................................................................14

2.2 Switchgear Equipment..................................................................................................14

viii
 2.2.1 Switch......................................................................................................................15

2.2.2. Air Break Switch................................................................................................15

2.2.3. Isolator or Disconnecting Switch.......................................................................16
2.2.4. Oil Switch..........................................................................................................16
2.2.5 Fuse..........................................................................................................................16

2.2.6 Circuit Breakers.......................................................................................................17

A circuit breaker is a switching device that interrupts the abnormal or fault

current. It is a mechanical device that disturbs the flow of high magnitude (fault)
current and in additions performs the function of a switch. The circuit breaker is
mainly designed for closing or opening of an electrical circuit, thus protects the
electrical system from damage.........................................................................................17

Types of Circuit Breaker........................................................................................................18

2.2.7 Relays.......................................................................................................................19

The relay is the device that open or closes the contacts to cause the operation of
the other electric control. It detects the intolerable or undesirable condition with
an assigned area and gives the commands to the circuit breaker to disconnect the
affected area. Thus protects the system from damage.It can be divided into three
parts viz.............................................................................................................................19

2.2.8 Bus bar:....................................................................................................................20

Chapter: 3.................................................................................................................................22

3.1 HT Panel........................................................................................................................23
3.1.1 Basic Functions of HT Panel...................................................................................24

3.2 Classification of HT Panel..............................................................................................25

3.2.3 Potential Transformer....................................................................................28
Applications of Potential Transformer......................................................................................29

Applications of Potential Transformer are-................................................................................29

3.2.4 Voltmeter.......................................................................................................29
Advantages of HRC Fuse.................................................................................................31

Disadvantages of H.R.C Fuse...........................................................................................32

3.2.8 Limit Switch....................................................................................................33

3.2.9 Current Transformer......................................................................................34

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 3.2.11 Heat Sensor..................................................................................................35
3.2.12 Heater..........................................................................................................36
3.3 Vacuum Circuit Breaker (VCB) Panel.................................................................36
Figure 3.3: Vacuum Circuit Breaker (VCB) Panel.....................................................36
Advantages of VCB......................................................................................................37
Disadvantages of VCB.................................................................................................37
3.3.1. Main Part of VCB Panel.....................................................................................37
3.3.2. Vacuum Circuit Breaker (VCB).......................................................................38
3.3.3 Potential Transformer (PT).............................................................................38
3.3.4 Current Transformer (CT)...............................................................................39
3.3.5 Relay..............................................................................................................40
3.3.6 Bus-Bar...........................................................................................................40
3.4 LT Switchgear................................................................................................................41
3.4.1 Major Components of LT Switchgear Panel...........................................................42

3.4.3 Miniature Circuit Breaker (MCB)........................................................................43

3.4.5 Molded Case Circuit Breaker (MCCB).................................................................44
MCCB operates...................................................................................................................44
Overload Protection..........................................................................................................44

Electrical Fault Protection against short circuit currents..................................................45

Electrical Switch for disconnection..................................................................................45

3.4.6 Air circuit breaker (ACB).....................................................................................45

3.4.7 Fuse....................................................................................................................46
3.4.8 Multimeter.........................................................................................................47
Figure 3.4.8: Multimeter.............................................................................................47
3.4.9 LED.....................................................................................................................48
3.4.10 Current Transformer........................................................................................49
Chapter: 4.................................................................................................................................50

4.1 Power Factor Improvement (PFI) Plant.........................................................................51

4.1.1 Major Components of PFI Panel.............................................................................53

4.1.2 Capacitor Bank........................................................................................................53

4.1.3 Magnetic Contactor..................................................................................................54

Chapter: 5.................................................................................................................................57

Conclusion................................................................................................................................57

x
5.1 Recommendation..........................................................................................................58
5.2 Conclusion....................................................................................................................58
Reference............................................................................................................................58

xi
 List of Figures
Figure 2.2.8: Bus-bar....................................................................................................11
Figure 3.1: HT Panel..................................................................................................
Figure 3.2.1:LBS Panel................................................................................................13
Figure 3.2.3: Potential Transformer.............................................................................14
Figure 3.2.4: Voltmeter................................................................................................15
Figure 3.2.5: HRC Fuse...............................................................................................16
Figure 3.2.6: Bushing & Bus-Bar................................................................................17
Figure 3.2.8: Limit Switch...........................................................................................17
Figure 3.2.9: Current Transformer...............................................................................18
Figure 3.2.11: Heat Sensor...........................................................................................19
Figure 3.2.12: Heater....................................................................................................19
Figure 3.3: VCB Panel.................................................................................................20
Figure 3.3.2: Vacuum Circuit Breaker (VCB).............................................................21
Figure 3.3.3: Potential Transformer (PT).....................................................................22
Figure 3.3.4: Current Transformer (CT)......................................................................22
Figure 3.3.5: Relay.......................................................................................................23
Figure 3.3.6: Bus-Bar...................................................................................................23
Figure 3.4: LT Switchgear Panel.................................................................................24
Figure 3.4.2: Bus-bar....................................................................................................25
Figure 3.4.3: Miniature Circuit Breaker (MCB)..........................................................26
Figure 3.4.5: Molded Case Circuit Breaker (MCCB)..................................................27
Figure 3.4.6: Air circuit breaker(ACB)........................................................................27
Figure 3.4.7: Fuse.........................................................................................................28
Figure 3.4.8: Multimeter..............................................................................................28
Figure 3.4.9: LED........................................................................................................29
Figure 3.4.10: Current Transformer.............................................................................30
Figure 4.1: Power Factor Improvement (PFI) Panel....................................................31
Figure 4.1.2: Capacitor Bank.......................................................................................33
Figure 4.1.3: Magnetic Contactor................................................................................34
Figure 4.1.4: APFC Relay............................................................................................35
Figure 4.1.5: HRC Fuse...............................................................................................36
Figure 4.1.6: Control Fuse...........................................................................................36
 Chapter 1

Introduction

1 1
2 2
1.1 Introduction
In an electric power system, switchgear is composed of electrical disconnect
switches, fuses or circuit breakers used to control, protect and isolate 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 directly linked to the
reliability of the electricity supply.

The earliest central power stations used simple open knife switches, mounted on
insulating panels of marble or asbestos. Power levels and voltages rapidly escalated,
making opening manually operated switches too dangerous for anything other
than isolation of a de-energized circuit. Oil-filled switchgear equipment allow arc
energy to be contained and safely controlled. By the early 20th century, a switchgear
line-up would be a metal-enclosed structure with electrically operated switching
elements, using oil circuit breakers. Today, oil-filled equipment has largely been
replaced by air-blast, vacuum, or SF6 equipment, allowing large currents and power
levels to be safely controlled by automatic equipment.

High-voltage switchgear was invented at the end of the 19th century for
operating motors and other electric machines.[1] The technology has been improved
over time and can now be used with voltages up to 1,100 kV.[2]

Typically, switchgear in substations are located on both the high- and low-voltage

sides of large power transformers. The switchgear on the low-voltage side of the
transformers may be located in a building, with medium-voltage circuit breakers for
distribution circuits, along with metering, control, and protection equipment. For
industrial applications, a transformer and switchgear line-up may be combined in one
housing, called a unitized substation (USS). According to the latest research by
visiongain, the worldwide switchgear market is expected to achieve $152.5 billion by
2029 at a CAGR of 5.9%. Growing investment in renewable energy and enhanced
demand for safe and secure electrical distribution systems are expected to generate the
increase.[3]

3
1.2 Background
Switchgear plays a vital role in the overall power distribution and consumption
system. Generally speaking, switchboards are the term one uses to designate low
voltage switching whereas switchgear connotes HT usage scenarios. The term
“switch” brings to mind a device that makes or breaks an electrical contact. In the
industrial and LT/HT context switchgear is more complex as switchgear dealers will
tell you. Switchgear is typically classified into categories like low voltage/low tension
switchgear, medium voltage switchgear and high voltage-high tension switchgear. A
typical system has the power components and control system with a variety of safety
and monitoring features. One of the best names in the switchgear business is Larsen &
Toubro. L&T Switchgears are the first choice of industries and power distribution
companies for their total reliability and faultless performance.

