Professional Documents
Culture Documents
ENGINEERING
NAME : G.K.T.PREMARATHNA
FIELD : ELECTRICAL ENGINEERING (POWER)
PREFACE
This report presents the experiences and knowledge I have gathered during the first 3 months
training period starting from 10th February 2014 to 09th May 2014 at Orange Electric of OREL
Corporation (Pvt) Limited.
Chapter one reviews information about the training organization, its main functions,
organizational structure, business products, welfare and safety practices. The experience and
knowledge gained within the period of industrial training are presented in the second chapter.
Information about the work shop I visited, duties and functions performed during the training
period is included. Problems encountered during training and solutions found are also discussed
in the second chapter. In the third chapter, gives a conclusion of training and of this report.
I would like to offer my sincere gratitude to the Advanced Technological Institute (ATI)
Colombo 15, National Apprentice and Industrial Training Authority (NAITA) and OREL
Corporation (Pvt) Limited for offering this training opportunity.
Further I must extend my deepest gratitude to Mrs. Anodya Ariyarathna, Director of ATI
Mattakkuliya. In addition, Mr. Yogaganeshan, Head of Department Electrical Engineering and
all academic staff of my Institute who guides me at all the times.
I am grateful to Factory Manager of OREL Corporation (Pvt) Limited. for giving us this
opportunity. I also appreciate the cooperation from Mr. Ekanayaka the training coordinator of
Orange Electric. I would be grateful to thanks Production Manager Mr. Gervin Sugath, who gave
me the guidance for a better training. My special gratitude‟s also offered to all the Engineers and
other officers. My sincere thanks also belong to Head of Department and supervisor in the
Electrical department. Also I would like to thank all the other Electricians and Operators who
helped me in many ways during this training period.
Above all the things, it is the efforts of my parents and the family members gave me strength and
support. Finally I wish to convey my gratitude to everyone that I may have forgotten to mention
above, who supported me to complete my In-plant Training successfully.
G.K.T.Premarathna,
Student of HNDE,
Department of Electrical Engineering,
Advanced Technological Institute,
Colombo 15.
LIST OF TABLES
OREL Corporation Private Limited (Orange Electric Corporation) is the biggest electric
company, which is manufacturing, exporting and importing world class Electrical Products based
in Sri Lanka.
With their customer oriented approach, all the business policies are based on high ethical values.
They endeavor to maintain complete transparency in all the business procedures. All the 1000
employees of the company stand by the company‟s vision of attaining complete client
satisfaction. They have earned the confidence of many eminent clients from countries like India,
England, Australia, Austria, Maldives, Bangladesh, Pakistan, Singapore, Korea, Japan, Taiwan,
Cypress, Nepal, Dubai, and Uganda.
The Orange Electric was started in 1978. It started as an Australian Sri Lankan joint venture with
Clipsal, with a simple assembly line producing a limited range of switches and sockets. From
then on, the company experienced phenomenal growth and market leadership, manufacturing a
complete range of electrical products. The sale of Clipsal Australia to the French multinational
company Schneider Electric was a turning point in the history of the company, as this twist of
fortune led to the foundation of Orange Electric. At this critical juncture it was decided to resist
against the sale of the company to a multinational.
1.1.2. Vision
"To create a billion dollar global electrical brand"
1.1.3. Mission
"To add more to life with electricity"
Bulbs
CFL Lamps are created a strong foothold in the business of manufacturing and exporting world
class CFL Lamps. Tube lights and LEDs also produced in orange
Cables
The Electrical Cables are specially manufactured using the best grade raw materials. Thus, these
Electrical Cables are the best choice that is available in the markets all across the world.
Moreover, the clients can access this enviable range of Electrical Cables in varied specifications
that too at very reasonable rates.
1.1.7. Organization
Orange electrical is very highly organized company and It has very complicate organization
system. The total number of employees at Orange electric is about 1000. This is main
organization structure of orange electric.
Board of Directors
Chairmen
Managing Director
Other Director
Factory Production Manager
EPF is required Employee‟s contribution is 8% of the total monthly earnings (To be deducted
from the Employee‟s Salary) and Employer‟s contribution is minimum of 12% of the total salary
of the employee monthly.
