MJP ROHILKHAND UNIVERSITY

DEPARTMENT OF ELECTRICAL ENGINEERING

PROJECT REPORT OF

CONTACTOR BASED INDUSTRIAL PROTECTION SYSTEM

PROJECT COORDINATOR:- PROJECT GUIDE:-

Dr. SULABH SACHAN Mr. ROHIT KUMAR VERMA

(Asst. Prof) (Astt. Prof)

SUBMITTED BY:-

KIRAN DEVI (16EE22)

KRISHNA RANJAN SINGH (16EE24)

NISHCHAY PRATAP SINGH (16EE33)

SHRIKANT YADAV (16EE51)

 CONTENTS
1. Introduction

2. Literature Survey

3. Methodology

4. Instrument Used

5. Advantage and Disadvantage

6. Conclusion
 1. INTRODUCTION
This project will basically cover the complete protection of the industrial used application procedures.
The real time use of contactors will used to make it more efficient and reliable. The basic switching of the
unit and protection is used to be done with the help of contactor. This device is capable of running on the
high ampere ratings.
This device will make over temperature along with the voltage regulation control systems. The higher
voltage as well as the lower voltage along with the temperature shut down procedure will execute using
the Contactor. The multiple alarms along with the visual notifications will execute. The voltage increase
or decrease will execute on auto transformer. The relay section along with sensing element will make the
start of the basic protection system.
When a relay is used to switch a large amount of electrical power through its contacts, it is designated by
a special name: contactor. Contactors typically have multiple contacts, and those contacts are usually (but
not always) normally-open, so that power to the load is shut off when the coil is de-energized. Perhaps the
most common industrial use for contactors is the control of electric motor

Fig (3): - Contactor Used For Providing Fig (2):-Circuit Diagram of Temperature

Temperature Protection Protection

 2. LITERATURE SURVEY
In present scenario, as the human race is developing day by day so their need of more advance devices
and machines have increased, which increase the occurrence of fault frequently, so to overcome such
hazardous condition we need to give all our equipment protection from electrical parameters like over
voltage, under voltage, over current, over temperature, short circuit. So to cut out our devices from main
supply we have to make such mechanism whenever the above electrical parameters occur we can do
switching with an ease. The all above topics under one roof called switchgear and protection, switchgear
is a generic term which includes all the switching devices associated with power system protection. It also
includes all devices associated with control, metering and regulating of electrical power systems.
Assembly of such devices in a logical manner forms switchgear. In other words systems used for
switching, controlling and protecting the electrical power circuits and different types of electrical
equipment are known as switchgear. And for industrial purpose where most of the electrical equipment’s
which draws large amount of current i.e. More than 15 amps contactor is a perfect shot for our need.

3. METHODOLOGY
This project proposes an effective scheme for controlling the electrical parameters like over voltage,
under voltage, over current, over temperature, short circuit. It reduces the manual effort to switch over the
circuit and break it, and by decreasing the manual effort we also lower the risk any impact to human life.
So we are increasing the life of machine and human also. Under this topic for complete this study. Design
architecture is the main block function for the proposed design. While the components description will.

Contactor is the heart of this project, which performs the main task that is switching, and when it have to
switch will be send through various sensors.
 4. COMPONENTS USED
4.1 CONTACTOR

A contactor is an electrically-controlled switch used for switching an electrical power circuit. [1] A
contactor is typically controlled by a circuit which has a much lower power level than the switched
circuit, such as a 24-volt coil electromagnet controlling a 230-volt motor switch.
Unlike general-purpose relays, contactors are designed to be directly connected to high-current load
devices. Devices switching more than 15 amperes or in circuits rated more than a few kilowatts are
usually called contactors. Apart from optional auxiliary low-current contacts, contactors are almost
exclusively fitted with normally open ("form A") contacts. Contactors range from those having a breaking
current of several amperes to thousands of amperes and 24 V DC to many kilovolts. The physical size of
contactors ranges from a device small enough to pick up with one hand, to large devices approximately a
meter (yard) on a side.
Contactors are used to control electric motors, lighting, heating, capacitor banks, thermal evaporators, and
other electrical loads.

Fig (3):- Three Phase Contactor

4.2 RELAYS

A relay is an electrically operated switch. It consists of a set of input terminals for a single or multiple
control signals, and a set of operating contact terminals. The switch may have any number of contacts in
multiple contact forms, such as make contacts, break contacts, or combinations thereof.
Relays are used where it is necessary to control a circuit by an independent low-power signal, or where
several circuits must be controlled by one signal. Relays were first used in long-distance telegraph circuits
as signal repeaters: they refresh the signal coming in from one circuit by transmitting it on another circuit.
The traditional form of a relay uses an electromagnet to close or open the contacts, but other operating
principles have been invented, such as in solid-state relays which use semiconductor properties for control
without relying on moving parts. 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.