The term switchgear refers to a collection of various devices such as:

 Fuses

 Circuit breakers

 Isolators

 Relays, coils

 Disconnect switches

 Current transformers for sensing and monitoring as well as protection

All these components of switchgear may be contained in a suitable metal cabinet that
is usually earthed for safety reasons. However, HT distribution systems with large
circuit breakers and switchgear are usually housed in a building.

Apart from switching on and off electricity supply, switchgear must also control
power to the load, detect overload conditions and have features to automatically trip,
such as circuit breakers. This protects the equipment that consumes power and it also
keeps cables and switchgear protected. Switchgear may also have multiple sources of
supply and automatically switch load in case one source fails.

Switchgear and protection may be automated or manually operated though the former

is preferable since the automated system detects overloads and short-circuits and
immediately disconnects supply thus preventing a major hazard.

4
1.3 Learning Objectives
The learning objectives of the switchgear are-

 Introduction to switchgear
 Switchgear equipment
 Fuse, Circuit breakers, relays
 Bus-Bar
 Current transformer
 Potential transformer
 HT panels
 LT panels
 Power factor improvement panel

1.4 Company Overview

Powermann Bangladesh Limited started manufacturing of Distribution Transformer in
the year 2001 with a strong team of Transformer and Switchgear background.
Powermann offer customers complete substation and transformer is one its key item
on which the company has achieved a mile-stone on quality. Due to this the company
has earned a good faith from more than thousands of Private entrepreneur and
Government policy maker. Eventually the company started manufacturing of Power
Transformer and keeping good example by making up to 5MVA, 33KV system. Now
this manufacturing setup is ready to make up to 10/14MVA. The factory is one of the
largest independent manufacturing unit for manufacturing of high-quality, custom
solutions for power systems for big or small Industrial units, Commercial complexes
and Government utilities. Powermann factory is now one of the resourceful
engineering setups on 100,000 SFT shaded area with good quality manpower,
machineries and test laboratories. Powermann is developing its continuous
improvement in design and using the modern production technique with latest
technology and experience.

Powermann LTD established date and its slogan is as follows-

Year of Incorporation: 27th November, 2000

Corporate Slogan: Engineered to excel

5
1.5. Management Philosophy
The management philosophy of the Powermann Bangladesh Limited is “to produce
High-quality engineering that create a possible impression and satisfy customer by
Applying the local technologies we have developed throughout our history with the
Aim of contribution to a more affluent way of life”. Taking advantage of our
engineering expertise thus acquired, Powermann will continue to create impact and
offer satisfaction in local markets; earn the unwavering confidence and respect of
customers; enter in to global markets and ensure long-term growth and continuously
enhance corporate value well into the future. In order to enhance corporate value in
this way, we consider it essential that the company cultivate a youthful corporate
climate and willingness to new challenge and implements; adopt an equitable
personnel evaluation system that encourages employees to demonstrate their abilities
as much as possible and gain a thorough understanding of global environment
protection and compliance.

1.5.1 Quality Policy

As a consistent guarantee of the highest management quality, Powermann has
achieved ISO 9001:2000 certified in the year 2004. This certification is done by the
united resister of system Ltd., UK and marked UKAS Quality Management. Regular
internal and external Quality audits ensure full and continuous conformity with these
international standards.

The same United Register is also maintaining the regular audits and also achieved
ISO 9001-2008 for operating as ‘QUALITITY MANAGEMENT SYSTEMS’ form
GLOBAL, Australia. Powermann is also started working environment issues.

Total Quality Management followed all over the company. In all the area of factory
and offices entire work-culture is maintaining 5S (SEIRI, SEITON, SEISO,
SEIKETSU, SHITSUKE) and QC Circle is bringing the talent floor/field level to top
level.

Quality Control is carried on the in every step of production, from incoming raw
material to finished product to ensure quality of each product in the line of

6
international standard. The company is committed and focused on continuous
improvement on quality management system with zero defects in the end product.

1.5.2 Corporate Philosophy

Powermann Bangladesh LTD corporate philosophies are as follows -
 Pursuit of safety: None of our components will be dispatched without test.
 Pursuit of quality: We aim at world class quality in our product.
 Pursuit of low cost: We keep our prices down by market design reasonably
Good through R&D.

1.5.3 Mission
To be top in the power sector with the very positive power of people.

1.5.4 Vision

To create quality power products with world class accuracy and to provide round the
clock services to the clients in a very competitive price.

1.5.5 Spirits
The spirits of Powermann ltd are as follows-
 Working hard and aiming high.
 Serving and devoting to through customers.
 Working with unity and solidarity.
 Co-operation in a friendly way with colleagues and clients.
 Developing through reforms.
 Seeking truth from facts.
 Depending upon fairness and honor.
 Always abiding by laws and regulations.
 Making contribution to the nation by developing industry.
 Raise voice of customers.

7
1.5.6 Products Handling
They are stirring the products very carefully. When they handle the products, they
maintain some criteria and that are as follows -
 Manufacture, Supply, Installation of –
 Distribution transformer up to 4000KVA, 33KV
 Power transformer up to 10/14 MVA, 33KV
 MV & LV switchgear up to 33KV
 PFI plant, Distribution board
 All kind of metering panel & units
 Industrial control & Automation panel
 Motor control center
 Industrial voltage stabilizer (IVS)
 11KV Load Break Switch & Vacuum Circuit Breaker

8
 Chapter-2

Switchgear Equipment

9
2.1 Switchgear
The apparatus used for controlling, regulating and switching on or off the electrical
circuit in the electrical power system is known as switchgear.The switches,
fuses, circuit breaker, isolator, relays, current and potential transformer, indicating
instrument, lightning arresters and control panels are examples of the switchgear
devices.The switchgear system is directly linked to the supply system. It is placed in
both the high and low voltage side of the power transformer. It is used for de-
energizing the equipment for testing and maintenance and for clearing the fault.

When the fault occurs in the power system, heavy current flow through equipment
due to which the equipment get damaged, and the service also get interrupted. So to
protect the lines, generators, transformers and other electrical equipment from damage
automatic protective devices or switchgear devices are required.

The automatic protective switchgear mainly consists of the relay and circuit breaker.
When the fault occurs in any section of the system, the relay of that section comes
into operation and close the trip circuit of the breaker which disconnects the faulty
section. The healthy section continues supplying loads as usual, and thus there is no
damage to equipment and no complete interruption of supply.[5]

Switchgear has two types of components:

 Power-conducting components: These conduct or interrupt the power flow;

such as switches, circuit breakers, fuses, isolators, relays, lightning arrestors,
and so on.
 Control systems: These monitor, control and protect the power-
conducting components; such as control panels, current transformers,
potential transformers, associated circuitry, and so on.

Although the circuit breaker is the main component, it is the combination

of equipment within the switchgear enclosure that allows high voltage currents to be
interrupted.

10
Essential Features of Switchgear

The essential features of switchgear are :

 Complete Reliability
 Absolutely certain discrimination
 Quick operation
 Provision for manual control

1. Complete reliability

With the continued trend of interconnection and the increasing capacity of generating
stations, the need for reliable switchgear has become of paramount importance.

