INDUSTRIAL TRAINING REPORT

Carried Out

At

BELLESONICA AUTO COMPONENT PVT LTD

IMT MANESAR, GURUGRAM

Submitted to: Submitted By:

Mrs. SHIPRA AGGARWAL MOHIT
Mrs. RACHNA AGGARWAL Electrical Engg.
Industrial Training Mentor EL-2404-2K14
Electrical Engg. Department

YMCA UNIVERSITY OF SCIENCE AND TECHNOLOGY,

FARIDABAD

1
 INDUSTRIAL TRAINING REPORT

CARRIED OUT
AT

BELLESONICA AUTO COMPONENT PVT. LTD

IMT MANESAR, GURUGRAM

SUBMITTED IN PARTIAL FULFILLMENT OF REQUIREMENT FOR

BACHELOR OF TECHNOLOGY

(ELECTRICAL ENGINEERING)

SUBMITTED BY:-

MOHIT

EL-2404-2K14

UNDER THE GUIDANCE OF

MR. HITTESH ATTRI

ASSISTANT MANAGER (MAINTENANCE DEPARTMENT )

(BELLESONICA AUTO COMPONENT PVT. LTD.)

YMCA UNIVERSITY OF SCIENCE & TECHNOLOGY,

FARIDABAD

2
Ref: Date:

TRAINING CERTIFICATE

This is to certify that Mr. /Ms. MOHIT bearing Roll No. EL-2404-2K14 a student
from YMCA University of Science and Technology, Faridabad (HR) has
undergone industrial Training in our company from July 01, 2017 to December 31,
2017. He /She has completed his training period successfully.

His conduct during the course of training has been good and found him sincere and
hardworking student, eager to learn.
I wish him /her all the success in his /her future career.

Mahesh
(Sr. Executive-Human Resource)

3
 CANDIDATE’S DECLARATION

I hereby certify that the work which is being presented in this project report “SWITCH GEAR AT
BELLESONICA” submitted to “YMCA University of Science and Technology, Faridabad”, is an
authentic record of my own work carried out in the company “...............”. The work contained in this

thesis has not been submitted to any other University Or Institute.

MOHIT
EL-2404-2K14

Examiners Evaluation

The project report has been evaluated by us.

Internal Examiner

Name: _____________________ Signature: ______________

Designation: ________________ Date: _______________

External Examiner

Name: _____________________ Signature: _______________

Designation: ______________ Date: __________________

4
 ACKNOWLEDGEMENT

I, MOHIT a student of YMCA University of Science & Technology, Faridabad

express my deepest gratitude to all who contributed in imparting me the valuable
knowledge during my training period.

The constant guidance & encouragement received from Mrs. SHIPRA AGGARWAL,
Mrs. RACHNA AGGARWAL & Dr. RAJESH AHUJA (Chairman), Training
Head of Department of Electrical Engineering, YMCA U.S.T. FARIDABAD has been
of great help in carrying out the present work & is acknowledged with reverential
thanks.

We would like to express a deep sense of gratitude& thanks profusely to our Training
In charge, Mr. HITTESH ATTRI (BELLESONICA AUTO COMPONENRT PVT
LTD). Without his counsel & able guidance, it would have been impossible to complete
the project in this manner. We also express our gratitude to other faculty members of
Dep’t. Of Electrical Engineering, for their intellectual support throughout the course of
this work.

Finally we are indebted to all whosoever have contributed in this project work.

MOHIT

EL-2404-2K14

1
 CONTENTS
 About Bellsonica

 Single line diagram of electrical supply to Bellsonica

 Miniature Circuit Breaker

 Construction
 Characterstics of MCB
Residual

 RESIDUAL CURRENT CIRCUIT BREAKER (RCCB)

 SENSITIVITY OF RCCB

 Motor Protection Circuit Breakers (MPCB)

 Contactor
 Features
 Parts of Contactor
 GUIDELINES FOR SELECTION OF CONTACTOR
 Types of Contactors

 Applications of Switch gear

 Soft starter
 Variable frequency drives

 Control Panel

 Components of control panel

 Bus Bar
 Circuit Breaker
 Relaying Block

 Air Circuit Breaker

 Types of ACB
 Working principle of ACB
 Metering Panel and High tension Panel

 Transformer
 Basic Principle of Transformer
 Transformer Protection
1. Buchholz Relay
2. Conservator and Breather

 Cooling Tower

 Capacitor Bank and DC Battery

 Solar Power
 Introduction
 Path to Solar Power

 Servomotor
 Mechanism
 Encoders
 Motors
 Control
 Common Industrial applications of servomotor
ABOUT BELLESONICA

Compamy Name Bellsonica Auto Component India Private Limited (Abbreviated to BACI)
Established August 2006
Capitalization 1.18 billion rupees(Bellsonica 70%,Maruti Suzuki 30%)
Representative Mr. Kazutaka Suzuki Managing Director(CEO)
Director Mr. Manabu Kawai(Joint Managing)
Executive Director Mr. Katsuhito Suzuki
Executive Director Mr. Yoichi Suzuki (Maruti Suzuki executive officer)
Employees 1000
Annual sales March 2016_7.7 billion yen
Site area 47,250 square meters
Facilities area 23,350 square meters
Product parts Various body parts for small passenger vehicles
Plot No.1, Phase3A, IMT Manesar, Distt.
Address
Gurgaon, Manesar-122 051, Haryana, India