ETF is required Employee‟s contribution of 3% percentage of the earning of an employee.
The normal working hours of the Orange Electric Factory are 7.30 am to 5.00 pm. Excess of
normal working hours to be treated as overtime. The transport service is gone on according to the
working times.
An office employee shall be granted 14 days annual leave with pay in respect of the second and
any subsequent year if he has been continuously in employment during the year.
Welfare
Orange Electric, a company who places great emphasis on the welfare of its employees has
recently implemented several distinctive programs, giving new meaning to „work life balance‟
whilst taking their „Healthy Employee‟ concept to an altogether higher plain. The Company has
devised some interesting and special programs that greatly contribute.
Yoga and Karate sessions.
Meditation programs and First Aid facility.
Changing Room and Lockers.
Meals, Tea & Washing facilities.
Annual cricket match, New Year festival and annual trip.
Bonus and Loans.
Transport service.
Welfare shop.
In the Orange Electric workshop, we used safety methods, because of electrocution is mainly due
to serious injury. The operation of tools and machineries also cause to hazards. We considered
about personal safety, human health and equipment safety.
Below safety instructions were followed in workshop for the prevent from electrical hazards,
We used personal protective equipment such as Safety shoes, Gloves, Ear Plugs,
Mufflers, Safety Goggles and etc.
Used appropriate tools and equipment for work.
Before done the work, instruction was read properly.
We followed out to wear suitable cloth, not too tight and not too loose.
After the work was finished, cleaned the surface and electrical switch off the machineries
power supply.
We kept the floor of workplace free from oil, water and grease.
Used cleaners for the clean the body.
The company has a response for all electrical work, systems and equipment under their control.
They must ensure that and are given sufficient information of any known hazards or risks to
health and safety to enable them to work safely;
In Orange Industrial Electrical workshop, Power Electrical Panels were designed as per the IEC
standards. These power electrical panels were trusted for Safety Reliability and Quality in Low
Voltage Power Distribution. Power Electrical Panels made available in various specifications in
Industrial Electrical workshop,
Distribution panels
o Main distribution panels
o Sub distribution panels
Changeover panels
o Manual Changeover Panels
o Automatic Changeover Panels (ATS panel)
Motor control panels
Capacitor Bank panels
Steel enclosures
The Power Electrical Panels consist of metering devices, protective devices, switching devices,
conductors, bus bar chambers, indicators, circuit breakers, capacitors and many other types of
equipment.
Before designing electric panel the following details should be incorporated into it.
Location and dimension of the panel
Load description, Amperage, Voltage required
Cable size and conduit size
Type of insulation.
Ventilation, temperature and space arrangement in the panel
IEC regulation
I was able to practice the process of panel assembling and panel wiring in Orange Electric
workshop.
2.1.1. Panel assembling procedure
First of all, the panel box, cover plates, panel door, mounting plate and benches were
selected according to the given drawing.
Door arrangement was fixed by using Panel hinge according to general arrangement.
The door Beading and panel key mount was attached to the door.
The cover plate bracket was prepared by using drill machine, tap cutting tool, flat screw
driver.
Switch gear benches and din rails were arranged on the mounting plate according to
drawing.
Mark holes position to fix the benches, din rail bracket, profile using pencil and drilled all
holes using drilling machine.
Taped all holes using tap cutting tool.
Din rails and benches were fixed by using flat screw.
Arrange bus bars, bus bar insulators, neutral link, neutral bar, earth bar, earth link as
general arrangement using bus bar bend machine.
When I was assembling the panels in the workshop, Fallowing tools and machineries were used.
Before I used these tools and machineries safety rules and operating instruction were fallowed
correctly.
Cable Cutters
Cable cutters are useful to cut cables. Gilbow cutter (heavy-duty cable cutters) cuts the large
size cables & common bas bar.
Crimping Tool
A crimping tool is a tool designed to crimp or connect a connector or lug to the end of a
cable. To use this crimping tool, each wire is first placed into the correct position. The
hydraulic crimping tool crimps high gauge wire easily with steady hydraulic power.
Electric Drill
A Drill is a driving tool attachment, usually a drill bit. It is used for drilling, tapping and
boring holes in various materials. Some electric drills drown with rechargeable batteries.