This is not surprising because it is added to the power system to improve reliability.
When a fault occurs on any part of the power system, they must operate to isolate the
faulty section from the remainder circuit.

2. Absolutely certain discrimination

When a fault occurs on any section of the power system, the switchgear must be able
to discriminate between the faulty section and the healthy section.

It should isolate the faulty section from the system without affecting the healthy
section. This will ensure continuity of supply.

3. Quick operation

When a fault occurs on any part of the power system, the switchgear must operate
quickly so that no damage is done to generators, transformers and other equipment by
the short-circuit currents.

If the fault is not cleared quickly, it is likely to spread into healthy parts, thus
endangering complete shut down of the system

11
4. Provision for manual control

Switchgear must have provision for manual control. In case the electrical (or
electronics) control fails, the necessary operation can be carried out through manual
control.

Types of Switchgear:
The switchgear is mainly classified into two types are-

1. Outdoor type

2. Indoor type

Outdoor type

For voltage above 66kV, the output switchgear is used. Because for the high voltage,
the building work will unnecessarily increase the installation cost owing to large
spacing between the conductor and large size of insulators.

Indoor type

Below the 66kv there is no difficulty in providing the building work for the
switchgear at a reasonable cost. The indoor type switchgear is of metal clad type and
is compact. Because of the compactness, the safety clearance for operation is also
reduced and thus reduced the area required.

2.1.1 Classification of Switchgear

Switchgear can be classified on the basis of voltage level in to the following,

 Low voltage switchgear (LV).
 Medium voltage switchgear (MV).
 High voltage switchgear (HV).

12
 2.1.2 Low Voltage (LV) Switchgear

Low-voltage switchgear is typically used name for metal-enclosed or metal-clad low

voltage power circuit breaker switchgear rated for 600V alternating current (AC) and
below. The metal-enclosed switchgear is completely enclosed on all sides and top with
metal sheets and has stationary primary power circuit switching or interrupting
elements, or both, with buses and connections. The metal-clad low-voltage switchgear
has removable circuit breakers which are housed in individual earthed metal
compartments.[2]

low-voltage switchgear carries the following ratings:

 Maximum voltage (Typically up to 635V)

 Power frequency (Typically 50Hz and 60Hz)
 Insulation level (Typically 2.2kV)
 Continuous current (Typically up to 10,000A)
 Short-circuit withstand current (Typically up to 200kA)
 Short-time withstand current (Typically up to 100kA, 30 cycles)

2.1.3 Medium Voltage (MV) Switchgear

From 3 kV to 36 kV switchgear system is categorized as medium voltage switchgear or

MV switchgear. Medium-voltage switchgear provide centralized control and protection
of medium-voltage power equipment and circuit in industrial, commercial, and utility
installation involving generators, motors, feeder circuits, and transmission and
distributions lines.[5]

Medium voltage switchgear should be able to perform the following functions:

 Short circuit current interruption

 Switching capacitive currents
 Switching the inductive currents
 Performing normal ON/OFF switching

13
  Other special applications

Ultimately, all the functions mentioned must be undertaken with a high degree of
reliability and safety.

2.1.4 High Voltage (HV) Switchgear

A high voltage Switchgear is a type of switchgear that has special features that
enables it to handle power systems of higher than 36kV.

The types of High Voltage Switchgears that are available are:

Air Insulated High Voltage Switchgear: This type uses air as the main insulating
material for conductive components in the switchgear.

Gas Insulated High Voltage switchgear: It is a type of high voltage switchgear that
uses superior dielectric gas (SF6) as the main insulating material for conductive
elements within the switchgear.

The function of High Voltage Switchgear includes:

 It has devices that help in the distribution and controlling of electric

current.

 Connection and disconnection of electric induction motors.

 Performing quantitative and qualitative power supply measurements.

 It has devices that offer protection against overloading and short

circuits.

 This helps in ensuring the safety and functionality of the electrical

equipment.

14
2.2 Switchgear Equipment
Switchgear covers a wide range of equipment concerned with switching and
interrupting currents under both normal and abnormal conditions. It includes switches,
fuses, circuit breakers, relays and other equipment. A brief account of these devices is
given below.[5]

1. Switch

 Air break switch

 Isolator or disconnecting switch
 Oil switch

2. Fuse

3. Circuit breaker

4. Relay

5. Bus bar

2.2.1 Switch
a switch is an electrical component that can disconnect or connect the conducting path
in an electrical circuit, interrupting the electric current or diverting it from one
conductor to another. The most common type of switch is an electromechanical
device consisting of one or more sets of movable electrical contacts connected to
external circuits. Switches are made in many different configurations; they may have
multiple sets of contacts controlled by the same knob or actuator, and the contacts
may operate simultaneously, sequentially, or alternately. A switch may be operated
manually, for example, a light switch or a keyboard button, or may function as
a sensing element to sense the position of a machine part, liquid level, pressure, or
temperature, such as a thermostat.

15
2.2.2. Air Break Switch
The switch whose contacts open in the air and quenching of an arc achieves by
compressed air, such type of switch is called an air break switch.The air acts as a
dielectric medium for the air-break switch. It is more effective and reliable as
compared to another switch.The air break switch is operated manually when their
handle is placed on a ground level.

The air break switches install in outdoor and mainly use for switching and
isolation. The air break switch is mostly installed in the distribution network as a
switching point. It interrupts the small excitation current of a transmission line or the
capacitive charging current. The maximum voltage for the switches is up to 35kV.
The air-break switches are classified into two types. They are Single-Pole Air-Break
Switch and the Gang Operated Air-Break Switch.

Single pole air-break switch uses for the opening of only one conductor. And for the
opening of more than one conductor at a time gang operated air break switch is used.
The switches which opened together are called the gang switches. The air-break
switches are installed in two ways, i.e., either horizontally or vertically and it is placed
on the pole top or in pad mounted metal enclosure.[1]

2.2.3. Isolator or Disconnecting Switch

An Isolator or Disconnector is an isolating or disconnecting switch which disconnects

or isolate the whole or a specific part of the circuit. It is used where we need to
disconnect a portion of the circuit in case of faults from the main power supply for
maintenance purposes. Isolator blocks the DC current and allow the AC current to
flow through it (same like a capacitor). HV and MV Switch Disconnectors and
Isolators are used in high voltage equipment such as transformer, substation etc.
Switch Disconnectors are used in MV installation nowadays. HV/MV Switch
Disconnectors And Isolators are used where power installations exceeding 1 kV AC.
[10]

16
2.2.4. Oil Switch
An oil switch is a high-voltage switch whose contacts are opened and closed in oil.
The switch is actually immersed in an oil bath and contained in a steel tank. The
reason for placing high- voltage switches in oil is that the oil will break the circuit
when the switch is opened. With high voltages. a separation of the switch contacts
does not always break the current flow because an electric arc forms between the
contacts. If the contacts are opened in oil. the oil will quench the arc.

2.2.5 Fuse

A fuse is an electrical safety device (a component) that removes electrical current

from an electrical circuit when the current in the electrical circuit is too high.When
the too much current is produced due to the heavy flow of current in the electrical
circuit, the fuse gets soften and it opens the circuit. The extreme flow of current may
direct to the collapse of the wire and prevents the supply.The 'fuse rating' is the
electrical current that will blow the fuse, for instance 3 amps, 10 amps or 13 amps.

A fuse is a current sensitive piece of wire – when the fuse is working the wire is not
broken, when the fuse has ‘blown’ the wire breaks.