・ 2,500 ton Transfer Press

・ 1,600 ton Transfer Press
・ 1,000 ton Tandem Line 1,000t-600t-500t-500t-500t
・ 500 ton Tandem Line 500t-300t-300t-300t
・ 300 ton Tandem Line 300t-300t-300t-300t
・ 300 ton Progressive press/BL…2
・ 160 ton…6
・ 110 ton…4

Equipment ・ 80 ton…5
・ Spot welding robot…174
・ Manual spot welding gan…37
・ Station spot welding machine…79
・ AW welding robot…25
Machine Tools（Milling Machine、Lathe、Drilling
・
Machine）
Others（Die Spotting Press、Forklift、Crane、Smoke
・
Exhaustion Device）
・
 CHAPTER-1

MINIATURE CIRCUIT

BREAKER (MCB)
MINIATURE CIRCUIT BREAKER (MCB)

 MCB is used for overload and short circuit protection of feeders having
lower current rating.

 RATING OF MCB:- 0.5A – 125A

 MCB CIRCUIT DIAGRAM:-

1
 CONSTRUCTION:- IT has bimetal for Overload and electromagnet4 S.C

1) ACTUATOR LEVEL
2) ACTUATOR MECHANISM

3) CONTACTS
4) TERMINAL
5) BIMETALIC STRIP
6) CALIBRATION SCREW
7) SOLENOID
8) ARC CHUTES

2


 CHARACTERISTICS OF MCB:-

II. Rated Current

III. Rated Short Circuit Breaking Capacity

IV. Type of Curve

V. Number of Poles

VI. Energy Limiting Class

3
 CHAPTER-2

RESIDUAL CURRENT

CIRCUIT BREAKER

(RCCB)
 RESIDUAL CURRENT CIRCUIT BREAKER (RCCB)

 RCCB is a device for making and breaking a circuit manually under

normal conditions, and breaking a circuit automatically when the residual
current exceeds a predetermiREned amount.

 RCCB gives protection against direct or indirect contact. It is available in

3 Pole and 4 Pole.

 RCCB can give Overload and Short Circuit Protection.

 The RCCB trips when a small leakage current returning back to earth
through earthing conductor or human body.

 SENSITIVITY OF RCCB:-
I. 30mA= For Personal Protection (e.g. Domestic Application).
II. 100mA= Installation Protection in industries.

III. 300mA= Installation Protection in industries having inherently

high leakage current.

1
 CHAPTER-3

Motor Protection Circuit

Breakers (MPCB)
 Motor Protection Circuit Breakers (MPCB)

 For a motor feeder it is a combination of the functions of switch short

circuit protection device and an adjustable range overload relay. While the
short circuit threshold levels in MCCB’s are in range of 5-10 times the
rated current for distribution application purpose, in MPCB’s its more than
11 times considering typical motor starting phenomenon

 Available from 0.16 A to 63 A and are suitable for switching motors upto
a rating of 45 HP

 Need for MPCB

1. It cannot provide effective protection in overload range (100%-200%)

2. Ambient temperature compensation may not be available
3. The mechanical life is not very high
4. Type 2 coordination requires special attention
5. Nuisance tripping during starting

 Advantages

1. Very high short circuit breaking capacity – upto 100 kA

2. Equipped with wide range of current adjustment, so that actual motor current
can be sent in MPCB

3. Panel size is less than MCCB or fuse as overload relay gets eliminated
4. Stand alone motor protection MPCB can be used for switching, control,
overload, and short circuit protection of motor in machine with single motor
and not requiring remote switching

MIIncreased life of motor feeder- Fusels motor protection can offered using
MPCB with contactor. Due to a contactor life of motor feeder increases, it
also provides remote switching.

1
 Chapter-4

CONTACTOR
 CONTACTORS

 Contactors are electromagnetically operated device used for switching,

capable of making; carrying and breaking currents under normal circuit
conditions. Including operating overload condition which can be operated
remotely.

 PRINCIPLE: - When a definite voltage is applied across a coil, energizing

an electromagnetic system comprising of fixed and moving parts.

The moving part gets attracted to fixed part. Thus the electric circuit is
complete through this contact system.

 Contactors have only limited breaking capacity, not able to break Short
Circuit current.

 FEATURES:-
a) High Electrical and Mechanical life
b) High Frequency of Operation
c) Remote Operation
d) Can provide No Volt Protection

 Contactors Have Two Electrical Circuits

I. MAIN CIRCUIT: - The main circuit involves power contacts and

handles the power drawn by the load. The main circuit mainly
consists of contacts and terminals. Double break contact system
ensures long contact life.

II. CONTROL CIRCUIT: - The control circuit involves coil and

auxiliary contacts. Auxiliary contacts are in built and are used for
interlocking, signaling etc.

1
 PARTS OF CONTACTOR:-

I. RUBBER PADDING: - It is provided for absorbing shocks during

closing and opening of contactors.

II. MAGNETS: - AC magnets are made up of laminations stacked

together to reduce effects of eddy current.

Whereas in DC, frequency is zero, so problem of eddy current losses

and hysteresis losses do not exist and hence no laminations are required.
There is a designed gap between the central limb of fixed magnet and
moving magnet. When this gap reduces over millions of operation, it
indicates that mechanical life of contactor is over and needs
replacement.

III. CONTACT SYSTEM: - The contacts are made of silver cadmium

alloy and have well anti welding properties.

