I.T.

S ENGINEERING COLLEGE
INDUSTRIAL TRAINING REPORT
ON
Understanding plate wiring of panel

Submitted to

In partial fulfillment for the award of the degree of

B. Tech.
in
Electrical and Electronics Engineering
Submitted
MANISH KUMAR by ROLL No: 1622221011

Under the Supervision of

MR. PRABHAKAR SHARMA

I.T.S ENGINEERING COLLEGE,

46, KNOWLEDGE PARK-III, GREATER NOIDA, U. P.
(INDIA)
 I.T.S ENGINEERING COLLEGE, GREATER NOIDA

CERTIFICATE
This is to certify that Manish Kumar (Roll no: 1622221011) has completed Internship
work presented in this report entitled “Understanding Plate Wiring of Panel” for the
award of Bachelor of Technology in the stream of Electrical and Electronics Engineering
from Dr. A.P.J. Abdul Kalam Technical University, Uttar Pradesh, Lucknow under
supervision of M r. Prabhakar Sharma The work embodies results of work, and studies
are carried out by the student himself and it is an authentic report.

Mr. Prabhakar Sharma

(Assistant Professor, EEE)

Mr. Upendra Kumar

Agarwal (HOD,EEE)

Mr. Rajesh Yadav

Quality Manager
COPY OF CERTIFICATE FROM INDUSTRY
 ACKNOWLEDGEMENT

It is my pleasure to be indebted to various people, who directly or indirectly

contributed in the development of this work and who influenced my thinking,
behaviour, and acts during the course of study. I express my sincere gratitude to
Dr.( Prof.) Vikas Singh, worthy Executive Director for providing me an
opportunity to undergo summer training at TRICOLITE ELECTRICAL
INDUSTRIES LTD. I am thankful to Mr. Prabhakar Sharma for his support,
cooperation, and motivation provided to me during the training for constant
inspiration, presence and blessings. I also extend my sincere appreciation to Mr.
Upendra Kumar Agarwal, Head of Department, EEE who provided his
valuable suggestions and precious time in accomplishing my project report.
Lastly, I would like to thank the almighty and my parents for their moral support
and my friends with whom I shared my day-to-day experience and received lots
of suggestions that improved my quality of work.

(Manish Kumar)
 DECLARATION

I, Manish Kumar, student of B.Tech Fourth Year, studying at

I.T.S ENGINEERING COLLEGE, GREATER NOIDA, hereby declare
that the Industrial training report on “Technology” submitted to Dr. A.P.J. Abdul Kalam
Technical University, Uttar Pradesh, Lucknow in partial fulfillment of Degree of
Bachelor of Technology is the original work conducted by me. The information and data
given in the report is authentic to the best of my knowledge. This summer training report
is not being submitted to any other University for award of any other Degree, Diploma
and Fellowship.

(MANISH KUMAR)
 CONTENT
1. ACKNOWLEDGEMENT……………………………………………………………….. IV
2. DECLARATION …………………………………………………………………………..
V
3. TRICOLITE ELECTRICAL PVT LTD……………………………………………….... VI
CHAPTER 1:
…………………………………………………………………………………… 8
INTRODUCTION ……………………………………………………………………... 8
CHAPTER 2:
…………………………………………………………………………………… 9
PROCESS OF PRODUCTION ……………………………………………………… 9
CHAPTER 3:
……………………………………………………………………………………12
TESTING ………………………………………………………………………………….
12
CHAPTER 4:
…………………………………………………………………………………...13
PROJECT…………………………………………………………………………………
13
CHAPTER 5: …………………………………………………………………………………..
14
Tools used ………………………………………………………………………………
14
CHAPTER 6:
…………………………………………………………………………………...15
PROCESS & ACCESSORIES AND COMPONENTS USED ….………….. 15
CHAPTER 7:........................................................................................ 17
 LIST OF FIGURE
FIGURE NO. NAME OF FIGURE. PAGE NO.
1 FABRICATION 8
2 ASSEMBLY 9
3 WIRING 10
5 TESTING 11
6 WIRING OPERATION AND
SCHEME TIME STUDY 12
7 WIRE CRIMPER 13
8 LUGS 14
9 FR-LSH & Z-FR CABLE 15
10 WIRE DUCT 16
11 FERRULE 16
12 STICKER PASTING 17
13 NUTRAL CONTACT 17
14 LIMIT SWITCH 19
15 TERMINAL STRIP 19
16 TERMINAL BLOCK 20
17 - 18 MCB 20
19 MCCB 20
20 RELAY 21
21 PLC 21
22 BUS BAR SIZE 22
23 CONTRACTOR
21
24-25 CT 22
26-27 MFM 22
28 MOUNTING PLATE INDETIFICATION 22
29 MCB CHANNEL FITMENT 23
30 PVC DUCT FITMENT 24
31-32-33 STICKER PASTING IN
ELECTRICAL COMPONENT 25
40 MADE ELECTRICAL CIRCUIT 31
41 BUS BAR SECTION 32
42 PACKING 35
 INTRODUCTION
Industrial training in an Electrical industry named Tricolite. About this company , From
trading of small home use electrical equipment to manufacturing of re-wirable switch
fuse units to leaders in manufacturing of custom build switchboards and turnkey
solutions provider, Tricolite has come a long way since its inception. At all stages of its
life it has always been lead by dynamic thinkers who believed in setting new trends in
the industry.