17
2.2.6 Circuit Breakers
A circuit breaker is a switching device that interrupts the abnormal or fault current. It
is a mechanical device that disturbs the flow of high magnitude (fault) current and in
additions performs the function of a switch. The circuit breaker is mainly designed for
closing or opening of an electrical circuit, thus protects the electrical system from
damage.

Circuit breaker essentially consists of fixed and moving contacts. These contacts are
touching each other and carrying the current under normal conditions when the circuit
is closed. When the circuit breaker is closed, the current carrying contacts, called the
electrodes, engaged each other under the pressure of a spring.

During the normal operating condition, the arms of the circuit breaker can be opened
or closed for a switching and maintenance of the system. To open the circuit breaker,
only a pressure is required to be applied to a trigger.

Whenever a fault occurs on any part of the system, the trip coil of the breaker gets
energized and the moving contacts are getting apart from each other by some
mechanism, thus opening the circuit.[11]

Types of Circuit Breaker

Circuit breakers are mainly classified on the basis of rated voltages. Circuit breakers
below rated voltage of 1000V are known as the low voltage circuit breakers and
above 1000V are called the high voltage circuit breakers.

The most general way of the classification of the circuit breaker is on the basis of the
medium of arc extinction. Such types of circuit breakers are as follows :-

1. Oil Circuit Breaker

 Bulk Oil Circuit Breaker

18
  Minimum Oil Circuit Breaker

2. Minimum Circuit Breaker

3. Air Blast Circuit Breaker
4. Sulphur Hexafluoride Circuit Breaker
5. Vacuum Circuit Breaker
6. Air Break Circuit Breaker

2.2.7 Relays
The relay is the device that open or closes the contacts to cause the operation of the other
electric control. It detects the intolerable or undesirable condition with an assigned area and
gives the commands to the circuit breaker to disconnect the affected area. Thus protects the
system from damage.It can be divided into three parts viz.

(i) The primary winding of a current transformer (C.T.) which is connected in

series with the circuit to be protected. The primary winding often consists of
the main conductor itself.
(ii) The second circuit is the secondary winding of C.T. connected to the relay
operating coil.
(iii) The third circuit is the tripping circuit which consists of a source of supply,
trip coil of circuit breaker and the relay stationary contacts.

Under normal load conditions, the e.m.f. of the secondary winding of C.T. is small
and the current flowing in the relay operating coil is insufficient to close the relay
contacts. This keeps the trip coil of the circuit breaker unexercised. Consequently, the
contacts of the circuit breaker remain closed and it carries the normal load current.

19
When a fault occurs, a large current flow through the primary of C.T. This increases
the secondary e.m.f. and hence the current through the relay operating coil. The relay
contacts are closed and the trip coil of the circuit breaker is energized to open the
contacts of the circuit breaker.[3]

2.2.8 Bus bar:

Figure 2.2.8: Bus-Bar

An electrical bus bar is defined as a conductor or a group of conductor used for

collecting electric power from the incoming feeders and distributes them to the
outgoing feeders. In other words, it is a type of electrical junction in which all the
incoming and outgoing electrical current meets. Thus, the electrical bus bar collects
the electric power at one location.

The bus bar system consists the isolator and the circuit breaker. On the occurrence of
a fault, the circuit breaker is tripped off and the faulty section of the busbar is easily
disconnected from the circuit.

The electrical bus bar is available in rectangular, cross-sectional, round and many
other shapes. The rectangular bus bar is mostly used in the power system. The copper
and aluminium are used for the manufacturing of the electrical bus bar.

20
The most common of the bus-bars are 40×4mm (160 mm2); 40×5 mm (200 mm2) ;
50×6 mm (300mm2) ; 60×8 mm (480 mm2) ; 80×8 (640 mm2) and 100×10 mm
(1000 mm2).

The various types of busbar arrangement are used in the power system. The selection
of the bus bar is depended on the different factor likes reliability, flexibility, cost etc.
The following are the electrical considerations governing the selection of any one
particular arrangement.

21
 Chapter: 3
HT and LT Part

22
HT Switchgear

The High Tension switchgear are used switching for system voltage of mid level
(6.305KV – 33KV) as well as high level voltage (33KV-230KV). For lower capacity
of sub-station it is used as LBS but for higher capacity of sub-station it used as VCB,
MOCB, SF6-CB these are facilitating both manual or remote operation.

3.1 HT Panel

HT panel is a metal enclosure fitted with HT Circuit Breakers, relays &metering  that
is used to receive 11KV/33KV supply (from one or more source) & distribute the
power through its outgoing feeders. Outgoing feeder may be one or more it depends
on the load of the building.

HT panel is installedin substations of Commercial complexes, residential colonies,

factories, schools, hospitals etc. to receive & distribute HT supply[8]. I have given
the picture of HT as show in figure

23
 Figure 3.1: HT Panel

3.1.1 Basic Functions of HT Panel

The basic functions of HT panel are as follows -
 To make & break HT supply (or switch on or switch off supply)
 To receive & distribute HT supply
 To provide protection against faults (Over Load , Short Circuit, Earth Fault
or any Electrical Fault)
 To provide metering to monitor various parameters

CONSTRUCTION

 Metal enclosed and air ventilated with sheet steel of SWG-14.

Properly welded steel structure

 Low voltage compartment on the top of the cubicle

 Long creapaze distance

 Circuit breaker mounted fixed or withdrawable truck

 Single bus-bar

 Fully factory assembled

24
  Power coating point

 Cable entrance usually provided in the bottom of the cubicles

 Top entry can also be provided upon request

Main Features

 To measure electrical power consumption, Energy Meter is installed in it.

 Meters are installed to measure electrical Voltage, Current, frequency, power
factor etc.
 Short circuit protection, over load protection, earth fault protection relays can
be installed in it against protection from faults.
 HT circuit breakers can be switched ON & OFF either manually or
electrically.
 Space heater is provided in HT panel to avoid moisture inside the panel.
 To measure Incoming Supply voltage, 11KV is converted into 110V through
PT (Potential Transformer). And 110V voltmeter is used for voltage
measuring purpose.

3.2 Classification of HT Panel

According to the transformer rating, HT panel are three types,

 LBS (Load Break Switch) type: Its need for (250kVA-500kVA) transformer

 VCB (Vacuum Circuit Breaker) type: Its need for (630kVA-above)

transformer

 OCB (Oil Circuit Breaker) type: Its need for (1250kVA-above) transformer

25
3.2.1 Load Break Switch(LBS)Pannel

Fig 3.2.1: LSB Panel

A load break switch ie. on load break switch (LBS) which is a capable small fault
current breaking switchgear.This protective equipment is used at 11 kV sub-station.
The main Load Break Switch

(LBS) mechanism is available for 630A & the over current protection scheme is done
through

HRC fuse. The panel includes 3 numbers of CT (Current Transformer) & 2/3 numbers
of PT

(Potential Transformer) for measuring system current & voltage respectively & 3
numbers of

HRC (High Rupturing Capacity) Fuses for protection of overload. The scheme is so
designed

26
that if fault occurs in any phase it will isolate the whole three phases from the system
instantly.

The panel also includes 3 numbers of Ampere meters & one number of Voltmeter
with selector

switch for monitoring system current & voltage. The standard panel size is
900x900x1800 mm &

weight is around 450 kg [6]. I have given the picture of load break switch as shown in
Figure 5.2.

Load break switch can deenergize circuits under normal operating conditions. It
should

be capable of making and breaking normal load currents. The load break switch must
be able to

perform making operations under short-circuit conditions, since this is a possible

operation

condition when energising a medium voltage circuit under short-circuit conditions.

