BASIC ELECTRICAL a With Numerical Problems VOLUME I‘This book has been recommended by the Directorate General of Employment and Training (DGE&T), New Delhi, vide-their circular No. DGET-14(2)/86-CD, dated April 1, 1986, Volume II has been recommended by the Directorate General of Employment and Training (DGE&T), New Deihi, vide-their circular No. DGET-10(6)88-CD, dated November 22, 1988. Tata. McGraw-Hill © 1985. Tata McGraw-Hill Publishing Company Limited 30" reprint 2006 RADLRDRERLBQQ: No part of this publication can be reproduced in any form or by any means without the prior written permission of the publishers This edition can be exported from India only by the publishers, Tata McGraw-Hill Publishing Company Limited ISBN 0-07-451586-1 Published by Tata McGraw-Hill Publishing Company Limited, 7 West Patel Nagar, New Delhi 110, and printed at Ram Book Binding House, New Delhi 110 020.Contents Foreword wii Preface ix First-Year Syllabus for the Trade Theory—Electrician’ xii 1._Introduction i 2._Wires, Cables and General Electrical Accessories 22 3._Nature of Electricity and its Fundamental Laws 4l 4. Work, Power and Energy 60 5.__Chemical and Heating Effects of Electric Current 7 6 Magnetism, Electromagnetism and Electromagnetic Induction oF 7L_DC Generators 107 8.__DC Motors. 137 9%. Cells and Batteries 162 10._ Wiring System 192 Ut. Single-Phase AC Circuits. 0 12,__Poly-Phase System 241First-Year Syllabus for the Trade Theory—Electrician The following syllabus is for the first 52 weeks consisting of: Induction Training 1 week Allied Trade Training Firing 3 weeks ‘Carpent 3 weeks. Sheet Metal Work 2 weeks (Knowledge of Making Panel Board) Week 1. Introduction to thé trade, scope for training in the trade, Safety precautions, elementary first'aid, resuscitation and treatment for electric shock, burns ete, Week 2, Description, specification & general care and maintenance of common hand tools, identification and measurements of bolt, nuts & screws. Electron theory, miniature solar system elements, atom and free electron. Fundamental terms, definitions, units, etc., effects of electrie current. Week 3. Qualities of good electrical conductors, common conductors, theit shape, sire and use of wire—gauge, etc. Insulated conductors in general use. Their kinds as regards insulation & voltage. Grades, low, medium and high voltage. Week 4. Soldering—its purpose, different percentage of solder used, use of flux. Different fluxes for different purposes or metals, use of resin and core solder. Description of soldering equipment. Care & maintenance of the blow lamp. Week $. Common electrical accessories, specification & common insulating materials used. Ohm's law and its application. Series connection of appliances of resistances, characteristics and uses. Use of valt- ameter and ammeter. 3202—1965/4, 5) Week 6. Different types of resistances, parallel circuit, its characteristics and application. Use of protective devices like fuses, earthing, etc. Precautions in using Aluminium conductor cable, (1S: 732-1963 App-D) Main Trade Training 42 weeks Test 1 week ‘52 weeks ‘Week 7. Work, power and energy, their interrelation, calculation of power & energy in electrical circuits, Ohm's law. Simple problems. Week 8. Chemical effect of electrical current, principle of electrolysis, Farnday’s law of electrolysis. Electro- chemical equivalent. Values of £.C.E. for different electrolytes. Explanation of anode, cathode, te. Allied Trades Week 9. Introduction of fitting trade, safety pre- cautions to be observed. Descriptions of files, hammers,chisels, hacksaw frames, blades, their spe- cification and grades. Care and maintenance of steel ules, try-square and files. Week 10, Marking tools, description and use. Types of drills, description of drilling machines, proper use, care and maintenance. Week 11, Description of taps and dies, types of rivets and riveted joints, Use of thread gauge. Carpentry Week 12, Description of carpenter's common hand tools, such as saws, planes, chiscls, mallct, claw hammer, marking and dividing and holding tals, their care & maintenance, Week 13, Timber, its description, seasoning process and their use for different purposes. Week 14. Finishing and polishing. malerials, Sand papers—their grades and proper selection. Prepara- tion of spirit polish and polishing. process,‘Sheet Metal Week 15. Description of marking and cutting tools, such as snips, shears and punches, etc and other tools like bammers, mallets, etc. used by sheet metal workers, Types of soldering iroas—their proper use, description and proper usc of different bench tools used by sheet metal workers, ‘Week 16. Description of M.S. tinned and galvanised sheets and their advantages. Soldering materials, fluxes and process of soldering methods of jointing and soldering. Week 17. Magnetism—terms used, types and shapes of magnets, properties of magnets, General care and mainicnance, methods of magnetising. Magnetic ‘materials. Week 18. Electromagnet, advantages and uses. Princi- ple of electromagnetism, cork screw rule and right hand thumb rule, magnetic field of current varrying conductor and loop. Earth magnetism, solenoid, its polarity, palm rule, eve, Magnetic terms and equations. Week 19. Principle of electromagnetic induction, Faraday’s