A privately held organization, it has its presence in three verticals of manufacturing,

marketing and turnkey projects. Manufacturing forms the main business while
Marketing and Turnkey Projects are forward and backward integrated businesses,
where too Tricolite has made a significant presence.

The manufacturing setup based in Delhi NCR utilizes about 2,00,000 sqft area for its
operations. Installed with state of the art machinery in all functions from Fabrication to
Testing, the layouts are designed as per flow manufacturing and TQM
recommendations to minimize non-essential movement of man and material. Latest
Designing and testing programs that make our working efficient and error free like
EPLAN, PRIMAVERA, Biloma etc. are used to optimize working time. We are the first in
the industry to use Pro-panel software that enables us to plan inventories of even C
class items.

TRICOLITE today is the first choice of industry leaders. Through decades of delivering
quality products, it has acquired patrons across the length and breadth of the country.
 PROCESS OF PRODUCTION
1.Fabrication :- the fabrication of Electrical panel is a place where body of
control panels this place also contribute to large extent to the quality
control of pane
the various accessories that are being made in this
process are 1).base frame
2)Mounting plate 3)Side
covers 4)Partitions etc.
the material used for making of plate is CRCA (cold rolled cold
annealed iron plates) a 2 - 3mm .

Figure.1
 Figure.2

2. PAINT :- the parts from the fabrication shop are brought in to the paint shop where ther the 8 tank
process which are as follows :-
1) Degreasing
2) Rinsing
3) De rusting
4) Surface activation
5) phosphating
6) Passivation
7) Scratch Hardening test 8). Salt spray test

3. ASSEMBLY AND WIRING :- The assembly shop is the most important shop of all other sh
, it can be considered as the Heart of the company where the panel is made to
function. The design department, which prepares the drawing according t which every dept. works,
actually influences the assembly shop the most.
 The Assembly Shop plays the major
role in the quality control of the
product; even a mistake in the wiring
or the selection of the electrical
instrument can disturb the working of
Assembly and mounting of
components

Figure.3

The wiring diagrams

given by the design
department is the guide
for the construction of
the assembly.

Figure.4Wiring
 TESTING
Testing of electrical panel is performed for
checking following features :-
-for checking the wiring connections.
-checking the continous supply.
-testing the components
-for checking the wiring connections.
-for checking the leakage in the panel , so that it
will be reduced.

Figure.5
 PROJECT
WIRING OPERATION AND SCHEME TIME STUDY

In this project , we are study about the wiring of the electrical

control panels , their operate SLD (single line diagram) and then
records the time taken . This project is completed in the "Rajesh
Yadav Sir"

panel wiring consists of 2 types :-

1.plate
wiring
2.door wiring

Figure.6
 Tools used
1. Screw driver:- this is used to tighten or lossen the bolt in the
swithgear
•.
2. Nut and Bolts.
3. poly carbonate sheet
4.Wire cutter
• 5.Crimper:- it is used to punch the lugs in the wire.

Figure.7-Wire Crimper
6.Drill machine :- it is used to make the holes in sheet.
7.Electric bolt machine :- this machine is used to tightening
of bolt into the sheet and

Accessories and Components used:-

1. Lugs :- lug is an important connector used to join two or

more electrical circuits .

Figure.8
2. Wires or cables :- theses are the electrical conductors , which are used to join
one com and make a circuit.
wires are of three types :-
1) FR cable :- FR means fire resistant cable. This cable has following properties
:-
-low fire
-smoke is high
-halogen is low
2) FR-LSH cable :- this cable stands for fire resistant and low smoke halogen .
the properties of fr-lsh cable are:-
-fire is low
-smoke is low
-
3)Z-FR cable -halogen is high
:- this cable stands for zero fire resistant cable . The properties are
:-
-fire is zero
-smoke is zero
-halogen is zero

Figure.9
 Rating of wire size of wire

1 ampere to 10 ampere 2.5mm

16 amp to 25 amp 4mm
25 amp to 32 amp 6mm
32 amp to 40 amp 10mm
40 amp to 63 amp 16mm

3). Wire Duct :- this is a wire holding u-shape channel, which

covers all the wires and gives a good appearance for wires.