At the bottom of the figure we could see the three CTs. Those are connected in series

with the 3 load break switches. The HRC fuses are put with these LBSs. There are
PTs as well

on the head of the fuses to assist the voltmeters to take the reading. Load break
switches are not

used that much. These are basically used instead of VCBs sometimes. It depends on
the client’s need.

Advantage of LBS

It is very economical compare to the VCB panel. Hence many clients order it to
reduce the cost.

27
Disadvantage of LBS

There are lots of disadvantages involved in it. Here fuses need to be replaced after
once it

is damaged. It should have to be done in presence of an engineer. Its manual operation

is not

very user friendly like VCB as well.

3.2.2 Main Parts of LBS Panel

Parts of HT (LBS) are:

1. Potential Transformer

2. Voltmeter

3. HRC Fuse

4. Bushing & Bus bar

5. LBS On/Off Switch

6. Limit Switch

7. Current Transformer

8. Ammeter

9. Heat Sensor

10. Heater

3.2.3 Potential Transformer

Potential transformers are a type of instrument transformer and these transformers are
used to measure the voltages of high transmission lines or any electrical circuits.
Potential transformers are used to step down the high voltages. Their primary coils are
connected to high voltage side and their secondary coils are connected to various

28
instruments such as voltmeters, wattmeters, power factor meters etc. These potential
transformers provide 100v to 150 v on their secondary winding so that the measuring
instruments are connected easily according to their input voltages and these are
sufficient to operate in this range of voltage. Measuring instruments such as
wattmeters, voltmeters which are connected to the secondary winding of potential
transformer provide low readings according to their input voltage. The exact readings
are obtained from these measuring instruments by dividing the transformation ratio.
So that we can easily obtain the exact amount of voltage with the help of potential
transformer[10]. I have given the picture of PT as show in figure

Figure 3.2.2: Potential Transformer

Applications of Potential Transformer

Applications of Potential Transformer are-

1. It is used for a metering purpose.

2. For the protection of the feeders.
3. For protecting the impedance of the generators.
4. For synchronizing the generators and feeders.

3.2.4 Voltmeter
I have given the picture of voltage measuring instrument as show in figure, that
instrument measures voltages of either direct or alternating electric current on a scale
usually graduated in volts, millivolts (0.001 volt), or kilovolts (1,000 volts). The

29
typical commercial or laboratory standard voltmeter in use today is likely to employ
an electromechanical mechanism in which current flowing through turns of wire is
translated into a reading of voltage. Other types of voltmeters include the electrostatic
voltmeter, which uses electrostatic forces and, thus, is the only voltmeter to measure
voltage directly rather than by the effect of current. The potentiometer operates by
comparing the voltage to be measured with known voltage; it is used to measure very
low voltages. The electronic voltmeter, which has largely replaced the vacuum-tube
voltmeter, uses amplification or rectification (or both) to measure either alternating-
or direct-current voltages. The current needed to actuate the meter movement is not
taken from the circuit being measured; hence, this type of instrument does not
introduce errors of circuit loading.The instruments just described provide readings
in analogue form, by moving a pointer that indicates voltage on a scale. Digital
voltmeters give readings as numerical displays. They also provide outputs that can be
transmitted over distance, can activate printers or typewriters, and can feed into
computers. Digital voltmeters generally have a higher order of accuracy than analogue
instruments.[

Figure 3.2.3: Voltmeter

30
3.2.5 HRC Fuse
This type of fuse contains a fuse wire in it, which carries the short circuit current
safely for a given time period. During this period, if fault is removed, then it does not
blow off otherwise it will melt and remove the circuit from electrical supply hence,
the circuit remains safe.
The common material, which is used to make an HRC fuse is glass, but this is not
always the case.
HRC Fuse consists of highly heat resistant material (such as ceramic) body having
metal-end caps, which is welded by silver current carrying element. The fuse body
internal space is completely packed with a filling powder.When a fuse blows out the
tripping device during the fault condition, it will cause the circuit breaker to operate.
The body of fuse is made of ceramic material with a metallic cap fixed at each end.
They are connected by series of silver fuse elements. There is a plunger at one end,
which hits the tripping mechanism of circuit breaker under fault conditions, which
leads it to operate the circuit. The plunger is connected through a fusible link and a
tungsten wire to the other end of the cap.As fault occurs, the first element to be blown
out is silver fuse and current is transferred to tungsten wire. The travel of the plunger
is set such a way that is not ejected from the fuse body during fault conditions[4].I
have given the picture of HRC fuse as show in figure

Figure 3.2.5: HRC Fuse

Advantages of HRC Fuse

 It clears high as well as low fault currents.

 Do not deteriorate with age.

 Having high-speed operation.

 Provides reliable discrimination.

31
  Require no maintenance.

 Cheaper than other circuit interrupting devices with same rating.

 Permit consistent performance

 Fusing operation is fast without Noise and Smoke

Disadvantages of H.R.C Fuse

 After each operation, they have to be replaced.

 Heat being produced by the arc may affect the associated switches.

3.2.6 Bushing & Bus bar

Bushing is an insulated device that allows an electrical conductor to pass safely
through a grounded conducting barrier such as the case of a transformer or circuit
breaker. Bushings are typically made from porcelain; though other insulating
materials are also possible, generally porcelain is used.
In electric power distribution, a busbar (also bus bar) is a metallic strip or bar,
typically housed inside switchgear, panel boards, and busway enclosures for local
high current power distribution. They are also used to connect high voltage equipment
at electrical switchyards, and low voltage equipment in battery banks. They are
generally uninsulated, and have sufficient stiffness to be supported in air by insulated
pillars. These features allow sufficient cooling of the conductors, and the ability to tap
in at various points without creating a new joint.

Figure 3.2.4: Bushing & Bus-Bar

32
3.2.7 LBS ON/OFF Switch
We use a manual on-off switch to control the LSB panel. We control the line through
this switch.

3.2.8 Limit Switch

Limit switches are used to automatically detect or sense the presence of an object or
to monitor and indicate whether the movement limits of that object have been
exceeded. The original use for limit switches, as implied by their name, was to define
the limit or endpoint over which an object could travel before being stopped. It was at
this point that the switch was engaged to control the limit of travel. It may be operated
by a by a cam or lever fitted with the machine to stop, reverse or slow down the
operation of the device used for a particular application. The electrical ratings of the
limit switches must be carefully matched to the loads to be controlled. The limit
switch contacts should not be overloaded. Contacts must be selected according to the
proper load, that is, the proper current and voltage, according to the manufacturer’s
specifications. I have given the picture of HRC fuse as show in figure

Figure 3.2.8: Limit Switch

33
3.2.9 Current Transformer

Current transformer is an instrument transformer, used along with measuring or

protective devices, in which the secondary current is proportional to the primary
current (under normal conditions of operation) and differs from it by an angle that is
approximately zero.The current transformer basically consists of an iron core upon
which primary and secondary windings are wound. The primary winding of the
transformer is connected in series with the load and carries the actual current flowing
to the load, while the secondary winding is connected to a measuring device or a
relay. The number of secondary turns is proportional to the current flowing through
the primary; i.e., the larger the magnitude of current flowing through the primary,
more the number of secondary turns.

The ratio of primary current to the secondary current is known as the current
transformation ratio of the CT. Usually the current transformation ratio of the CT is
high. Normally the secondary ratings are of the order 5 A, 1 A, 0.1 A, whereas the
primary ratings vary from 10 A to 3000 A or more.