Nail
Screw
Flat washer
Spring washer
Bolt (CSK Bolt - 4x10mm, 4x12mm, 5x10mm, 5x12mm, 5x16mm, 5x20mm)
(PH Bolt - 5x35mm, 5x20mm, 4x10mm, 4x12mm)
(Hex Bolt - 8x30mm, 8x15mm, 6x8mm, 6‹12mm, 6‹15mm, 6‹20mm)
Allen Bolt
Self tapping bolt
Nuts
Stud nuts
Insulator Mounts
Bus Bar Insulator mounts are used for connecting line and neutral bar with panel mounting
board and connecting bus bar with panel board.
Cable Duct
Cable duct is wire and cable management product for routing and concealing electrical
wiring in control panels. Available in many sizes
2.3.1. Fuses
A fuse is a type of protection device in electrical applications. Fuses are designed to open circuits
the filament when excessive currents are present due to overloads or faults and to prevent further
damage to the system. Short circuit, system overload, other device failures, lightning, static
electricity or system overload are some common results in blown fuses.
Cartridge Fuse
In cartridge fuse the fuse wire is enclosed in a transparent glass tube or bulb, the whole unit is
sealed off. In case the fuse blows, it is to be replaced by new one as the cartridge fuse can not be
rewired due to its sealing. In cartridge type fuses have many other sub types as MCB type, screw
type, etc.
HRC Fuse consists of highly heat resistant material (such as ceramic) body having metal-end
caps, which is welded by silver current carrying element. HRC Fuse has high rupturing capacity.
It has constant fusing characteristics and operates fast.
Figure 2.3.1 - Cartridge Fuse Figure 2.3.2 - HRC Fuse with holder
My experience
2.3.2.1. Standard dimensions of MCBs
I was able to measure the standard size (in mm) of the MCB and RCCB. It was very
important for the panel designing and arranging the panel box.
I designed fallowing Distribution Boxes for the 300 houses in the housing apartment. This
was designed for single phase 30A house.
I have been used 30A isolator switch, 30A RCCB, four MCBs of 10A and six MCBs of 6A
according to the requirement. All were Orange production.
4mm2 CU/PVC insulated wire was used for the wiring and single phase common bus bar was
used to connect the MCBs.
The Residual Current Circuit breakers (RCCB or RCD) are the safest device to detect and trip
against earth leakage currents, thus ensuring protection against electric shock caused by indirect
contacts. These devices must be used in series with an MCB. RCCB Available in 2 Pole and 4
Pole for domestic and Industrial application
1. Electromagnet
2. Current transformer secondary winding
3. Transformer core
4. Test switch
L - Live conductor
N- Neutral conductor Figure 2.3.3.1 - Internal connection of RCCB
The RCCBs with a rated residual operating current (I∆n) of 30mA or less are used in place of
more conventional RCCBs with higher residual operating current ratings. The Rated current
range varied 10mA to 1A.
In every panel which I wired MCCB was used as the main breaker. I was able to connect trip
coils, auxiliary contacts, inter lock and panel holders with MCCB. In Orange Electric workshop
I had used “ABB”, “Schneider”, “ATION”, and “Orange” brands‟ MCCBs.
The Moulded case circuit breakers have been developed for use in commercial and industrial
protection. MCCB has thermal-magnetic operation. Trip current may be adjustable in larger
ratings.
I was able to identify the main features of a MCCB more than MCB,
High short circuit current breaking capacity ( < 20kV).
Used for high current ratings ( < 10000A )
Adjustable current and tripping time rating.
Shunt and UVT coils are used for remote opening of circuit breaker. The Shunt trip coil consists
of an electro-magnetic trip coil that is connected in series with an external field wired switch.
When energized the shunt coil, causing the breaker‟s mechanical latch to move to the open
position. Shunt coil supply is connected normally open (NO) contact point of the component.
Usually EFR, ELR are connected with the shunt coil
UVT coil is energized and activated to close the breaker when the coil supply voltage dips below
85% of the rated voltage. When we use the UVT coil with MCCB‟s we connect coil supply
through the normally close (NC) contact point of the component. At a fault condition, it stops the
supply flown through the UVT coil and then the UVT coil trips the breaker. So when a UVT coil
is used in a circuit, the MCCB cannot be switched on if there is no current supply.