IV. LEAF SPRING: - The moving contact has to be held under certain
contact pressure which is ensuring by providing leaf springs over the
contact carrier bridge. It also helps in bounce free closing.

V. RETURN SPRING: - The moving assembly is held against the

stored energy of two main springs called as return springs which helps
the bridge assembly in opening the contacts.

VI. TERMINALS:-Terminals are made of silver plated copper and are

provided for both power circuit and control circuit termination.

2
 VII. AUXILARY CONTACTS: - Set of Normally Open (NO) Normally
Closed (NC) is available for indication and alarm purpose.

VIII. ARC CHUTES: - While breaking high currents the arc between the
contacts needs to be effectively quenched. Arc is quenched by
splitting the arc.

 Tt

I. Study the application and find out utilization category.

II. Select contactor current rating equal to or more than full load current.

III. Contactor should have sufficient breaking capacity.

IV. Capacitor should have sufficient making capacity. V. No. of operations

should be fulfilled by contactor.

VI. Coil has to be selected as per control circuit voltage AC/DC.

VII. If number of built in auxiliary contacts are not sufficient then add on
block has to be selected.

VIII. Lesser in VA rating of coil smaller will be the size of control

transformer. So VA consumption of coil should be less.

 TYPES OF CONTACTORS:-

I. POWER CONTACTOR: - These types of contactors are used to

operate actual loads so they consist of main contact system.

II. CONTROL CONTACTOR: - These contactors are used only in

control. If the auxiliary contacts available in contactor are insufficient
then control contactor is used to multiply the auxiliary contacts.
Control contactor consist of auxiliary contacts and coil only.

III. CAPACITY DUTY CONTACTORS: - These contactors are

specially

3
 designed for capacity duty. Capacitor during starting act as a short
circuit, so very high current flows through the capacitor which has to be
made by contactor. Due to high inrush current contactor life drastically
reduced, so specially designed capacity duty contactor is used.

IV. AC CONTACTOR: - AC contactor has AC control circuit hence AC

coil.

V. DC CONTACOR: - DC contactor has DC control circuit hence DC

coil.

VI. VACUUM CONTACTOR: - Vacuum contactor has contact system

invacuum. Due the absence of air the arcing will not be there. So
these types of contactors are used where high electrical life, high
making and breaking current is expected. Generally they are available
in high ratings.

VII. 3 POLE CONTACTOR: - These contactors are used for switching of

loads.

VIII. 4 POLE CONTACTOR: - This contactor is used for changeover

between two sources. Where neutral also has to be disconnected. For
these types of contactors the utilization category specified is AC1,
since they are not used for switching of any particular load.

4
 CHAPTER-5

Applications of Switch gear

5
Applications of Switch gear

I. SOFT STARTER:-
A reduced voltage soft starter helps protect the motor and connected equipment from
damage by controlling the terminal voltage. This limits the initial inrush of current and
reduces the mechanical shock associated with motor startup and provides a more gradual
ramp up to full speed. Soft Starters are also beneficial to electrical systems with limited
current capacity when using a soft starter for motor starting to limit the inrush current.
By gradually increasing the motor terminal voltage the soft starter produces a more
regulated motor acceleration up to full speed. Soft starters are also capable of providing a
gradual ramp to stop where sudden stopping may create problems in the connected
equipment.
 II. VARIABLE FREQUENCY DRIVES(VFD) :

A variable frequency drive (VFD) is a motor control device that protects and controls the
speed of an AC induction motor. A VFD can control the speed of the motor during the
start and stop cycle, as well as throughout the run cycle. Variable frequency drives are
also referred to as adjustable frequency drives (AFD). Also Variable Voltage Variable
Frequency Drives (VVVF).

o How do VFDs work :

Variable frequency drives convert constant frequency and voltage input
power to adjustable frequency and voltage source for controlling the speed
of AC induction motors. The frequency of the power applied to an AC motor
determines the motor speed, based on the following equation:

Where: N = speed (rpm)

f = frequency (Hz)

p = number of motor poles

o Variable Frequency Drives Main Circuit Diagram :

• AC supply: Comes from the facility power network (typically 208V,

230V, 480V, 575V, 690V / 60 Hz AC)
Pulse width modulation: Switches the inverter semiconductors in varying widths and
times that, when averaged create a sine waveform.

o Benefits of using a variable frequency drive :

 Performance :
Fully adjustable speed (pumps, conveyors, fans, etc.)
Controlled starting, stopping, and acceleration
Dynamic torque control
Provides smooth motion for applications such as elevators and escalato rs
Maintains speed of equipment, making drives ideal for manufacturing
equipment and industrial equipment such as mixers, grinders, and
crushers.

 Versatility :
Self-diagnostics and communications
Advanced overload protection
PLC-like functionality and software programming

Digital inputs/outputs (DI/DO)

Analog inputs/outputs (AI/AO)

Relay outputs
 CHAPTER-6

CONTROL PANEL
Control Panel

A control panel is a flat, often vertical, area where control or monitoring instruments are
displayed.

They are found in factories to monitor and control machines or production lines and in places
such as nuclear power plants, ships, aircraft and mainframe computers. Older control panels are
most often equipped with push buttons and analog instruments, whereas nowadays in many
cases touch screens are used for monitoring and control purposes.