The CT handles much less power. Rated burden can be defined as the product of
current and voltage at the secondary side of the CT. It is measured in volt ampere
(VA)[7]. I have given the picture of CT as show in figure

Figure 3.2.9: Current Transformer

Functions of CT

Current transformers perform the following functions:

 Current transformers supply the protective relays with currents of magnitude

34
 proportional to those of power circuit but sufficiently reduced in magnitude.

 The measuring devices cannot be directly connected to the high magnitude

supplies. Hence current transformers are used to supply those devices with
currents of magnitude proportional to those of power

 A current transformer also isolates the measuring instruments from high voltage
circuits.

3.2.10 Ammeter
The meter uses for measuring the current is known as the ammeter. The current is the
flow of electrons whose unit is ampere. Hence the instrument which measures the
flows of current in ampere is known as ampere meter or ammeter.The ideal ammeter
has zero internal resistance. But practically the ammeter has small internal resistance.
The measuring range of the ammeter depends on the value of resistance. In LBS
ammeter connected with C.T by Series Connection.

3.2.11 Heat Sensor

Heat sensor is basically a sensor which will auto sense the heating of the handset and
with the help of the processor inside the device it will work smartly to cool down the
device and stop the excess heat on the device.

Figure 3.2.11: Heat Sensor

Advantage of Heat Sensor

The advantages of heat Sensor include:

1. Low installation cost

35
 2. Low life cycle cost
3. Stability
4. Operation under varied environmental conditions

3.2.12 Heater
Switchgear space heaters are designed minimize moisture inside electrical and
mechanical equipment enclosures and also maintain temperature.

3.3 Vacuum Circuit Breaker (VCB) Panel

11/33KV Vacuum Circuit Breaker Indoor Panel that is used for the protection of
transformer. These panels are precisely designed following strict industry parameters
and are appreciated for features like superior quality and cost effectiveness. The
Vacuum Circuit Breaker offered exceptional performance during the restriction of
electrical short circuit. VCB Panels are also available from original equipment
manufacturers (OEM) to incorporate installations or for use in repair, retrofit and
upgrade projects.In case of current rating 630A to 1250 A Vacuum circuit breaker is
used in HT panel. I have given the picture of VCB panel as show in figure

Figure 3.3: Vacuum Circuit Breaker (VCB) Panel

36
Advantages of VCB

Vacuum offers the utmost insulating strength. So it has extreme superior arc
quenching properties than any other medium.

 The vacuum circuit breaker has a long life.

 Unlike Oil Circuit Breaker (OCB) or air blast Circuit Breaker (ABCB),
the explosion of VCB is avoided. This enhances the safety of the
operating personnel.
 No fire hazard
 The vacuum CB is fast in operation so ideal for fault clearing. VCB is
suitable for repeated operation.
 Vacuum circuit breakers are almost maintenance free.
 No exhaust of gas to the atmosphere and Noiseless operation.

Disadvantages of VCB
 The main disadvantage of VCB is that it is uneconomical at voltages
exceeding 38 kVolts.
 The cost of the breaker becomes excessive at higher voltages. This is due
to the fact that at high voltages (above 38 kV) more than two numbers of
the circuit breaker are required to be connected in series.
 Moreover, the VCBs production is uneconomical if produced in small
quantities.

3.3.1. Main Part of VCB Panel

The main part of VCB panel are-
 Vacuum Circuit Breaker (VCB)
 Potential Transformer (PT)
 Current Transformer (CT)
 Relay
 Bus-Bar

37
3.3.2. Vacuum Circuit Breaker (VCB)
A breaker which used vacuum as an arc extinction medium is called a vacuum circuit
breaker. In this circuit breaker, the fixed and moving contact is enclosed in a
permanently sealed vacuum interrupter. The arc is extinct as the contacts are
separated in high vacuum. It is mainly used for medium voltage ranging from 11 KV
to 33 KV.Vacuum circuit breaker has a high insulating medium for arc extinction as
compared to the other circuit breaker. I have given the picture of VCB board as show
in figure 

Figure 3.5: Vacuum Circuit Breaker (VCB)

The vacuum circuit breaker has mainly two phenomenal properties.

1. High insulating strength: In comparison to various other insulating media used in

circuit breaker vacuum is a superior dielectric medium. It is better than all other
media except air and SF6, which are employed at high pressure.
2. When an arc is opened by moving apart the contacts in a vacuum, an interruption
occurs at the first current zero. With the arc interruption, their dielectric strength
increases up to a rate of thousands time as compared to other breakers.

3.3.3 Potential Transformer (PT)

Potential transformer is a voltage step-down transformer which reduces the voltage of

a high voltage circuit to a lower level for the purpose of measurement. These are
connected across or parallel to the line which is to be monitored.The primary winding

38
consists of a large number of turns which is connected across the high voltage side or
the line in which measurements have to be taken or to be protected. The secondary
winding has lesser number of turns which is connected to the voltmeters, or potential
coils of wattmeter and energy meters, relays and other control devices. These can be
single phase or three phase potential transformers.Since the voltmeters and potential
coils of other meters have high impedance, a small current flows through the
secondary of PT. Therefore, PT behaves as an ordinary two winding transformer
operating on no load. Due to this low load (or burden) on the PT, the VA ratings of
PTs are low and in the range of 50 to 200 VA.

Similar to the normal transformer, the transformation ratio is specified as,

V1/V2 = N1/N2

Figure 3.6: Potential Transformer (PT)

3.3.4 Current Transformer (CT)

Current Transformers are the type of "Instrument Transformer" used to measure the
value of current through the conductors and used as the protective device. It works on
the theory of mutual induction same as the other transformer. In this an alternating
current is produce on its secondary winding which is proportional to the current being
measured in its primary. Current Transformer reduce the high voltage current to a
much lower value that it can be measure by Ammeter.

39
 Figure 3.7: Current Transformer (CT)

3.3.5 Relay
Relays control one electrical circuit by opening and closing contacts in another
circuit. Relays are generally used to switch smaller currents in a control circuit and do
not usually control power consuming devices.Protective relays can prevent equipment
damage by detecting electrical abnormalities, including overcurrent, undercurrent,
overloads and reverse currents. In addition, relays are also widely used to switch
starting coils, heating elements, pilot lights and audible alarms.

Figure 3.8: Relay

3.3.6 Bus-Bar
Busbar is a metallic strip or bar, typically housed inside switchgear, panel boards,
and busway enclosures for local high current power distribution. They are also used to
connect high voltage equipment at electrical switchyards, and low voltage equipment
in battery banks. They are generally uninsulated, and have sufficient stiffness to be
supported in air by insulated pillars. These features allow sufficient cooling of the
conductors, and the ability to tap in at various points without creating a new joint. I
have given the picture of Bus-bar as show in figure

40
 Figure 3.9: Bus-Bar

3.4 LT Switchgear
In industries and domestic’s applications, various electrical and electronics devices
and distribution boards such panels use. Low tension panels receive power from a
generator or transformer and distributor. It is also a kind of electrical distribution
board.Most of the LT Panels (Low Terminal) are making and designed for work with
low electricity consumption. It is also more cost-effective.

To provide luxury living for the human, in the continuity of the electrical supply for
the load appliances like fans, motors, etc. Low Terminal (LT) Panel plays a critical
role in industry and factory[9].