law, Lenz's law—resisiance variation of Tesistance with temperature, material, cross section length. Week 20. Principle of de. generator—Fleming’s it hand rule. Use of slip rings and split rings and the function of commutator. Ohm's law and its application. ‘Week 21. Parts and functions of de generator, emf equation, self and scparatcly eacited generators, their application in practical field. Use of meager. ‘Week 22. Types and characteristics of de generators such as series, shunt and compound, their appli- cation, Simple problems on electric circuit. Making acircuit diagram, Week 23, Armature-reaction, use of interpoles and their polarity, connection of interpoles, commutation, Week 24. Electromagnetic drag, Fleming's left hand tule, Principle of de motor. Week 25. Terms used in dc motor such as torque, speed, back emf, ete. their relation and practical application. Week 26. Types and characteristics. of de motor. Indus trial application of de movor, Starting methods. ‘Week 27. Types of de motor starters, 3 point and 4 Points. Protective devices used, First-Year Syllabus—Electrician —xtii ‘Week 28, Methods of controlling speed of dc motur —their advantages and disadvantages and industrial application. Week 29. Types, grades, sizes of insulated wircs and cables such as rubber insulated, CTS, weather proof, PYC, multicored, armoured cables, etc.—their selec+ tion as per standards laid down. ‘Week 30, Principles and description of voltaic cell defects and remedies. Leclanche cell and dry cell description, voltages, advantages, use, care and maintenance. Grouping of cells for different voltage and current. Week 31. Lead acid cell, description of parts. Methods of charging—precautions 10 be taken and testing equipment. ‘ ‘Week 32. General defects and remedies of lead acid cells, Gencral maintenance and up-kecp of lead acid cells and nickel-alkaline cells. General idea of growing importance of alternating current sysiem with suitable examples. ‘Week 33. Kirchhofl’s laws and its application, Wheat- stone bridge and its application. Week 34, Alternating current related terms viz., frequency, cms value, ete. with simple problems. Genera! idea of standard sizes of casing and cap- ing. (US: 732-1963/table-1) ‘Week 35, Resistance of capacitance and inductance. Simple definitions. Simple problems proving the effect of varying frequency. Phase relationship, power and power factor. Identification of ac and de meters. Use of watt meters and energy meters. ‘Week 36. Resistance, capacitance and inductance. Simple definitions. Simple problems proving the eflect of varying frequency. Phase relationship, power and power factor, Identification of ac and de meters, Use of watt meters and energy meters. ‘Week 37, Ac curcuit. Simple problems on ac circuits containing R & XI, Rand L and XC. Calculating current, voliage drop across each and impedance of circuit. General idea of conduits and its accessories. ining to conduit pipe wiring. —do— Week 39. Poly-phase circuits, star-deha connection. Relation between line and phase voltage, and simple problems based on it, {.E. rules. Use of reference book and tables, ‘Week 40. Alternators, parts, emf equation, regulation, Phase sequence. Teansformers—construction, wark-xiv First-Year Syllabus—Electrician ing principic, cooling method. Conduit capacities and JE rules pertaining to conduit pipe installations. (AS : 3186-Part 1/1965 APP. C. and E) Week 41, Aliernators, parts, emf equation, regulation. Phase sequence. Transformers—construction, work- ing principle, Cooling method. Conduit capacities and IE-rules pertaining to conduit pipe. Installations. Week 42. Working principle of induction motor. Con- struction and characteristic of squirrel cage and slip ting induction motor. Week 43, Single-phase motors, Split phase, capacitor. Repulsion and series motor—working principle, parts and characteristics. Starters—types and characteristics, Week 44. Single-phase motor. Split phase, capacitor. Repulsion and scries motors—working principle, parts and characteristics, Starters—types and charac+ teristics, . Week 45. Electric instruments: Classifications as re- gards force employed, ete., constructional detatts of MG and MI type meters. Dynamometer and hot wire instrument, Constructional details of energy- meter and megger. Use of shunt and multiplier. Principle and use of CT and PT. Week 46. Ac Winding terms: ac armature winding terms—toil side, coil end, coil lead, coil group and connections. Adjacent pole connected armature Winding, and alternate pole connecied armature winding, lap and wave connected. Week 47. Coil wound armature according to their shapes and arrangement—single and multi-coils. Week 48. De winding terms: Introduction, winding terms such as lap winding, wave winding pole pitch, cail pitch or back pitch, front pitch, resultant pitch, progressive and retrogressive winding. ‘Week 49. Mercury vapour and sodium vapour tamp— Construction, characteristic and wattage available. Fluorescent tube—construction, characteristic, size and wattage available, Types of lighting. Week 50, —REVISION— Week 51. —REVISION— ‘Week 52. -TEST—1 Introduction 1.1 SAFETY PRECAUTIONS We know electricity is invisible. Therefore, while Working in electrical installations one should always first take care of