Control panel is a cabinet which contains electrical components to control the motors and
equipments. Cables are used for the interconnection. Two types of cables are used. Power cable
and control cable.
1. Power cables (which is used to connect the motor to panel component and panel to main
supply)
2. Control cables (which is used to connect the control circuits)

CONTROL PANEL AT BELLESONICA

 COMPONENTS OF CONTROL PANEL :-
 BUSBAR

Incoming supply is connected to bus bar and distributed from bus bar. It is normally made by
Aluminum. In electrical power distribution, a busbar (also spelled bus bar, or sometimes as buss
bar or bussbar, with the term bus being a contraction of the Latin omnibus, "for all",
or buss being short for buttress) is a metallic strip or bar (typically copper, brass or aluminium)
that conducts electricity within a switchboard, distribution board, substation, battery bank, or
other electrical apparatus. Busbars are used to carry substantial electric currents over relatively
short distances; their greater surface area (compared to a wire of the same weight) reduces losses
due to corona discharge.
 CIRCUIT BREAKERS

A miniature or moulded - case circuit breaker is an automatically

operated electrical switch designed to protect an electrical circuit from damage caused
by overcurrent or overload or short circuit. Its basic function is to interrupt current flow
after protective relays detect a fault. Unlike a fuse, which operates once and then must be
replaced, a circuit breaker can be reset (either manually or automatically) to resume normal
operation. Circuit breakers are made in varying sizes, from small devices that protect an
individual household appliance up to large switchgear designed to protect high voltage circuits
feeding an entire city. The generic function of a circuit breaker, RCD or a fuse, as an automatic
means of removing power from a faulty system is often abbreviated to ADS (Automatic
Disconnection of Supply

There are various types of circuit breakers viz,.,

According to their arc quenching media the circuit breaker can be divided as-

 Oil circuit breaker.

 Air circuit breaker.
 SF6 circuit breaker.
 Vacuum circuit breaker.

According to their services the circuit breaker can be divided as-

 Outdoor circuit breaker

 Indoor breaker.

According to the operating mechanism of circuit breaker they can be divided as-

 Spring operated circuit breaker.

 Pneumatic circuit breaker.
 Hydraulic circuit breaker.
According to the voltage level of installation types of circuit breaker are referred as-

 High voltage circuit breaker.

 Medium voltage circuit breaker.
 Low voltage circuit breaker.

Fig. Circuit Breaker

 RELAYING BLOCK

A relay is an electrically operated switch. Many relays use an electromagnet to mechanically

operate a switch, but other operating principles are also used, such as solid-state relays. Relays
are used where it is necessary to control a circuit by a separate low-power signal, or where
several circuits must be controlled by one signal. The first relays were used in long
distance telegraph circuits as amplifiers: they repeated the signal coming in from one circuit and
re-transmitted it on another circuit. Relays were used extensively in telephone exchanges and
early computers to perform logical operations.

A type of relay that can handle the high power required to directly control an electric motor or
other loads is called a contactor. Solid-state relays control power circuits with no moving parts,
instead using a semiconductor device to perform switching. Relays with calibrated operating
characteristics and sometimes multiple operating coils are used to protect electrical circuits from
overload or faults; in modern electric power systems these functions are performed by digital
instruments still called "protective relays".
There are various types of relays available..

 Definite time relays

 Inverse time relays with definite minimum time(IDMT)
 Instantaneous relays.
 IDMT with inst.
 Voltage restraint over current relay

Fig. various relays

Relay works on two main operating principles:-
 Electromagnetic Attraction

 Electromagnetic Induction

 RELAY USED IN CONTROLLING PANEL

 Differential Relay
A differential relay is one that operates when vector difference of the two or more electrical
quantities exceeds a predetermined value. If this differential quantity is equal or greater than the
pickup value, the relay will operate and open the circuit breaker to isolate the faulty section.
 Over Current Relay
This type of relay works when current in the circuit exceeds the predetermined value. The
actuating source is the current in the circuit supplied to the relay from a current transformer.
These relay are used on A.C. circuit only and can operate for fault flow in the either direction.
This relay operates when phase to phase fault occurs.

 Earth Fault Relay

This type of relay sense the fault between the lines and the earth. It checks the vector sum of all
the line currents. If it is not equal to zero, it trips.
 Tripping Relay

This type of relay is in the conjunction with main relay. When main relay sense any fault in the
system, it immediately operates the trip relay to disconnect the faulty section from the section
 Auxiliary Relay
An auxiliary relay is used to indicate the fault by glowing bulb or showing various flags.
 CHAPTER-7

AIR CIRCUIT BREAKER

 AIR CIRCUIT BREAKER
ACB (Air Circuit Breaker) is a mechanical switching device capable of making, carrying &
breaking current under normal and specified abnormal conditions such as a short circuit. In
this device contacts open and close in air at atmospheric pressure.

Make Carry Break

Normal Yes Yes Yes

Overload Yes Yes Yes

Short circuit Yes Yes Yes

In LV system normal air is sufficient to quench the arc, so all switchgears have air break contacts
which open and close in air at atmospheric pressure.

 Types of ACB

Based on Closing Mechanism :-

Manually Operated ACB: These types of ACB are closed manually. In this breaker the closing
is independent of force offered by operator. An operator has to go to breaker for ON operation.