Figure.10
4). Ferrule :- this is a tube which insert on the wire and it
gives the information about , this wire is
connected. It makes easy to undersand the
connection of wiring.

Figure.11

5). Tapeing :- in this process tape is stick on the component and infront of
that
component

Figure.12

6). Neutral contact/link :- this component is used to connect the system

with
neutral .

Figure.13
7)Limit Switch :- this switch is used in opening and closing of door
of the panel. function of the limit switch is :-
-when door of panel is open then light will 'ON'
-when door is closed then light will 'OFF'

Figure.14

8). Terminal strip :- this strip is used to connect many number

of
wires trough one terminal

Figure.15
9). Terminal blocks:- it is uesd to connect one circuit to other
circuit.

Figure.16

10). MCB :- Miniature circuit breaker , used to break the circuit when fault
occurs.

Figure.17 Figure.18
11). MCCB :- Moulded case circuit breaker, it is used for trip the circuit at high
voltage .

Figure.19
 12). Relay :- it is a fault,overloading sensing device which intiate to the circuit
breaker.

Figure.20
13)PLC :- Programmable logic control, it is a progamme based device which work
on the s
-PLC is used to operate the position of DG (deisel generator)
automatically.
-it is used for synchronising of 2 DG's automatically.
-PLC is used in " Towers" i.e. Mobile towers , TV towers etc.
-it is a fast operating automatic device.

Figure.21
14)Bus bar :- bus bar is an electrical component which gives supply from
substation
to feeder - it is a plate which is made up of Aluminium(low voltage).
- it is a plate which is made up of copper(high voltage).
-bus bar is insulated with heat silicon resistance tape.

The size of bus bar for general panel is shown in figure.

Figure.22

15). Contractor :- it is a device which is used at the starting of motor. It is used with
starter DOL starter, star-delta starter etc.

Figure.23
16). C.T. :- current transformer , it is used for regulation of current for transformer or
alter

Figure.24 Figure.25
17)MFM :- Multi function meter , it is fitted in the front of the panel for indication of
:-
-voltage of the panel
-current of the panel
-power factor of the panel
-power in panel

Figure.26 Figure.27

--> THE PROCESS OF WIRING :-

In the process of wiring there are many steps are as following :-

1) Mounting plate identification :-

>Study the GA drawing to get the feeder size.
>choose length and height (L*H) as (L-102)*(H-5)mm
> example , dimension of feeder L*H is 600*30mm, then mounting plate will
be
498*295mm

Figure.28
2). MCB Channel Fitment :-
>measure width of component to be mounted on channel.

>mark the require length of channel using a pencil.

>cut channel upto the mark using channel cutter
> mark the locations of holes to be drilled on mounting plate by taking
refrece of provided on the channel.
> drill the holes by using 3.2mm drill machine on mounting plates and
tap them.
>finally mount the channel using 12*4mm screw and + type screw driver

Figure.29
3). PVC Duct fitment :-
>duct selection
chart.

Figure.30
 Figure.31
> mark the duct and duct cover with a pencil upto the length calculated using
formula.
>cut the duct using duct cover
> drill the holes on mounting plates taking as refrence to hole provided on the
duct itself.
>tighten the duct on mounting plate using 4*12mm screws
>after completion of wiring put the duct cover.

4) Ferrule and sticker printing :-

>select the ferrule as per wire size :-
-for 1.5mm wire size take 3.5mm size ferrule tube.
-for 2.5mm wire size take 4.2mm ferrule tube
>input the ferrule number as per the scheme drawing and print

sticker printing
>print letters on yellow tape which is shown in scheme drawings e.g.
for control MCB, wire "F" . Here F is followed by a numeric digit denoting the MCB
number
, power contractor as "C".
>set number of stickers required
>give the print command .
 Figure.32

5). Switchgear fitment :-

drill --> switchgear fitment --> sticker pasting

Figure.33

6) Control wiring :-
>first take a rough easurement of size of control wiring measurement of size of conrol
wiring bunch by measurement distance between panel and plate.
>take wire of dia 1.5mm (r,y,b,n) for control and 2.5mm forct wiring and measure leng
from component ter to termi , cut it from wire wire cutting giving 150mm margin for
panel door opening and closing.
>cut the ferrul halfway along its dia and fit it at the end of control wires.
>strip the wire folowed by crimping the end .
>connect the crimp wire at all the component matching the ferrule number
>to scheme of wiring .
 Figure.36