Figure 2.3.5.1 – SPD device Figure 2.3.5.2 – wiring diagram of “OBO” SPD device
Phase failure relay is adjustable under voltage over voltage control device with the option of
additional sequence control. If it detects any under voltage, over voltage and phase losses in
power system, the relay coils is energized and trip the MCCB using under-voltage(UVT)trip coil.
The overload is a heat operated relay where a coil heats a bimetallic strip and releasing a spring
to operate contacts. It has NO & NC auxiliary contact points for the controls. If the overload
senses excess current in the load, the coil is de-energized. Electric motors need over current
protection to prevent damage from over-loading the motor, or to protect against short circuits in
connecting cables or internal faults in the motor windings.
Earth leakage relay monitor the leakage of current to earth on 3 phase electrical systems. The
earth leakage relay is used in conjunction with a core balance transformer (CBCT) which is
available in five different sizes to cover all sizes of three phase installations. If make a fault
condition, this core balance transformer send a signal to the ELR. The relays are available with
either a fixed 30mA or 300mA instantaneous trip point or with a user adjustable trip point and
time delay both adjustable.
Earth Fault Relay is used for the protection from earth faults. The function of EFR is as same as
ELR. Instead of a CBCT, four separate CT‟s are used to connect an EFR. It is an Electronic Trip
Unit, designed to protect the Electrical installation in case of faults or leakage currents beyond a
preset level. The tripping range for both fault current and delay time to be adjusted.
It has four current transformers. If there is a fault condition, these CTs send a signal to the earth
fault relay. Then its electronic circuit sends a signal to the protection component‟s normally open
contact. Then this normally open contact point gets closed. Now that signal is sent to the shunt
coil through the normally close contact point. Then the shunt coil is energized and trips the
breaker.
My experience
2.3.9.1. Characteristic settings procedure of Earth Fault Relay
I was able to perform the set fault current and trip time of DELAB Earth Fault Relay
Press [Select] once to enter mode (it will show the existing value Range 0.03 ~ 30 A)
Set the desired Fault current using the [Up / (+) or Down / (-)] button.
Press [ Select ] to store / confirm new value
Press [ Select ] until mode is displayed.(it will show the existing value Range 0.05 ~ 20s)
Set the desired trip time using the [Up / (+) or Down / (-)] button.
Press [ Select ] to store / confirm new value.
Current transformers can reduce or "step-down" current levels from thousands of amperes down
to a standard output of a known ratio to either 5 Amps or 1 Amp for normal operation. CTs are
used with watt meters, power factor meters, watt-hour meters, protective relays and metering
applications, because they are insulated away from any high-voltage power lines. Its primary
winding is just a conductor or bus bar placed through a central hole. The secondary winding may
have a large number of coil turns wound on a laminated core as shown below.
The current transformer should never be open-circuited or operated with no-load attached when
the main primary current is flowing. If the ammeter is to be removed, a short circuit should be
placed across the secondary terminals first. This is because when the secondary is open-circuited
it will produce a large secondary voltage. Current transformers are available in Ring type,
Bushing type, square type, bar type and etc.
Accuracy decreases with increased burden (load) or low line current. Accuracy Class of
Metering CTs:
Metering Class CT
Class Applications
0.1 To 0.5 Precision measurements or protection
1 General industrial measurements more sensitive
3 General industrial measurements
5 Approximate measurements
Table 2.4.1 - Metering Accuracy Classes of CTs
Increasing the number of primary turns can decrease the turn‟s ratio. A current transformer with
a 300 to 5 turn‟s ratio can be changed to a 150 to 5 turn‟s ratio by passing the primary twice
through the window. Also the turn‟s ratio can be either increased or decreased by wrapping wire
from the secondary through the window of the current transformer.
The Core Balance Current Transformer is a current transformer is used for earth fault protection
in grounded three phase systems. It is also known as the zero-sequence current transformer. Each
phase conductor and neutral should pass through the core balance current transformer. It is
essential that each conductor passes through the device in the same direction.
