Substation Engineering Lesson-2

Electrical Panel Board

Due to poor wiring and electrical safety standards most home and factories are at risk for any big damages or
fire accidents. Electrical panel board is the heart of your electrical system. Electrical panel board determines
how much power is available for any circuits to distribute to all the appliances, equipments and outlets in a
home or industry based system. There are tons types of electrical panel or panel board for different specific
purposes provided by different panel board Manufacture Company.

In previous ceramic cut out fuses are inserted in many electrical circuits. There is a maximum limit on the
current which can safely flow through a circuit. If by accident the current exceeds this safe limit, the wires may
blow off and break the circuit to avoid overheated and may cause fire. These days’ miniature circuit breakers
(MCBs) are increasingly being used in place of fuses. These are switches which automatically turn off when
current in a circuit exceeds the safe limit. An electrical panel in where combinations of many components like,
circuit breaker switches, many alarms, safety ratings, different types of power, control and operator devices are
located. Electrical panels come in scores of sizes and configurations. Electrical control panels are used to
control packaged equipment. Electrical control panels are used to control every piece of equipment in every
industry. It’s difficult to describe all of the possible device combinations because every industry and most
companies have defined preferences.
Electrical panels application in commercial buildings, hospitals, industries, dairies, telecommunications,
research laboratories etc.

There are different types of electrical panel board-

Breaker panel: A breaker panel is where all the circuit breaker switches are located. Because this is most
commonly use as home electrical system and appliances that often also known as a distribution board, service
panel board, or electric panel in short. All names contains in similar function. Each circuit breaker has a lever
that can be turned “on” or “off”. There’s likely a “main” circuit breaker that controls the power to the entire
house, but you’ll also see individual breakers, responsible for providing the electricity to various parts of your
home. The power to your home comes through an electrical meter located outside and is routed to your
electrical panel. The “main” circuit breaker, mentioned above^ It is usually larger than the rest and can be used
to shut “on” or “off” the power to the whole house at once. This is why those circuit breakers named as main
panel (MDB) which is more technically called a load center or service disconnect. The sub-panel (SDB/DB) is
what distributes electrical current to the various circuits within your home. The rest of the breakers known as
sub-panel should be labeled so you can identify the area of the house affected. The main breaker amperage
should be no less than 100 and can be 200 or 400 amps up to 1200 amps which for industrial uses.

Synchronizing Panel: Synchronizing Panel works between two or more different power sources like DG sets
to manage power supply. Synchronization helps in making different DG sets behave as a virtual single unit and
eliminates subdivision of total load. It helps in transferring load from one unit to another as during service
period, so that the unit requiring service can be easily shut off. In this way the critical load need not be
interrupted and there is no production loss. During low load we can run any single unit, and synchronize more
units as the load increases. This can be manual or automatic. Synchronizing panels is available with capacities
that reaches high amperage for 1KA to 10KA, and are fabricated by electrical components including copper bus
bar, insulations, wires/cable, PVC channels, transformers, meters and switches.

When closing a circuit breaker between two energized parts of the power system, it is crucial to match
voltages on both sides of the circuit breaker before closing. If this matching or "synchronizing" process is not
done correctly, a power system disturbance will result and equipment (including generators) can be damaged. In
order to synchronize properly, three different aspects of the voltage across the circuit breaker must be closely
monitored. The three aspects of the voltage are called the synchronizing variables and are:

1. The voltage magnitudes => if not closely matched, a sudden rise in Mvar flow will appear across the
circuit breaker as it is closed.

2. The frequency of the voltages => if not closely matched, a sudden change in MW flow will appear
across the circuit breaker as it is closed.

3. The phase angle difference between the voltages => if the phase difference between the voltages on
either side of the open circuit breaker is not reduced to a small value, a large MW flow increase will
suddenly occur once the circuit breaker is closed.