7) Power wiring :-
>choose wire size and colour for [power wirring as per chart . Measure wire length
for
MCB/MCCB/RCB terminal to cable alley to power terminal / busbar terminal and
cut
it fom terminal and cut it from power wire cuter.
> using a wire stripper mark on bth ends for inserting coloured wire sleeves
at late stage ;-
-no mark for neutral wire
-one mark for red phase wire

-2 mark for yellow wire

- 3 marks for blue phase wires

>bend the wires and cfeat a bunch using zip ties acc. To component placement.
> insert colour sleeves for phase identification , strip th ewire and select the
lugs the lugs acc to wire size and crimp.
>fix the crimp ends to components.
 #. Time study of wiring :-

Components HVAC panel (Out

used:- going):-
> neutral - 1
c ontact nos.(32A
> >MCB - mp)
>Terminals- - 1 nos.(32amp , AC) 6 nos.
1 nos.(32amp)
- MCCB fitting on sheet with neutral
contact

Time taken is 3 minutes , 17seconds

- single Duct fitting on

sheet

average time taken is 4 min , 6 sec

- All ducts
fiting
total time taken to fitting all the ducts is 38min 7sec
 Figure.37
--> Ferrule codes are as follows
:- "E" means Voltage supply / "N " means Neutral
"F " means
"D" current / contact
means DC supply (24v or
supply MCB
12v)
" J " means
AC supply
" K " means
>terminal contacts - 4 nos
>MCB - 1 nos.
>Neutral contact - 1 (32amp , dc )

In direct current (DC), the electric charge (current) only flows in one direction.
Electric charge in alternating current (AC), on the other hand, changes direction
periodically. The voltage in AC circuits also periodically reverses because the
current changes direction.
 > MCB - 5 nos. (DPST , 6amp)
> contractor - 1 nos.
> MCB - 2 nos. (SPST , 3amp)
> small relays - 80 nos.
> PLC 1 nos.
-
> power supply - 1 nos. (200v ac to 24v dc ,
6.5amp).

PLC panel wiring ,

Total time taken is wiring is 12 hr 40 min

wires in PLC wiring indication :-

grey wire for DC supply
black wire for feedback
blue wire for sensing
red wire for
(output)
standard input

Figure.38
 DG(diesel generator) Incomer panel
wiring

components used for dg panel are :-

>MCB
>contractors -91nos . (SPST).
- 8nos.
>relays
-
in DG incomer panel ,

total time taken in DG wiring is 3hrs , 9 min

APFC Bank realy panel :-

components used are :-

> CT's - 21 nos.
> MCCB - (10/5Amp)
> MCB - 7 9nos.
nos.(63amp)
(6amp)
> relay - 7nos. (240v)
> neutral contact - 9 nos.

In APFC bank relay ,

APFC Bank relay ckt wiring is 5 hr 24 min

 Figure.39

Figure.40

APFC bank relay circuit has following properties :-

- it is used for Automatic power factor controll.
- there display parameter is "power factor"
- supply sued is 90 to 250v AC ,50/60Hz

Door wiring

time taken to complete a door wiring in each feeder box

is

time taken in a single box of panel is 20min , 46 sec.

 features of door wiring :-
> it is used for indication of R,Y,B,N
> it is outside controll
> when supply of DG fails , it will starts automatically to 2nd
DG

Figure.41
Factors of improving the system are :-

1) Availability of material at all time near to the working person.

2) Non- availability of material increases in time of working.

3) . In PLC wiring , it takes 3 days to comple its wiring when a single person is work
on it . so , by increasing the TA,s on PLC wiring like 3 person which reduce the
time and
the wiring is completed in one day only

4). Difficult packaging wase more time in working

QUALITY ASSURANCE AND QUALITY
CONTROL
•QUALITY ASSURANCE :-Quality assurance is a way of preventing
mistakes and defects in manufactured products and avoiding problems
when delivering products or services to customers; which ISO 9000
defines as "part of quality management focused on providing confidence
that quality requirements will be fulfilled“ .

•QUALITY CONTROL :-Quality control is a process by which

entities review the quality of all factors involved in production. ISO
9000 defines quality control as "A part of quality management
focused on fulfilling quality requirements".

Figure.42
 PACKING SECTION
⚫ There are four types in packing of panels…
1. NORMAL PACKING (for distance upto250
km).
2. CORIGATED PACKING (fordistance
more than 250 km).
3. CARAT BOX PACKING ( for distance
more than 250 km).
4. C-WORTHY PACKING ( Export packing ).

Figure.43