1. Tripping is either manual (through trip push button) or electrical (through shunt
release)

2. Electrically Operated: These ACB can be closed electrically hence suitable for
remote & automatic operation. In electrically operated breaker the charging of the
spring is done by universal motor. The spring stores energy for closing and closing
command enables the breaker to switch ON, closing command is given by closing
coil

Based on the mounting in the panel :-

 1. Fixed type: It is directly mounted and fixed in the panel. The power terminals &
control terminals are also fixed. Maintenance is thus time consuming. Since whole
wiring and mounting has to be removed in order to take breaker out from panel

2. Draw out type: It has 2 parts: main brake & cradle. The cradle is fixed to panel and
breaker is loaded in a cradle on a movable telescopic rail. Power circuit has jaw contact
& flat terminal assembly & control circuit has Secondary Isolating Contacts (SIC) so
only breaker can be racked out for
maintenance purpose & electrical connections need not be removed. So reduces time.

ACB are of 4 different types

1. Manually Operated Fixed Type (MF)

2. Manually Operated Draw Out Type (MDO)
3. Electrically Operated Fixed Type (EF)
4. Electrically Operated Draw Out Type (EDO) 5. Wide range: ACB is available from
400-6300 A rating.

6. High s/c making and breaking capacities.

7. High short time withstand current rating, hence suitable for time based discrimination.
8. Various types of overcurrent releases.
9. Designed for accessible maintenance and repair.
  Working Principle of Air Circuit Breaker
The working principle of this breaker is rather different from those in any
other types of circuit breakers. The main aim of all kind of circuit breaker is
to prevent the reestablishment of arcing after current zero by creating a
situation where in the contact gap will withstand the system recovery
voltage. The air circuit breaker does the same but in different manner. For
interrupting arc it creates an arc voltage in excess of the supply voltage. Arc
voltage is defined as the minimum voltage required maintaining the arc. This
circuit breaker increases the arc voltage by mainly three different ways,

1. It may increase the arc voltage by cooling the arc plasma. As the
temperature of arc plasma is decreased, the mobility of the particle in arc
plasma is reduced; hence more voltage gradient is required to maintain the
arc.
2. It may increase the arc voltage by lengthening the arc path. As the length
of arc path is increased, the resistance of the path is increased, and hence
to maintain the same arc current more voltage is required to be applied
across the arc path. That means arc voltage is increased.
3. Splitting up the arc into a number of series arcs also increases the arc
voltage.
There is seperte air circuit breaker for each area(office, welding section, canteen, lathe etc.)

Air circuit breaker rating is given in ampere (2500A, 3200A, 1000A, 1600A are the ratings of
ACB present in the company).

ACB contacts after line to line fault

This digital indicator present with ACB will indicate the type of fault by glowing corresponding
LED.

We can trip down the supply of specific area by ACB.

 CHAPTER-8

METERING PANNEL

AND

HIGH TENSION PANNEL

METERING PANNEL

Metering pannel are instruments that display an input signal in an analog or

digital form. Metering panel measures the input power factor, input voltage,
total harmonic distortion etc. Many panel meters also include alarm options
as well as the ability to transfer data to a computer. Panel meters take a

sample of the voltage or current to create a visual representation of the

meassured value. Voltage measurements are read across the line, while
current measurements are taken in series with the load, sometimes utilizing
shunts or current transformers when the load current exceeds 10 amps.
overload protection device.

2. TECHNICAL DETAILS:-

Panel board should be consisting following items.

1. Three phase 3 Pole 11000 volts, 50Hz, 630AMP, VCB of breaking capacity 25 KA for
outgoing with microprocessor based protection relay including all protection like over current,
earth fault, over voltage and under voltage. Make Siemens, ABB, L & T or Schneider only

2. VCB relay control voltage should be 30 V DC.

3. Spring charging motor of VCB should be of 230 V AC.

4. Current Transformer (CT) of 50/50/5 for metering and protection.

5. Digital Ammeter of suitable range with selector switch to all three phase current

6. VCB should have Digital volt meter of range 0 to 12KV through suitable potential
transformer (PT) and selector switch should be provided for measuring all three phases.

7. LED indicating lamp in each phase(R Y B) on incoming supply.

8. Copper bus bar system should be designed in such a way that it should easily connect
through bus chamber to existing busbar.
HIGH TENSION PANNEL

HT Panel is an electrical distribution board that receives power from generator or transformer and
distributes the same to various electronic devices and distribution boards. Such panels are used in
industries both for internal and external use and, therefore, they are quite rugged to withstand different
climatic conditions. HT panel is used for high tension cable

From here we can cutoff the supply of the company by vaccum circuit breaker during
maintenance.

Here the supply is going to two different sub station :-

1.Old substation

2.New substation
 CHAPTER-9

TRANSFORMER
TRANSFORMER

A transformer is an electrical device that transfers electrical energy between two or

more circuits through electromagnetic induction. A varying current in one coil of the transformer
produces a varying magnetic field, which in turn induces a voltage in a second coil. Power can
be transferred between the two coils through the magnetic field, without a metallic connection
between the two circuits. Induction discovered in 1831 described this effect. Transformers are
used to increase or decrease the alternating voltages in electric power applications.

Since the invention of the first constant-potential transformer in 1885, transformers have become
essential for the transmission, distribution, and utilization of alternating current electrical
energy.[3] A wide range of transformer designs is encountered in electronic and electric power
applications. Transformers range in size from RF transformers less than a cubic centimetre in
volume to units interconnecting the grid weighing hundreds of tons.