A synchroscope is a simple piece of equipment that is used to monitor the three synchronizing variables. If the
voltage waveforms are at the same frequency, the synchroscope does not rotate. If the voltage waveforms are at
a different frequency, the synchroscope rotates in proportion to the frequency difference. The synchroscope
needle always points to the voltage phase angle difference. The synchroscope in Figure reflects a slight voltage
magnitude mismatch, and a stationary synchroscope with a phase angle of approximately 35°. A synchro-check
or synch-check relay electrically determines if the difference in voltage magnitude, frequency and phase angle
falls within allowable limits. The allowable limits will vary with the location on the power system. A typical
synch-check relay may allow closing if the voltage angle across the breaker is less than 30°. Modern power
plants typically utilize automatic synchronizers. Automatic synchronizers will automatically close the breaker
when it is within an allowable window. Substations on the transmission system have traditionally had
synchroscopes installed. However, few substations are now manned due to the availability of powerful SCADA
systems.
LT Panel: LT 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. It can also be comprised of Power Control Centre, Motor Control Centre, Synchronization panel
etc.. Good LT panels are designed to work with low electricity consumption by low tension cables that makes
them cost effective. LT panel operates on below 50KW (< 50KW).

Domestic-LT: for most individual residential connections.

Commercial-LT: for small shops and offices. Also for hotels, guest houses, theaters, etc.
Industrial-LT: for very small manufacturing units (like bakery, stone cutting, poha mills, etc).

HT Panel: HT Panel is like LT Panel except that it is used for high tension cables. HT panel operates on above
50KW (>50KW).

Domestic-HT: Bulk supply for residential colonies.

Commercial-HT: for bigger offices, film studios, etc.
Industrial-HT: for most heavy industries.
System for HT/ LT connection
• HVPN Supply
• GO Switch
• HT Metering
• VCB
• Transformer
• LT Panel (Power control centre, Power factor panel, AMF)
• Distribution Panel
• Sub Distribution panel

APFC (Automatic Power Factor Control) Panels: These panels are used in commercial buildings and
industries where there is fluctuation in voltage and power supply. The electrical load required by a unit depends
upon the type of machineries, cooling plants and other devices installed. There is always a possibility of damage
of these equipments if power fluctuates. In case of fixed loads they can be safeguarded using capacitors, but in
case of varied loads, a mechanism to switch in and switch out the capacitors is required which is basically
handled using APFC panels.

PCC (Power Control Center) Panels: Its basic function is to control power supply to various units and
equipments as per their load requirement so that they can work in harmony. Power Control Centre (PCC) is
used for distribution and control of different power source used in industry. Usually Power Control Centers is
set up near power source hence fault level is high. It is planned to suit fault level of 50KA or 65 KA for 1 sec.
Power Control Centers are intended to suit the fault level as well as temperature rise to 40°c above ambient.
These are accessible in a wide range (from 630A to 6300 A) to match every user’s requirement.

-> Separate bus bar chamber for vertical droppers.

-> Can be operating by remote on / off.
-> Require Control voltage facilities with control.
-> Cubicle type extensible on each side.

MCC (Motor Control Centre) Panel: These are effectively used with motors or submersible pumps to provide
sufficient protection from overloads and short circuits. These are high on performance, require low maintenance
and can withstand extreme temperature variations. Motor control centers are in contemporary perform a factory
assembly of some motor starters. A motor control center can contain changeable frequency drives,
programmable controllers and metering, it may also be the electrical service access for the building. A motor
control center (MCC) is a congress of single or multiple enclosed sectors having a ordinary power bus and
mainly having motor control units.

A motor control center consists of single or multiple perpendicular metal cupboard sections with power bus and
condition for connect mounting of individual motor controllers. Extremely huge controllers may be locked in
place but slighter controllers can be unlocked from the cupboard for testing or preservation. Every motor
controller hold a contactor or a solid-state motor controller, excess relays to guard the motor, fuses or a circuit
breaker to supply short-circuit guard, and a disconnecting switch to separate the motor circuit. Every motor
controller in an MCC can be particular with a variety of choices such as separate control transformers, control
switches, extra control terminal blocks, pilot lamps, different types of thermal overload protection relays.