FIG (4):- Simple electromechanical relay

4.3 CAPACITOR
Capacitor is an electronic component that stores electric charge. The capacitor is made of 2 close
conductors (usually plates) that are separated by a dielectric material. The plates accumulate electric
charge when connected to power source. One plate accumulates positive charge and the other plate
accumulates negative charge.
The capacitance is the amount of electric charge that is stored in the capacitor at voltage of 1 Volt.
The capacitance is measured in units of Farad (F).
The capacitor disconnects current in direct current (DC) circuits and short circuit in alternating current
(AC) circuits.

FIG (5):-Actual Pictures of Fig (6):- Symbols of Different Capacitors

Different Type of Capacitors
4.4 INDUCTOR

An inductor is a passive electronic component that stores energy in the form of a magnetic field. In its
simplest form, an inductor consists of a wire loops or coil. The inductance is directly proportional to the
number of turns in the coil. Inductance also depends on the radius of the coil and on the type of material
around which the coil is wound.

Fig (7):- Different Type of Inductors Fig (8):- Symbol of Inductor

4.5 RESISTOR
resistor is a passive two-terminal electrical component that implements electrical resistance as a circuit
element. In electronic circuits, resistors are used to reduce current flow, adjust signal levels, to divide
voltages, bias active elements, and terminate transmission lines, among other uses. High-power resistors
that can dissipate many watts of electrical power as heat may be used as part of motor controls, in power
distribution systems, or as test loads for generators. Fixed resistors have resistances that only change
slightly with temperature, time or operating voltage. Variable resistors can be used to adjust circuit
elements (such as a volume control or a lamp dimmer), or as sensing devices for heat, light, humidity,
force, or chemical activity.

Fig (9):- An array of axial-lead resistors Fig (10):- Symbol of Resistor

4.6 TRANSFORMER
A transformer is a passive electrical device that transfers electrical energy between two or more circuits.
A varying current in one coil of the transformer produces a varying magnetic flux, which, in turn, induces
a varying electromotive force across a second coil wound around the same core. Electrical energy can be
transferred between the two coils, without a metallic connection between the two circuits. Faraday's law
of induction discovered in 1831 described the induced voltage effect in any coil due to changing magnetic
flux encircled by the coil.
Transformers are used for increasing or decreasing the alternating voltages in electric power applications,
and for coupling the stages of signal processing circuits.

Fig (11):- Cross Sectional View of Three Phase Transformer

4.7 DIODE
A diode is a two-terminal electronic component that conducts current primarily in one direction
(asymmetric conductance); it has low (ideally zero) resistance in one direction, and high (ideally
infinite) resistance in the other. A diode vacuum tube or thermionic diode is a vacuum tube with
two electrodes, a heated cathode and a plate, in which electrons can flow in only one direction, from
cathode to plate. A semiconductor diode, the most commonly used type today, is a crystalline piece
of semiconductor material with a p–n junction connected to two electrical terminals. [5] Semiconductor
diodes were the first semiconductor electronic devices.

Fig (12):- Semiconductor Diode

4.8 RECTIFIER
A rectifier is an electrical device that converts alternating current (AC), which periodically reverses
direction, to direct current (DC), which flows in only one direction.
The process is known as rectification, since it "straightens" the direction of current. Physically, rectifiers
take a number of forms, including vacuum tube diodes, mercury-arc valves, stacks of copper and
selenium oxide plates, semiconductor diodes, silicon-controlled rectifiers and other silicon-based
semiconductor switches. Historically, even synchronous electromechanical switches and motors have
been used. Early radio receivers, called crystal radios, used a "cat's whisker" of fine wire pressing on a
crystal of galena (lead sulfide) to serve as a point-contact rectifier or "crystal detector".

Fig (13):-Circuit Diagram of Rectifier

4.9 TRANSISTOR
Transistor is a semiconductor device that can both conduct and insulate. A transistor can act as a switch
and an amplifier. It converts audio waves into electronic waves and resistor, controlling electronic
current. Transistors have very long life, smaller in size, can operate on lower voltage supplies for greater
safety and required no filament current. The first transistor was fabricated with germanium. A transistor
performs the same function as a vacuum tube triode, but using semiconductor junctions instead of heated
electrodes in a vacuum chamber. It is the fundamental building block of modern electronic devices and
found everywhere in modern electronic systems.

Fig (14):-circuit diagram an n–p–n Fig (15):- An-p-n Transistor Actual Picture
4.10 IC 555 TIMER
The 555 timer IC is an integrated circuit (chip) used in a variety of timer, pulse generation,
and oscillator applications. The 555 can be used to provide time delays, as an oscillator, and as a flip-flop
element. Derivatives provide two (556) or four (558) timing circuits in one package. [2]
Introduced in 1972[3] by Signe tics,[4] the 555 is still in widespread use due to its low price, ease of use,
and stability. It is now made by many companies in the original bipolar and in low-
power CMOS technologies. As of 2003, it was estimated that 1 billion units were manufactured every
year.[5] The 555 is the most popular integrated circuit ever manufactured.