one's own safety. A little carelessness can result in an accident, which many times can be fatal. Therefore, electricity needs certain precau- tions of handling it to avoid danger. The following “Do Nots"’ (precautions) should always be observed before starting work on electrical equipment and apparatus : (i) Do not forget that electric shocks are generally received by the worker and can be avoided. Be careful, Do not forget to put off the main switch near it) in the case of a per- son still in contact with a live conductor or apparatus Do not attempt to disengage a person in contact with a live apparatus which you cannot switch ok immediately. Insulate yourself from the earth by standing on a rubber mat or dry board of wood before attempting to get him clear. Even then do not touch his body; push him clear with a piece of dry wood. Do not forget to put off the main switch and take away the fuse carrier along while working on an installation. Also, then puta caution notice on or near the main switch inseribing “Danger. Men at Work”. () Do not have a false feeling of security by believing that resuscitation can always bring a person back to life after an electric shock. First of all, call the doctor at once and apply artificial ti ion quickly. oi discontinue artificial respira- tion until recovery or death is certified by the doctor. (il) Do not forget to put on your safety belt before starting work ona pole. If (iy titi) tiv) a ladder is used, it must be held by another man to avoid slipping. (iii) Do not have any sharp tool protruding from the pocket when working on a high voltage overhead line. Always keep one hand in the pocket. {ix) Do not secure a position where the head is likely to become a conductor in overhead lines, (x) Do not forget to discharge the over- head lines by earthing or by other suitable means. (xf) Do not forget to earth all metallic coveringsof the electrical wiring instal- lation. (xii) Do not forget to connect a switch on a live conductor. (xiii) Do not use wires and poor insulation. (xir) Do not open or close a switch slowly or hesitatingly. Do it quickly. @¥)Do not disconnect a plug point by pulling a flexible cable. (xv) Do not work on energised circuits without taking all precautions, such asthe use of a rubber mat, shoes and gloves, etc. (svi) Do not tamper with an electrical equipment or a conductor, unless you are sure thai it is dead and earthed. (xviii) Do not renew a blown fuse until you are satisfied as to it cause and have rectified the fault. (xia) Do not close any switch unless you are familiar with the circuit which it controls and know the reason for it being open. (xx) Do not allow unauthorised persons to touch or handle electrical apparatus or come within the danger zone of high voltage apparatus. (xxi) Do not add water to acid while pre- paring an electrolyte. Always add acid to water. tools having2+ Basic Electrical Engineering (xxi) Do not bring a naked flame near an accumulator. Also,” keep the room where the accumulator is housed well- ventilated, (xxili) Do not th = w water ona live conductor ‘or equipment in the case of a fire. (oxy) Do not use a fire extinguisher on electri- equipment unless it is clearly marked for that purpose. Use only carbon tetrachloride or liquid carbon dioxide extinguishers or dry sand, It is advisable to switch off the main switch before attempting to put off an electric fire. (xxv) Do not forget that safety depends upon good carthing; so always keep Be earth connections in a good con- ‘4° dition. 1.2 METHODS FOR RESCUING AN U IOUS PERSON SUFFERING :, FROM AN ELECTRIC SHOCK Ifa person receives a shock, it is the utmost diity of the observer to disconnect him imme~ “diately from the live supply mains by cither switching off the main switch. The body should be pushed away with a dry stick or rope. Ifa stick is not available, then insulate yourself by standing on a dry wooden board, thick card- board or rubber (or coconut) matting before trying te get him clear, and even then do not touch his body. Pull him with his loose clothes like his shirt or coat. Then extinguish the spark if there is any smouldering on the clothes of the victim. If the licart of the victim stops beating it means death is certain. However, if the victim becomes thnconscisus and stops breath- ing, but hi art still beats, he should be immediately given artificial respiration because a slight delay may cause death. Artilicial res- piration should be continued till the patient regains his natural breathing or as the doctor advises after his arrival. A slight regaining of natural breathing is not an indication for stopping the artificial respi- ration because the victim may stop breathing again. Therefore, the patient should be care- fully watched and if the natural breathing ‘stops again, the artificial respiration should be followed at once. Before starting the first aid for resuscitation, the clothes around the throat, chest and waist should be loosened. If'there are any false teeth or any foreign body in the mouth, they should be removed. ‘The doctor should be sent for and till the doctor arrives, artificial respiration should be continued. There are many methods of artificial respi- ration and any one of them can be followed depending upon the necessity and requirement. Some of these methods are given below, First Method It is the best method of ial respiration and can be followed as explained below : 1. Lay the vi in Fig. 1.1 ‘on the ground as illustrated Fig.1.1 Inspiration 2. Puil his arms forward and put his head on one side resting on an arm so that he can breath easily. 