Figure 3.4: LT Switchgear

41
Construction

 14/16 SWG steel fabricated

 Powder coated rust proof
 Dust and vermin proof
 Dead Front cover construction
 Top and bottom cable entry

 Ample cabling space for easy connections

 Premium Design with glass door construction

Features

 Precise Design

 Cost effective

 Long Lifetime

 Safety

3.4.1 Major Components of LT Switchgear Panel

LT switchgear consists of the-
 Bus-bar
 Miniature circuit breaker (MCB)
 Molded case circuit breaker (MCCB)
 Air circuit breaker (ACB)
 Fuse
 Multimeter
 LED
 CT

42
3.4.2 Bus-bar

The bus bar air-protected and made of high caliber and high conductivity, high-
quality aluminum. The interconnection between bus bars and different parts will be
high conductivity aluminum. The bus bars will have uniform cross-segment all
through the length. The bus bars and interconnections will protect with heat
shrinkable PVC sleeve. And be shading cod is red, yellow, blue and dark to
distinguish the three stages and impartial of the LT board. I have given the picture of
Bus-bar as show in figure

Figure 3.4.2: Bus-Bar

3.4.3 Miniature Circuit Breaker (MCB)

A miniature circuit breaker (MCB) is a little circuit breaker that utilized for residential
and mechanical application. It has two function, for example,

Switching function : Switching function for the MCB permits the association/
separation of the LT panel.

Insurance function : Protection function of MCB must seclude the LT panel in case of
over current and over – burden and short circuits. I have given the picture of MCB as
show in figure

43
 Figure 3.4.3: Miniature Circuit Breaker (MCB)

3.4.5 Molded Case Circuit Breaker (MCCB)

A moulded case circuit breaker (MCCB) is a type of electrical protection device that
is used to protect the electrical circuit from excessive current, which can cause
overload or short circuit. With a current rating of up to 2500A, MCCBs can be used
for a wide range of voltages and frequencies with adjustable trip settings. These
breakers are used instead of miniature circuit breakers (MCBs) in large scale PV
systems for system isolation and protection purposes[12]. I have given the picture of
MCCB as show in figure

Figure 3.4.5: Molded Case Circuit Breaker (MCCB)

MCCB operates

The MCCB uses a temperature sensitive device (the thermal element) with a current
sensitive electromagnetic device (the magnetic element) to provide the trip
mechanism for protection and isolation purposes. This enables the MCCB to provide:

 Overload Protection,

44
  Electrical Fault Protection against short circuit currents, and

 Electrical Switch for disconnection.

 
Overload Protection

Overload protection is provided by the MCCB via the temperature sensitive

component. This component is essentially a bimetallic contact: a contact which
consists of two metals that expand at different rates when exposed to high
temperature. During the normal operating conditions, the bimetallic contact will allow
the electric current to flow through the MCCB. When the current exceeds the trip
value, the bimetallic contact will start to heat and bend away due to the different
thermal rate of heat expansion within the contact. Eventually, the contact will bend to
the point of physically pushing the trip bar and unlatching the contacts, causing the
circuit to be interrupted.

The thermal protection of the MCCB will typically have a time delay to allow a short
duration of overcurrent which is commonly seen in some device operations, such as
inrush currents seen when starting motors. This time delay allows the circuit to
continue to operate in these circumstances without tripping the MCCB.

 
Electrical Fault Protection against short circuit currents

MCCBs provides an instantaneous response to a short circuit fault, based on the

principle of electromagnetism. The MCCB contains a solenoid coil which generates a
small electromagnetic field when current passes through the MCCB. During normal
operation, the electromagnetic field generated by the solenoid coil is negligible.
However, when a short circuit fault occurs in the circuit, a large current begins to flow
through the solenoid and, as a result, a strong electromagnetic field is established
which attracts the trip bar and opens the contacts.

Electrical Switch for disconnection

45
In addition to tripping mechanisms, MCCBs can also be used as manual
disconnection switches in case of emergency or maintenance operations. An arc can
be created when the contact opens. To combat this, MCCBs have internal arc
dissipation mechanisms to quench the arc.

3.4.6 Air circuit breaker (ACB)

Air circuit breaker, which generally utilized for the assurance of electrical gear with a
stumbling loop. It associated with a hand- off intended to open the breaker naturally
under irregular conditions. For example, overflow, over- burdens, and so on. Air
circuit breaker gives the short out, Over- burden, earth flaw insurance of LT board.
The approaching section has incoming Bus-bar, Air circuit breaker (ACB). The sub-
approaching section comprises of monitoring gadgets. For example, LEDs, Meters
and Protection gadgets like Relays, Rotary Switches, Miniature Circuit Breaker
(MCB), and fuses. The feeder section has Feeder Bus-bars[12]. I have given the
picture of MCCB as show in figure

Figure 3.4.6: Air circuit breaker (ACB)

The main function of air circuit breaker is to:

 Open and close a 3 phase circuit, manually or automatically.

 Open the circuit automatically when a fault occurs. Faults can be of various types
– under or over voltage, under or over frequency, short circuit, reverse power,
earth fault etc.

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 The main feature of ACB is that it dampens or quenches the arcing during
overloading.

3.4.7 Fuse
fuse is an electrical safety device built around a conductive strip that is designed to
melt and separate in the event of excessive current. Fuses are always connected in
series with the component(s) to be protected from overcurrent, so that when the fuse
blows (opens) it will open the entire circuit and stop current through the
component(s). A fuse connected in one branch of a parallel circuit , of course, would
not affect current through any of the other branches.

Normally, the thin piece of fuse wire is contained within a safety sheath to minimize
hazards of arc blast if the wire burns open with violent force, as can happen in the
case of severe overcurrents. . In the case of small automotive fuses, the sheath is
transparent so that the fusible element can be visually inspected. I have given the
picture of MCCB as show in figure

Figure 3.4.7: Fuse

3.4.8 Multimeter
A multimeter, also known as a volt-ohm meter, is a handheld tester used to measure
electrical voltage, current (amperage), resistance, and other values. Multimeters come
in analog and digital versions and are useful for everything from simple tests, like
measuring battery voltage, to detecting faults and complex diagnostics. They are one
of the tools preferred by electricians for troubleshooting electrical problems on

47
motors, appliances, circuits, power supplies, and wiring systems. I have given the
picture of MCCB as show in figure

Figure 3.4.8: Multimeter

The function of Multimeters are-

Multimeters are capable of many different readings, depending on the model. Basic
testers measure voltage, amperage, and resistance and can be used to check
continuity, a simple test to verify a complete circuit. More advanced multimeters may
test for all of the following values:

 AC (alternating current) voltage and amperage

 DC (direct current) voltage and amperage
 Resistance (ohms)
 Capacity (farads)
 Conductance (siemens)
 Decibels
 Duty cycle 
 Frequency (Hz)
 Inductance (henrys)
 Temperature Celsius or Fahrenheit 

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Accessories or special sensors can be attached to some multimeters for additional
readings, such as:

 Light level
 Acidity
 Alkalinity
 Wind speed
 Relative humidity

3.4.9 LED

Light emitting diodes, commonly called LEDs, are real unsung heroes in the
electronics world. They do many different jobs in all kinds of devices. They form
numbers on digital clocks, transmit information from remote controls, light up
watches and tell you when your appliances are turned on. Collected together, they can
form images on a jumbo television screen or illuminate a traffic light.

Basically, LEDs are just tiny light bulbs that fit easily into an electrical circuit. But
unlike incandescent bulbs, they don't have filaments that burn out, they use less
electricity, and they don't get especially hot. They're illuminated solely by the
movement of electrons in a semiconductor material, and they last just as long as a
standard transistor. The life span of an LED surpasses the short life of an incandescent
bulb by thousands of hours. Because of these advantages, tiny LEDs are one of the
most popular technologies used to light LCD TVs.

3.4.10 Current Transformer

A current transformer (CT) is a type of transformer that is used to reduce or multiply
an alternating current (AC). It produces a current in its secondary which is
proportional to the current in its primary.