 BASIC PRINCIPLE OF TRANSFORMER

An ideal transformer is a theoretical, linear transformer that is lossless and

perfectly coupled. Perfect coupling implies infinitely high core magnetic permeability and
winding inductances and zero net magnetomotive force.
A varying current in the transformer's primary winding creates a varying magnetic flux in the
transformer core and a varying magnetic field impinging on the secondary winding. This varying
magnetic field at the secondary winding induces a varying EMF or voltage in the secondary
winding due to electromagnetic induction. The primary and secondary windings are wrapped
around a core of infinitely high magnetic permeability so that all of the magnetic flux passes
through both the primary and secondary winding.

According to Faraday's law, since the same magnetic flux passes through both the primary and
secondary windings in an ideal transformer, a voltage is induced in each winding. The primary
EMF is sometimes termed counter EMF. This is in accordance with Lenz's law, which states that
induction of EMF always opposes development of any such change in magnetic field.

INDUSTRIAL TRANSFORMER
TRANSFORMER PROTECTION
Transformers are totally enclosed static devices and generally oil immersed. Therefore chances
of fault occurring on them are very easy rare, however the consequences of even a rare fault may
be very serious unless the transformer is quickly disconnected from the system. This provides
adequate automatic protection for transformers against possible faults. Various protection
methods used for transformers are:-

 Buchholz Relay
Buchholz relay is a safety device mounted on some oil-filled power transformers and reactors,
equipped with an external overhead oil reservoir called a conservator. The Buchholz Relay is
used as a protective device sensitive to the effects of dielectric failure inside the equipment.
Depending on the model, the relay has multiple methods to detect a failing transformer. On a
slow accumulation of gas, due perhaps to slight overload, gas produced by decomposition of
insulating oil accumulates in the top of the relay and forces the oil level down. A float switch in
the relay is used to initiate an alarm signal. Depending on design, a second float may also serve
to detect slow oil leaks. If an arc forms, gas accumulation is rapid, and oil flows rapidly into the
conservator. This flow of oil operates a switch attached to a vane located in the path of the moving
oil. This switch normally will operate a circuit breaker to isolate the apparatus before the fault
causes additional damage.

 Conservator and Breather

When the oil expands or contacts by the change in the temperature, the oil level goes either up
or down in main tank. A conservator is used to maintain the oil level up to predetermined value
in the transformer main tank by placing it above the level of the top of the tank. Breather is
connected to conservator tank for the purpose of extracting moisture as it spoils the insulating
properties of the oil. During the contraction and expansion of oil air is drawn in or out through
breather silica gel crystals impregnated with cobalt chloride. Silica gel is checked regularly and
dried and replaced when necessary.
 CHAPTER-10

COOLING TOWER
COOLING TOWER

A cooling tower is a heat rejection device that rejects waste heat to the atmosphere through the
cooling of a water stream to a lower temperature. Cooling towers may either use
the evaporation of water to remove process heat and cool the working fluid to near the wet-bulb
air temperature or, in the case of closed circuit dry cooling towers, rely solely on air to cool the
working fluid to near the dry-bulb air temperature.

Fig. Cooling tower

Common applications include cooling the circulating water used in oil

refineries, petrochemical and other chemical plants, thermal power stations and HVAC systems
for cooling buildings. The classification is based on the type of air induction into the tower: the
main types of cooling towers are natural draft and induced draft cooling towers.
Cooling towers vary in size from small roof-top units to very large hyperboloid structures that
can be up to 200 metres (660 ft) tall and 100 metres (330 ft) in diameter, or rectangular structures
that can be over 40 metres (130 ft) tall and 80 metres (260 ft) long. The hyperboloid cooling
towers are often associated with nuclear power plants, although they are also used in some coal-
fired plants and to some extent in some large chemical and other industrial plants. Although
these large towers are very prominent, the vast majority of cooling towers are much smaller,
including many units installed on or near buildings to discharge heat from air conditioning.

An HVAC (heating, ventilating, and air conditioning) cooling tower is used to dispose of
("reject") unwanted heat from a chiller. Water-cooled chillers are normally more energy efficient
than air-cooled chillers due to heat rejection to tower water at or near wet-bulb temperatures.
Air-cooled chillers must reject heat at the higher dry-bulb temperature, and thus have a lower
average reverse-Carnot cycle effectiveness. In areas with a hot climate, large office buildings,
hospitals, and schools typically use one or more cooling towers as part of their air conditioning
systems. Generally, industrial cooling towers are much larger than HVAC towers.

In BELLESONICA four cooling tower are installed for air conditioning of the industry.
 CHAPTER-11

CAPACITOR BANK

AND

DC BATTERY
CAPACITOR BANK

The demand of active power is expressing Kilo Watt (kw) or mega watt (mw). This power
should be supplied from electrical generating station. All the arrangements in electrical pomes
system are done to meet up this basic requirement. Although in alternating power system,
reactive power always comes in to picture. This reactive power is expressed in Kilo VAR or
Mega VAR.The demand of this reactive power is mainly originated from inductive load
connected to the system. These inductive loads are generally electromagnetic circuit of motors
mainly..

This reactive power should be properly compensated otherwise, the ratio of actual power
consumed by the load, to the total power i.e. vector sum of active and reactive power, of the
system becomes quite less. This ratio is alternatively known as electrical power factor, and fewer
ratios indicates poor power factor of the system. If the power factor of the system is poor, the
ampere burden of the transmission, distribution network, transformers, alternators and other
equipments connected to the system, becomes high for required active power. And hence
reactive power compensation becomes so important. This is commonly done by capacitor bank.
There are mainly two equipments used for this purpose. (1) synchronous condensers (2) Static
capacitors or Capacitor Bank synchronous condensers, can produce reactive power and the
production of reactive power can be regulated. Due to this regulating advantage, the synchronous
condensers are very suitable for correcting power factor of the system, but this equipment is
quite expensive compared to static capacitors. That is why synchronous condensers, are justified
to use only for voltage regulation of very high voltage transmission system.