3. Kneel over the victim, placing your hand flat on his back near the lowest rib in such a manner that the thumbs touch each other and are parallel to the spine. Now spread the fingers on each side over his lower ribs. 4. Lean forward gently over the patient, exerting a downward pressure for two seconds. Similarly, release the pressure slowly by moving backward, keeping the hands in the same position for two seconds as shown in Fig. 1.2. This expands and contracts the patient’s Jungsso as to imitate the breathing. Fig. 1.2. Expiration5. When the victim starts: breathing, it is better if the rescuer synchronizes his own breathing with him so that the victim can arrive at the natural rate of breathing. This process should be repeated 12 to IS times per minute and should be followed continuously with great patience because it can take hours to bring the respiration back. Second Metbed This method is adopted only when a victim's body has some burns on the chest or anywhere on the front side of the ‘body. The patient must be laid on the floor as shown in Fig. 1.3 with a pillow or rolled coat under his shoulder, Then the following procedure should be followed. 1. The operator should kneel in the position ‘shown in Fig. 1.3. Fig. 1.3 Inspiration 2. Tilt the head a litte back. It keeps the tongue out of the throat, thus giving passage to the air. 3. Hold the victim just below the elbow and draw his hand over his head until they are horizontal. Keep them in that state for about two seconds. 4, Now bring the victim's arms down on each side of his chest, pressing inward on his arms so as to compress his chest as in Fig. 1.4. Fig. 1.4 Expiration Introduction 3 5. After two seconds, repeat the process again. It should be done 12 to15 times a minute till the patient resumes breathing. In this procedure two persons are necessary for performing the artificial respiration because it is required to draw the tongue of the patient out~during each inhalation attempt and release it during each expiration stroke. For this reason this method is a little bit difficult and inconvenient to perform. - ‘Third Method (Artificial Respirator Method) It is the easiest od of arti- ficial respi available. ‘When the victim has suffered an electric shock and is unconscious, and it is required to bring his respiration-‘back, an artificial respirator is used. It consists of a rubber-bulb mask and an air filter along with a transparent celluloid valve arrangement. Th air enters through the holes of rubber bulb and goes out through the outlet valve. The mask is placed on themouth and nose of the patient as shown in Fig. 1.5 and the rubber bulb is pressed at the rate of 12 to 15 times per minute to bring his respira- tion back. This process should be continued regularly till the doctor advises to stop. The operation of the respirator is explained below. Fig. 1.5 Artificial respirater ‘The rubber mask is fitted on the mouth and nose of the victim. When the rubber bulb is pressed the air of the bulb passes through the air filter which lifts the inlet valve and closes the outlet valve. Now this filtered air enters the lungs of the patient through the mask and nose. When the pressure on the bulb is relea- sed, the inlet valve closes and the outlet valve is opened which now gives path tothe used air to go out. The detailed diagram of the resus- citator is shown in Fig. 1.6.4 = Basic Electrical Engineering Fig. 1.6 Resuscitator Special Instructions 1, Never give any drink to the unconscious man. 2. Violent operation of the process must be avoided because an internal injury in the affected organ may be harmed due to quick and excessive pressure. 3. fe is. a burn on the body, it should be properly dressed after the recovery of the patient. 4. The patient should be kept warm. 5. No medicine should be given without the consent of the doctor. 6. An owner of the factory must provide and fix. a chart explaining the methods of arti- ficial respiration and carrying, the name ofthe nearest doctor, telephon¢ number, and hospital and residential address so that he may be contacted immediately in time of need. 1.3 COMMON HAND TOOLS, THEIR USES. CARE AND MAINTENANCE For easy performance and good quality of work, it is always preferred to have standard tools. Most accidents occur due to the use of cheap and blunt tools. It is, therefore, always necessary to take proper care and maintenance of tools (Table 1.1}, 1.4 IDENTIFICATION OF BOLTS, NUTS AND ‘SCREWS Bolt tis a locking device. which is used with the combination of outs. It is specified with its diameter and length. It is generally not fully threaded. (See Fig. 1.7). aes Fig. 1.7 Bolt Screw It is also a type of bolt but its threads are from the head to the bottom. The size of the screw is also measured according to its threaded length and diameter, as shown in a Fig. 18 Screw Nat It is generally used on screws and bolis for locking purposes. 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