Current transformers, along with voltage or potential transformers, are instrument

transformers. Instrument transformers scale the large values of voltage or current to
small, standardized values that are easy to handle for measuring instruments
and protective relays. The instrument transformers isolate measurement or protection

49
circuits from the high voltage of the primary system. A current transformer provides a
secondary current that is accurately proportional to the current flowing in its primary.
The current transformer presents a negligible load to the primary circuit

Figure 3.4.10: Current Transformer

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 Chapter: 4
Power Factor Improvement (PFI) Plant

51
4.1 Power Factor Improvement (PFI) Plant

Power factor (PF) is the ratio of working power, measured in kilowatts (KW), to
apparent power, measured in kilovolt amperes (KVA. Apparent power, also known as
demand, is the measure of the amount of power used to run machinery and equipment
during a certain period. It is found by multiplying (KVA= V x A). The result is
expressed as KVA units. To calculate power factor, we need a power quality analyzer
of power analyzer that measures both working power (KW) and apparent power
(KVA), and to calculate the ratio of KW/KVA.

The power factor formulacan be expressed in other ways:

PF = (True power)/(Apparent power)

OR

PF = W/VA

Power Factor of the system is degraded due to inductive load of different industries
and big apartments. Powermann manufactures PFI (Power Factor Improvement) Plant
for improving the degraded Power Factor of the system. They have microprocessor
based PFC (Power Factor Correction) relay up to 24 stages. The Capacitors they use
are of different ratings (2.5, 5, 10, 20, 25, 50 KVAR…. etc) and corresponding
Magnetic Contactor for suitable stepping of the Capacitor bank. Sometimes they also
use detuned Reactor with the Capacitors for harmonic filtration of the system[13].I
have given the picture of PFI plant as show in figure

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 Figure 4.1: Power Factor Improvement (PFI) Plant

Advantages of Power factor improvement

Following are the merits and benefits of improved Power factor;

 Increase in efficiency of system and devices

 Low Voltage Drop

 Reduction in size of a conductor and cable which reduces cost of the Cooper

 An Increase in available power

 Line Losses (Copper Losses) I2R is reduced

 Appropriate Size of Electrical Machines (Transformer, Generators etc)

 Eliminate the penalty of low power factor from the Electric Supply Company

 Low kWh (Kilo Watt per hour)

 Saving in the power bill

 Better usage of power system, lines and generators etc

 Saving in energy as well as rating and the cost of the electrical devices and
equipment is reduced 

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Disadvantages of low power factor

Poor power factor means that we are using power inefficiently. This matters to
companies because it can result in:

 Heat damage to insulation and other circuit components

 Reduction in the amount of available useful power

 A required increase in conductor and equipment sizes

Finally, power factor increases the overall cost of a power distribution system because
the lower power factor requires a higher current to supply the loads

4.1.1 Major Components of PFI Panel

The major parts of PFI panel are-

 Capacitor Bank
 Magnetic Contactor
 APFC Relay
 HRC Fuse
 Control Fuse

4.1.2 Capacitor Bank

Improving power factor means reducing the phase difference between voltage and
current. Since the majority of loads are of inductive nature, they require some amount
of reactive power for them to function.A capacitor or bank of capacitors installed
parallel to the load provides this reactive power. They act as a source of local reactive
power, and thus less reactive power flows through the line.Capacitor banks reduce the

54
phase difference between the voltage and current. I have given the picture of
Capacitor bank as show in figure

Figure 4.1.2: Capacitor Bank

4.1.3 Magnetic Contactor

The magnetic contactor is an electrical switches (electrical controlled ) which is used

for switching electrical power circuit.It work on  basic electromagnetic principles.It is
not a protection device. It cannot used as a protection devices like circuit breaker
etc.The basic purpose of magnetic contactor in a circuit is switching or it is simply
called switching device. This switching of high power and frequent operation can
done with the help of magnetic contactor.With the help of  magnetic contactor we can
operate motor of any rating from a distance and control with the help of single
switches. Different range of magnetic contactor are available in the market. I have
given the picture of Capacitor bank as show in figure

Figure 4.1.3: Magnetic Contactor

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4.1.4 APFC Relay

There will be a main incoming circuit breaker from main bus which voltage needs to
be maintain APFC. APFC will monitor this voltage.

PFI panel will be individual capacitor banks with individual CB of different KVAR
based on your requirement.

APFC will monitor the bus voltage and whenever the voltage dips, first cap bank of
some KVAR will be switched on by sending close command from APFC. even after
switching on one bank and still voltage is still dip, next bank also will be switched on.
I have given the picture of APFC as show in figure

Figure 4.1.4: Automatic power factor correction(APFC)

4.1.5 HRC Fuse

HRC stands for High Rupturing Capacity. HRC Fuse has high rupturing capacity.
Because of its high current rupturing capacity, a special method for extinguishing arc
is required in the design of HRC Fuse.
Under normal operating conditions the current flowing through the Fuse element does
not provide enough energy to melt the element. The heat produced is absorbed by the
surrounding filling powder. If a large current flows the energy produced melts and
vaporizes the fuse element before the fault current reaches the peak. The chemical
reaction between the fuse element vapour and filling powder results into high
resistance material which helps in extinguishing the arc.

56
Under overload condition the fuse element will not blow off but if the condition exists
for prolonged period, the Eutectic Material will melt and break the fuse element. This
is the purpose of providing Eutectic Material in the HRC Fuse.I have given the picture
of HRC fuse as show in figure

Figure 4.1.5:HRC Fuse

4.1.6 Control Fuse

The fuse consists of a low resistance metal cable enclosed in a non-combustible

material. Whenever a short circuit, overcurrent or mismatched load connection
occurs, then the thin wire inside the fuse melts due to the heat generated by the heavy
current flowing through it. Therefore, it disconnects the power supply of the
connected system. In normal circuit operation, the fuse cable is only a low resistance
component and does not affect the normal operation of the system connected to the
power supply. I have given the picture of Control fuse as show in figure

Figure 4.1.6:HRC Fuse

57
Chapter: 5

Conclusion

58
5.1 Recommendation
The recommendation are as follows-
 The space of powermann all section is comparatively less.
 A lot of people work in small space with less space, so accidents are
more likely happen.
 There are less educated and experienced people in the switchgear
section.

5.2 Conclusion
I have been closely monitoring the switchgear related all equipments during
this time of internship. I have noticed how these work and how they are
maintained. I have also noticed the working and maintenance of the PFI
Planel. Finally, I would like to say this report is very helpful for installation
of switchgear equipment. I am really very thankful to my department to give
such an opportunity to learn these things practically.

Reference
[1]. IEEE Std C37.20.2-1999. IEEE Standard for Metal-Clad Switchgear.

[2]. British Pattern GB 20069 Improvements in Apparatus for Controlling the

Application or Use of Electric Currents of High Tension and Great Quantity in 1893.

[3]. V.K Mehta, Rohit Mehta, (Revised Edition), “PRINCIPLES OF POWER

SYATEM”.2015

[4]. Mooz, Dietrich, and Rolf Dirks. "High voltage, high rupture capacity fuse."
U.SPatent No. 4,617,544. 14 Oct. 1986.

[5]. http://arelectropower.com/what-is-switchgear-features-components-classification/

[6]. Theraja, B. L., Theraja, A. K., & Deshpande, S. D. (1995). A text-book of

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59
Delhi: Nirja Construction & Development.

[7]. Zocholl, Stanley E., and D. W. Smaha. "Current transformer concepts."

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[11]. https://www.elprocus.com/vacuum-circuit-breaker-working-applications/

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