The rating of capacitor bank installed in company is 2000KVA.

Main functions of Capacitor Bank are:-

 Supply Reactive Power

 Improve Terminal Voltage

 Improve Power Factor

INTERNAL VIEW OF CAPACITOR BANK

DC BATTERY

DC battery are installed in the comkany for providing supply to all the digital meter used in the
system. The rating of battery used in the industry is of 12V/65Ah.
The amp-hour is a unit of battery energy capacity, equal to the amount of continuous
current multiplied by the discharge time that a battery can supply before exhausting its
internal store of chemical energy. ... Discharged batteries lose voltage and increase in
resistance

A rectifier is used to charge this batteries

CHAPTER-12

SOLAR POWER
INTRODUCTION

Solar panel refers to a panel designed to absorb the sun's rays as a source of energy for
generating electricity or heating.

A photovoltaic (PV) module is a packaged, connect assembly of typically 6×10 solar cells. Solar
Photovoltaic panels constitute the solar array of a photovoltaic system that generates and
supplies solar electricity in commercial and residential applications. Each module is rated by
its DC output power under standard test conditions, and typically ranges from 100 to 365 watts.
The efficiency of a module determines the area of a module given the same rated output – an 8%
efficient 230 watt module will have twice the area of a 16% efficient 230 watt module. There are
a few commercially available solar panels available that exceed 22% effciency and reportedly
also exceeding 24%. A single solar module can produce only a limited amount of power; most
installations contain multiple modules. A photovoltaic system typically includes a panel or an
array of solar modules, a solar inverter, and sometimes a battery and/or solar tracker and
interconnection wiring.

Solar modules use light energy (photons) from the sun to generate electricity through
the photovoltaic effect. The majority of modules use wafer-based crystalline silicon cells or thin-
film cells based on cadmium telluride or silicon. The structural (load carrying) member of a
module can either be the top layer or the back layer.
Cells must also be protected from mechanical damage and moisture. Most solar modules are
rigid, but semi-flexible ones are available, based on thin-film cells. Electrical connections are
made in series to achieve a desired output voltage and/or in parallel to provide a desired current
capability. The conducting wires that take the current off the modules may contain silver, copper
or other non-magnetic conductive [transition metals]. The cells must be connected electrically to
one another and to the rest of the system. Externally, popular terrestrial usage photovoltaic
modules use MC3 (older) or MC4 connectors to facilitate easy weatherproof connections to the
rest of the system.

PATH TO SOLAR POWER

NHPC has taken an initiative to be “ALL RENEWABLE” under which it started utilising solar
energy for its auxiliary purposes under Jawahar Lal Nehru scheme for solar power.

Depending on construction, photovoltaic modules can produce electricity from a range

of frequencies of light, but usually cannot cover the entire solar range
(specifically, ultraviolet, infrared and low or diffused light). Hence, much of the
incident sunlight energy is wasted by solar modules, and they can give far higher efficiencies if
illuminated with monochromatic light. Therefore, another design concept is to split the light into
different wavelength ranges and direct the beams onto different cells tuned to those ranges.This
has been projected to be capable of raising efficiency by 50%. Scientists from Spectrolab, a
subsidiary of Boeing, have reported development of multi-junction solar cells with an efficiency
of more than 40%, a new world record for solar photovoltaic cells.[5] The Spectrolab scientists
also predict that concentrator solar cells could achieve efficiencies of more than 45% or even
50% in the future, with theoretical efficiencies being about 58% in cells with more than three
junctions. Currently the best achieved sunlight conversion rate (solar module efficiency) is
around 21.5% in new commercial products[6] typically lower than the efficiencies of their cells in
isolation. The most efficient mass-produced solar modules have power density values of up to
175 W/m2 (16.22 W/ft2).Research by Imperial College, London has shown that the efficiency of
a solar panel can be improved by studding the light-receiving semiconductor surface
with aluminum nanocylinders similar to the ridges on Lego blocks.
CHAPTER-13

SERVOMOTOR
SERVOMOTOR

A servomotor is a rotary actuator or linear actuator that allows for precise control of angular or
linear position, velocity and acceleration.[1] It consists of a suitable motor coupled to a sensor for
position feedback. It also requires a relatively sophisticated controller, often a dedicated module
designed specifically for use with servomotors.

Servomotors are not a specific class of motor although the term servomotor is often used to refer
to a motor suitable for use in a closed-loop control system.

Servomotors are used in applications such as robotics, CNC machinery or automated

manufacturing.
 MECHANISM
A servomotor is a closed-loop servomechanism that uses position feedback to control its motion
and final position. The input to its control is a signal (either analogue or digital) representing the
position commanded for the output shaft.

The motor is paired with some type of encoder to provide position and speed feedback. In the
simplest case, only the position is measured. The measured position of the output is compared to
the command position, the external input to the controller. If the output position differs from that
required, an error signal is generated which then causes the motor to rotate in either direction, as
needed to bring the output shaft to the appropriate position. As the positions approach, the error
signal reduces to zero and the motor stops.