Fig (16):-Internal block diagram Fig (17):-A 555 Timer

Of 555 Timer

4.11 IC 741
The IC 741 operational amplifier looks like a small chip. The representation of 741 IC op-amps is given
below that comprises of eight pins. The most significant pins are 2, 3 and 6, where pin2 and 3 is pin 2 and
3 denote inverting & non-inverting terminals and pin6 denotes output voltage. The triangular form in the
IC signifies an op-amp integrated circuit. The current version of the chip is denoted by the famous IC 741
op amp. The main function of this IC 741 is to do mathematical operations in various circuits. IC 741 op
amp is made from various stages of transistor which commonly have three stages like differential i/p, a
push-pull o/p and an intermediate gain stage. The differential op-amps comprises of a set of FETs or
BJTs.

Fig (18):- Schematic Diagram of Fig (19):-AN IC 741 IC 741

IC 741
4.12 VARIABLE RESISTOR
A variable resistor is a resistor of which the electric resistance value can be adjusted. A variable resistor is
in essence an electro-mechanical transducer and normally works by sliding a contact (wiper) over a
resistive element. When a variable resistor is used as a potential divider by using 3 terminals it is called
a potentiometer. When only two terminals are used, it functions as a variable resistance and is called
a rheostat. Electronically controlled variable resistors exist, which can be controlled electronically instead
of by mechanical action. These resistors are called digital potentiometers.

Fig(20):-A 5k ohm Variable Resistor and its symbol

4.13 POWER DIODE
Power diodes are also similar to signal diodes but have a little difference in its construction.
In signal diodes the doping level of both P and N sides is same and hence we get a PN junction, but in
power diodes we have a junction formed between a heavily doped P + and a lightly doped N– layer which
is epitaxial grown on a heavily doped N+ layer. Hence the structure looks as shown in the figure below.

The N– layer is the key feature of the power diode which makes it suitable for high power applications.
This layer is very lightly doped, almost intrinsic and hence the device is also known as PIN diode, where i
stand. As we can see in the figure above that the net charge neutrality of the space charge region is still
maintained as was the case in signal diode but the thickness of space charge region is quite high and
deeply penetrated into the N– region.
However adding this N– layer significantly increases the ohmic resistance of the diode leading to more
heat generation during forward conduction state. Hence power diodes come with various mountings for

Fig (21):-Schematic Diagram of Fig (22):- A Power Diode

A Power diode
 5. ADVANTAGES
 It helps to protect the electrical machines and appliances. It interrupts the circuit that is
experiencing overload while still allowing currents to flow through the unaffected
circuits.
 It also provides isolation of circuits and the part of the system that is energized. This
provides protection to the person who is repairing the power system/equipment.
 It enhances system availability by allowing more than one source to feed a load
 It provide controlling of system from remote location
 No need of manual work for switching whenever fault occurs

5.1 LIMITATIONS

 Initial investment is higher compared to conventional manual switching

 Circuit Congaing to many circuitry complex and hard to maintain
 Op Amps are Used therefor atmospheric factor will also reduce effectiveness of whole protection
circuit
 Coil may burn due which would cause no magnetic field, hence the contacts won’t close and the
contactor wouldn’t operate.
 2- Contacts may burn or fray which may also cause the contactor not to work. Contacts may also
weld shut which may cause the load to keep running even when there is no control voltage which
may cause unsafe machine or machine damage.
 3- The insects can get in the contacts which may cause the contactor failure which may ultimately
cause the equipment failure.

While selecting the contactor the designer can remedy some of the problems such as using the cover over
the contacts so the insects don’t get in the contacts. Also, depending on application one may want to
choose a contactor which would have open contacts in case of fault or a redundant contactors so if
contacts of one shut close the other one could control and save the machine failure or save the machine
operator from being injured.
 6. CONCLUSION
For every successful and efficient working of any machinery its control and protection of different
parameters is necessary. Protection is not a new topic to the world of engineering but automatic and
remote control is still under development.

By using smart control and switchgear one can save surplus amount of energy and human investment
lowering the risk life. The system is versatile, extendable and totally adjustable to user needs. Switchgear
has a proven record of reliability and performance failures are rare, but there are precautions that should
be taken to ensure the safety of personnel working with or in the vicinity of protection circuit.

Older types of protection circuit have with time been proven to be deficient in some areas. This together
with changing system fault levels and poor or no maintenance can lead to high safety risks to personnel in
aged switchgear installations.
This risk can be largely eliminated by performing system studies followed by remedial actions such as
retrofitting aged installations with modern circuit breakers, high speed protection systems, remote
switching or ultimately the Internal Arc Fault feature.
 7. PREFERENCES
1. A.R. Van C. Warrington, “Protective relays-Their Theory and Practice, Vol. I & II” John Wiley & Sons

2. Advantages of Fixed Circuit Breaker Switchgear by Lionel Mackay, EDF Energy, and Mike Adams,
Schneider Electric Ltd

3. Improving safety on ageing switchgear E.H. worthmann (BSc electrical)

4. en.wikipedia.org

5. www.schneider-electric.co.in

6. www.rapidtables.com

7. www.electrical4u.com