2.4.3. Indicator
Indicators are used to get information about states of equipment such as ON (Green), OFF (red),
TRIP (Orange). Indicators are available in read yellow blue and orange and 12V to 230V.
2.4.4. Ammeter
An ammeter is a measuring instrument used to measure the electric current in a circuit. Current
transformers and ammeters are used together as a matched pair in which the design of the current
transformer is such as to provide a maximum secondary current corresponding to a full-scale
deflection on the ammeter. For most current transformers the primary and secondary currents are
expressed as a ratio such as rated current : 5A.
Power analyzers accurately measure electrical power characteristics of the system. Power
analyzers, also called power meters or watt meters, provide precise measurements of power
supply system. This is useful for getting to power consumption and many more values of the
system.
2.5.1 Relay
A relay is a switching device. Relays are used where it is necessary to control a circuit by a low-
power signal with complete electrical isolation between control and controlled circuits or where
several circuits must be controlled by one signal.
Relay consists with coil, normally open and normally closed contact points. When current starts
flowing through the control coil, the electromagnet starts energizing and contact points are
changed their position.
Coil voltage can be 12V to 230V AC or DC. Also contact current rating is important factor.
According to the contact pin arrangement, relays are categorized as 8 pins, 11 pins, 14 pins and
etc. relay is fixed with its base.
2.5.2. Contactor
I was able to identify the contactor construction and usages, because contactor was used in every
motor control panel. It was used for the high power application switching on power circuit. Also
I connected timers, auxiliary contact points (side and top), timers and mechanical interlock to the
contactors according to the requirement. In Orange Electric workshop I had used “ABB”,
“Schneider” and “LS” brands‟ contactors.
Contactor is also a type of relay. The contactor consists with normally Open contacts and also
auxiliary contact points. Also it can connect auxiliary contact points (side and top), timers and
mechanical interlock.
A contactor consists of mainly 2 parts-Fixed and movable jaws. the fixed jaws are firmly
connected with the circuit and is a provided with a coil having movable jaw as soon as current is
allowed to flow from the circuit the coil gets charged and due to electromagnetic effect it attracts
the movable metal jaw, thus the circuit is complete with the contact provided by the movable
jaw. This is the functioning of contactor. When current through the coil loss, coils demagnetize
and open the contacts. The coil consist with shaded pole core, because of avoiding the current
zero position of the AC supply.
The current rating of the contactor is depending on its category. The categories in standard are
described as:
AC-1 - Non-inductive or slightly inductive loads, resistance furnaces
AC-2 - Starting of slip-ring motors: starting, switching-off
AC-3 - Starting of squirrel cage motors. (Inductive and resistive loads)
AC-4 - Starting of squirrel-cage motors with inching and plugging duty.
ON delay
Upon application of input voltage, the time delay begins. At the end of the time delay, the output
is energized. Input voltage must be removed to reset the time delay relay & de energized the
output.
OFF delay
Upon application of input voltage, the time delay relay is ready to accept a trigger. When the
trigger is applied, the output is energized. Upon removal of the trigger, the time delay begins. At
the end of the time delay, the output is de-energized..
According to the requirement, Timer relay characteristics are selected according to fallowing
parameters.
Input coil current range - 12v to 440V (DC / AC)
Time settings - seconds, minutes, hours, days, month, years
Analog, digital, 24 hours, programmable, star-delta, etc.
Pin configuration - 8 pin, 11 pins, and 14 pins etc.
The selection of cables for panel wiring was best done with reference to the latest and specific
manufacturer‟s cable data and application guides with tables giving cable dimensional, and
current rating information.
The cross-sectional area of the conductors chosen should be of the optimum size to carry the
specified load current or short circuit short term current without overheating and should be
within the required limits for voltage drop.
PVC (Polyvinyl Chloride) – is the most commonly used thermoplastic insulator for cables. It
is cheap, durable and widely available. PVC Normal operating temperatures are typically
between 750C and 1000C (depending on PVC type)
PE (Polyethylene) – is part of a class of polymers called polyolefin. Polyethylene has lower
dielectric losses than PVC and is sensitive to moisture under voltage stress (i.e. for high
voltages only).