-> All starters are provided with type 2 co-ordination where required.
-> Can be operating by remote on / off.
-> Separate bus bar chamber for vertical droppers.
-> Cubicle type extensible on each side.
Lighting Control Panels: We can design and supply Distribution & Lighting Control Panels, which find
application in plants for distributing power in the lighting system, keeping in mind the specific requirements of
the clients.
VFD Control Panels: These are designed to control the speed of electric motor and feed pump. They are
widely used in drilling, pumping and other large machine applications. The VFD panels are widely used in tube
mills, paper mills, extruder plants, rolling Mills, cable industry and CTL Lines. They are even installed in
hospitals, business houses and other public places. VFD control panel are designed to match variable speed
requirements of a process unit and so are vigorously tested on various speed parameters.

Feeder Pillar Panels: The feeder pillar panels are used to terminate and distribute the control circuits. These
are used in almost all the industries, townships and housing societies to put all the cut-outs together.
Without above all there are plenty number of electrical control available in market /industry on very specific
applications. Some examples has drawn are-

A conflict among switchgear, switchboard and electrical panel boards.

The terms switchboard and distribution panel are basically interchangeable today. At one point we used
"switchboard" when it contained a series of fusible switches feeding loads and "distribution panel" when it
contained circuit breakers. "Switchgear" is a general term which includes both of these as well as says, panel
boards, motor control centers, unitized substations, etc....
Panel board: A single panel or group of panel units designed for assembly in the form of a single panel,
including buses and automatic over-current devices, and equipped with or without switches for the control of
light, heat, or power circuits; designed to be placed in a cabinet or cutout box placed in or against a wall,
partition, or other support; and accessible only from the front. Electrical panel board can be comprises by
Miniature and molded case circuit breaker. One other criterion that we use it from 100 amps up to 1200 amps
for a panel board

Switchgear: In an electric power system, switchgear is the combinations of electrical disconnect

switches, fuses or circuit breakers used to control, protect and isolate electrical equipment. Switchgears are used
both to de-energize equipment to allow work to be done and to clear faults downstream. This type of equipment
is directly linked to the reliability of the electricity supply. A general term covering switching and interrupting
devices and their combination with associated control, instrumentation, metering, protective and regulating
devices with associated interconnections, accessories and supporting structures used primarily in connection
with the generation, transmission, distribution and conversion of electric power.
Switchboard: An electric switchboard is a device that directs electricity from one or more sources of supply to
several smaller regions of usage. It is an assembly of one or more panels, each of which contains switches that
allow electricity to be redirected. A large single panel, frame or assembly of panels, on which are mounted, on
the face or back or both, switches, over-current and other protective devices, buses and usually instruments.
Individual sections of switchboards are sometime referred to as panels. It uses molded case and power circuit
breaker due to the over-current protection rate very high from 1600 amp and above.

A very important aspect is the technical documentation that has to be prepared by the manufacturer of the panel
that must include the following characteristics:

• the name or trade name of the manufacturer • peak withstand current;

or the organization that is legally responsible • nominal frequency;
for the panel; • nominal factors of contemporaneity;
• the date of construction; • degree of pollution;
• the serial number or other identification code • degree of protection;
unequivocal; • degree of protection to mechanical
• the reference standard (61439-1 + 61439-X). impact;
• rated operational voltage; • type of installation: internal or
• rated voltage; external;
• rated insulation voltage; • type of installation: stationary or
• rated impulse withstand voltage; mobile;
• rated conditional short-circuit current ; • type of use: PEI or PEC;
• rated current; • special conditions of use.
• short-time withstand current;
• rated current for each circuit;
Many a times the categories are also differentiated depending on the connected load and the tariffs increase if
the connected load is higher. Home can have either single phase or three phase depending on the load you have.
The cost of generation, transmission and distribution are the same, but the tariffs charged for different
consumers (single load or multi load panel) are different.
Example- The tariff charge is usually 2% of the rated capacity. So suppose you have 5 kVA stabilizers (which is
roughly 5 kW). So it would consume 2% of 5 kW = 100 watts. Which means in 10 hours of use it would
consume 100x10 = 1000 Wh or 1 unit of electricity.

Later I will discuss more on substation engineering.

Depending on response! This document prepared only for understanding.

Please feel free to ask me any question?

Have a good time.

Faisal Alam
Email- faisal2014@mail.ulsan.ac.kr