The very simplest servomotors use position-only sensing via a potentiometer and bang-bang
control of their motor; the motor always rotates at full speed (or is stopped). This type of
servomotor is not widely used in industrial motion control, but it forms the basis of the simple
and cheap servosused for radio-controlled models.

More sophisticated servomotors use optical rotary encoders to measure the speed of the output
shaft and a variable-speed drive to control the motor speed. Both of these enhancements, usually
in combination with a PID control algorithm, allow the servomotor to be brought to its
commanded position more quickly and more precisely, with less overshooting

 ENCODERS
The first servomotors were developed with synchros as their encoders.[7] Much work was done with these
systems in the development of radar and anti-aircraft artillery during World War II.[8]

Simple servomotors may use resistive potentiometers as their position encoder. These are only used at the very
simplest and cheapest level, and are in close competition with stepper motors. They suffer from wear and
electrical noise in the potentiometer track. Although it would be possible to electrically differentiate their
position signal to obtain a speed signal, PID controllers that can make use of such a speed signal generally
warrant a more precise encoder.
Modern servomotors use rotary encoders, either absolute or incremental. Absolute encoders can
determine their position at power-on, but are more complicated and expensive. Incremental
encoders are simpler, cheaper and work at faster speeds. Incremental systems, like stepper
motors, often combine their inherent ability to measure intervals of rotation with a simple zero-
position sensor to set their position at start-up.

Instead of servomotors, sometimes a motor with a separate, external linear encoder is

used.[9] These motor + linear encoder systems avoid inaccuracies in the drivetrain between the
motor and linear carriage, but their design is made more complicated as they are no longer a pre-
packaged factory-made system.

 MOTORS
The type of motor is not critical to a servomotor and different types may be used. At the
simplest, brushed permanent magnet DC motors are used, owing to their simplicity and low cost.
Small industrial servomotors are typically electronically commutated brushless motors.[10] For
large industrial servomotors, AC induction motors are typically used, often with variable
frequency drives to allow control of their speed. For ultimate performance in a compact package,
brushless AC motors with permanent magnet fields are used, effectively large versions
of Brushless DC electric motors.[11]

Drive modules for servomotors are a standard industrial component. Their design is a branch
of power electronics, usually based on a three-phase MOSFET or IGBT H bridge. These
standard modules accept a single direction and pulse count (rotation distance) as input. They may
also include over-temperature monitoring, over-torque and stall detection features.[12] As the
encoder type, gearhead ratio and overall system dynamics are application specific, it is more
difficult to produce the overall controller as an off-the-shelf module and so these are often
implemented as part of the main controller.

 CONTROL
Most modern servomotors are designed and supplied around a dedicated controller
module from the same manufacturer. Controllers may also be developed
around microcontrollersin order to reduce cost for large-volume applications
COMMON INDUSTRIAL APPLICATION OF SERVOMOTOR

Servo motors are small and efficient but critical for use in applications requiring precise position
control. The servo motor is controlled by a signal (data) better known as a pulse-width modulator
(PWM). Here are several of the more common servo motor applications in use today.

 Robotics: A servo motor at every "joint" of a robot is used to actuate movements, giving the robot
arm its precise angle.
 Conveyor Belts: Servo motors move, stop, and start conveyor belts carrying product along to
various stages, for example, in product packaging/bottling, and labeling.
 Camera Auto Focus: A highly precise servo motor built into the camera corrects a camera's lens to
sharpen out-of-focus images.
 Robotic Vehicle: Commonly used in military applications and bomb detonation, servo motors
control the wheels of the robotic vehicle, generating enough torque to move, stop, and start the
vehicle smoothly as well as control its speed.
 Solar Tracking System: Servo motors adjust the angle of solar panels throughout the day so that
each panel continues to face the sun, harnessing maximum energy from sunup to sundown.
 Metal Cutting & Metal Forming Machines: Servo motors provide precise motion control for
milling machines, lathes, grinding, centering, punching, pressing, and bending in metal fabrication
for such items as jar lids to automotive wheels.
 Antenna Positioning: Servo motors are used on both the azimuth and elevation drive axis of
antennas and telescopes such as those used by the National Radio Astronomy Observatory (NRAO)
 Woodworking/CNC: Servo motors control woodturning mechanisms (lathes) that shape table legs
and stair spindles, for example, as well as augering and drilling the holes necessary for assembling
those products later in the process.
 Textiles: Servo motors control industrial spinning and weaving machines, looms, and knitting
machines that produce textiles such as carpeting and fabrics as well as wearable items such as
socks, caps, gloves, and mittens.
 Printing Presses/Printers: Servo motors stop and start the print heads precisely on the page as
well as move paper along to print multiple rows of text or graphics in exact lines, whether it's a
newspaper, a magazine, or an annual report.
 Automatic Door Openers: Supermarkets and hospital entrances are prime examples of automated
door openers controlled by servo motors, whether the signal to open is via push plate beside the
door for handicapped access or by radio transmitter positioned overhead.

The world would be a much different place without servo motors. Whether they're used in
industrial manufacturing or in commercial applications, they make our lives better, easier, and in
many cases provide us with more affordable products.
 STUDENT PROFILE

NAME - MOHIT

ROLL NO - EL-2404-2K14

BRANCH - ELECTRICAL

SEMESTER - 7th

D.O.B - 27 JANUARY, 1997

MOB NO. - 7834993132