My Experience
I was able to create an electrical design & wire the fallowing distribution panel in the orange
workshop
This panel box was designed 250x400x150 size. The 150mm was not enough for the
“HOBUT” 200/5A core balance CT. so that I had to cut the cover plate of the panel, before
the wired.
In Orange workshop I observed Manual type and Auto type changeover panels. In Automatic
Changeover Panels we used several types of Auto transfer Switches (ATS). MCCB type,
Contactor type and Changeover type were some of them.
A changeover panel is operating on a mains power failure system. There are two types of
changeover panels.
I was able to wire the below control circuit of Automatic Changeover panel. The panel consisted
with “Telegarn” ATS changeover with motorized kit.
This circuit was designed to get continues power supply from CEB or generator. According to
this panel circuit it can automatically switch on the generator when CEB power failure.
Important points
The “Telegarn” ATS changeover unit was used separate auxiliary supply from CEB side
(used pin no 01 and 02) and generator (used pin no 03 and 04).
There was two selector switches, one was used to Auto-Manual selector other one was used
to select CEB or Generator in manual mode.
Phase Failure Relay (PFR) was used to detect the supply conditions in CEB and generator.
Motor Control panel consist of different motor starting methods such as Direct Online Starter
(DOL), Star-Delta Starter, Auto Transformers, Variable Speed Drives or Variable Frequency
Drives. Mainly used DOL and Star-Delta methods,
This is the most common method of starting low power induction motors, where the starter is
connected directly across the three phase of the supply. However, the starting current at the
moment of switching direct-on-line can be as high as 6-8 times the rated current.
A Direct Online Motor Starter (DOL) consists of following components.
Typically, the contactor of the DOL circuit is controlled by separate start and stop push buttons.
When the start push button is pressed, the current flow through the control circuit and the
contactor coil which will energize the contactor coil and then the NO contactor contact get
closed and self holding. So the current is passed to the motor. When the stop button is pressed or
the over load coil is operated, the control circuit get broken and the contactor drops out.
Important points
When very large (< 5HP) motors are started by DOL, they cause a disturbance of voltage on the
supply lines due to large starting current surges. To limit the starting current surge, large
induction motors are started at reduced voltage and then have full supply voltage reconnected
when they run up to near rotated speed. Star-Delta starter is the reduced voltage starting method.
This type reduces phase voltage to about 58% of the running voltage, which reduce the current
and the motor‟s torque.
Figure 2.10.3 – Power circuit and Control circuit of star delta panel
The Star/Delta starter is manufactured from three contactors, an on delay timer and a thermal
overload. The currents through the winding are 1/√ 3 of the current in the line.
There are two contactors that are close during run, often referred to as the main contractor and
the delta contactor. These are AC3 rated at 58% of the current rating of the motor. The third
contactor is the star contactor and that only carries star current while the motor is connected in
star. The current in star is one third of the current in delta, so this contactor can be AC3 rated at
1/3 (33%) of the motor rating.
In the star-delta starting method, firstly the motor starts as star after 80% of its full speed it can run as
delta. The one delay timer is sated that time of 80% of its full speed.
My Experience
I was able to create electrical design & wire the fire pump panel.
Two main pumps of 37kW and a jockey pump of 2.2kW were used for the panel.
The 37kW pumps are connected as star-delta and 2.2kW pump as direct online
connection.
Calculation
For Main pumps
o Full load current = P = 37 * 103 = 64.3 A
V √3 Cos Φ 415 * √3 * 0.8
o Main & delta contactors = Full load current * 1/√3 = 64.3 * 1/√3 = 37.3 A
o Star contactor = Full load current * 1/3 = 64.3* 1/3 = 21.4 A
o Main pump over load = 30A to 42A
o Main pump MCCB =100A
Important points
The panel was designed with two pressure sensors, when sensor 1 will gives signal to the
panel, main pump1 will operates. If pump1 will overload, the pump 2 will operates. The
Pump 1 or pump 2 needs more power, sensor 2 will gives signal to jokey pump operation.
“ABB” MCCBs, over loads and contactors were used.
“Omron” 11 pin relays and “ANLY” 8 pin timers are used.
The panel was designed as auto and manual operation.
Two position selector switches were used for auto manual selector and pump selector.
The “ABB” contactor has only one external normally open (NO) contact point and no any
normally close (NC) contact point. I had to fallowed one of below way to solve this,
o Can connect auxiliary contact points to the contactor.(side contact or top contact)
o Can use mechanical interlock instead to the contact point interlock.
o Can connect another relay with parallel to the contactor.
I was able to connect auxiliary contact points. Other solutions are not suitable for this panel.
When the panel was being tested, the one timer didn‟t operate correctly.
o According to the 8 pin timer connection, point 1 and point 8 are act as common. If
point 1 is connected to the incoming side, the point 8 must be connected to the
incoming side. Otherwise timer will not operate correctly.
Various industries and power system loads are inductive that take lagging current which decrease
the system power factor. The poor power factor increases the current flowing in conductor and
thus copper loss increases. Further high reactive power flows through the line, the apparent
power (KVA) and cost of electricity bill is high.
The power factor of a circuit may also be defined as the ratio of active power (KW) to the
apparent power (KVA). The lagging reactive power is responsible for the low power factor. It is
clear from the power triangle that smaller the reactive power component, the higher is the power
factor.
The power factor can be improved by connecting capacitors in shunt with the system operating at
lagging power factor. These static capacitors provide leading current. A number of capacitor
units are combined to capacitor bank arrangement. Capacitor bank connected in shunt with load.
They improve the electrical supply quality and increase the efficiency of the system. Also reduce
reactive power and cost effective. Power factor correction is an investment that helps to improve
company‟s profit performance. The capacitor bank with automatic regulation offers the most
economical solution.
Capacitor bank offers several advantages over other methods of power factor improvement.
Losses are low in static capacitors.
There is no moving part, therefore need low maintenance.
They are lightweight so it is can be easy to install.
My Experience
I was able to create electrical design & wire the capacitor bank according to the given details and
requirements.
Active Power is 260kW
Current power factor (cosØ1) = 0.7
Needed to improve up to (cosØ2) = 0.95. (0.95 is the default value)
Calculations
Current Apparent Power = 140kW / 0.7 = 200 kVA
Target Apparent Power = 140kW / 0.95 = 147.36 kVA
Current Reactive Power = 140 x tan(Ø1)= 142.8 kVAR
Target Reactive Power = 140 * tan(Ø1)= 46.01 kVAR
Needed capacitor bank = {Current Reactive Power - Target Reactive Power}
= 142.8 – 46.01 = 96.79 kVAR
Important points
Seven steps “LOVATO DCRK7 Automatic power factor controller” was used.
1000 x 2000 x 600 powder coated panel box was used.
According to rated values power and control circuit drawings were designed.
100A MCCB (ABB) was used as main breaker & 35mm2 wires are used.
1 x 1\8 copper bus bar chamber was used to distribute power to capacitors.
100/5 rated CT was used for current supply.
R1 relay was used in protection purpose, when generator will switched on, capacitors are
disconnected.
„LS‟ brand capacitive switching contactors with discharging resistors were selected
according to kVAR value & current value.
Control circuit was wired by using auto cable.
Temperature was one of the main stress factors for polypropylene type capacitors, an
average temperature of EPCOS” PFC Capacitor is 45 °C, so that two 230V cooling fans
are included in to the panel.
Panel was checked according to stranded.
At the first power up, the unit in manual mode and press the MODE key and set CT
primary current, Smallest step kVAR, Rated capacitor voltage, required cosØ2 value.
Clamp meter
Clamp meter is an electrical device having two jaws which open to allow clamping around an
electrical conductor. This allows properties of the electric current in the conductor to be
measured, without having to make physical contact with it, or to disconnect it for insertion
through the probe.
Megger tester
The Megger tester is a method of testing making use of an insulation resistance meter that will
help to verify the condition of electrical insulation. The tester generates a high DC voltage of
around 500V to 5KV or more. In distribution panels, insulation resistance more than 5 MΩ, it has
enough insulation resistance.
All equipments were tested to ensure that it operates correctly. All switches, isolators, analyzers,
EFR, ELR, PFR and circuit breakers must be manually operated and checked the connectivity to
ensure that they function correctly, also that they have been correctly installed and adjusted
where adjustment is required.