Career Episode 2

a) Introduction:

CE 2.1

This career episode is based on my project “Installation of transformer generator set with total
change over with Automatic Mains Failure (AMF) panel at the premises of Fabby Technologies
Pvt Ltd., Technopark, Trivandrum, Kerala”. By that time, I was employed by M.K Electricals
where I worked as an Electrical Engineer. The project started in February 2015 and
accomplished in November 2016. It was based in Trivandrum, India.
b) Background:

CE 2.2

M.K Electricals is on of biggest electrical engineering service provider in India. The client of this
project was Fabby Technologies Private Limited. The project was the installation of transformer
generator set with total change over with Automatic Mains Failure (AMF) panel at the premises
of Fabby Technologies Private Limited. The objectives of the project included; architecting
electrical design, obtaining scheme approval from the Kerala Electrical Inspectorate,
Government of Kerala, identifying the best and cost-effective model of approach, installation of
transformer generator set with total change over with Automatic Mains Failure(AMF) panel ,
regularization of electrical load at the customer premises, implementing standards that matched
the identity and corporate guidelines of Fabby Technologies Private Limited, and overall design
and implementation within the estimated deadline and cost.
CE 2.3

During the tenure of this project, I have performed the following tasks;

• Planned and designed the power stations/ electric power installations

• Determined the types and designed the arrangements of circuits, transformers, circuit
breakers, and transmission lines etc.
• Supervised the operation and maintenance of installation work
• Identified the customer requirements and provided appropriate solutions and technical
drawings
• Estimated project costs and scheduled timeline
• Carried out testing, evaluated the results, and modified the installations according to the
requirement
• Performed surveys to collect field data to develop drawings, layouts, and varied visual
aids
CE 2.4

Below is the hierarchy of the project with clear demonstration of my position;

Managing
Director

General Finance Purchase

HR Manager
Manager(Works) Manager Manager

Chief Electrical Accounts Purchase HR Admin

Engineer Executives Executives Executives

Electrical
Engineer
(Myself)

Supervisor

Draftsman

Technicians

c) Personal Engineering Activity:

CE 2.5

I designed the Main Switch Board (MSB) which was connected to the secondary side of the
transformer. I selected the transformer selected with specs; 500kVA, 11kV/433V, Dyn11,
ONAN, and indoor type. The generator selected was 500kVA, 415V, 3Ø, diesel generator. The
total connected load was 875HP+9.6KW. I calculated the maximum demand by dividing total
connected load by diversity factor. The diversity factor was assumed as 1.5. So, the maximum
demand was 400HP+5KW. For the design of MSB, I calculated the secondary current of the
𝑘𝑉𝐴
transformer using the equation 𝑠𝑒𝑐𝑜𝑛𝑑𝑎𝑟𝑦 𝑐𝑢𝑟𝑟𝑒𝑛𝑡 = 3∗𝑠𝑒𝑐𝑜𝑛𝑑𝑎𝑟𝑦 𝑠𝑖𝑑𝑒 𝑣𝑜𝑙𝑡𝑎𝑔𝑒 𝑜𝑓 𝑡𝑟𝑎𝑛𝑠𝑓𝑜𝑟𝑚𝑒𝑟
√
which was 666A. 15 m of 3 runs, 400sq.mm, AYFY cable was used to connect the busbar rated
100 ∗ 10𝑚𝑚 𝑎𝑙𝑢𝑚𝑖𝑛𝑖𝑢𝑚, for phase and 50 ∗ 10𝑚𝑚 𝑎𝑙𝑢𝑚𝑖𝑛𝑖𝑢𝑚 for neutral conductor. The
MSB consisted of voltage and current monitoring devices, current transformer rated 700/5A,
CL1, 15VA that was connected to the Automatic Power Factor Correction Relay (APFCR). The
cables from the transformer and generator entered the MSB busbar through Air Circuit Breaker
(ACB) rated 800A, 415V, 25KA, 4P, with 3O/C and E/F release. The switch board rating
corresponds to the breaker rating. I connected the Automatic Mains Failure (AMF) relay between
two ACBs, that was a micro-controller based unit which automates generator start and stop
actions during mains failure. It was done by controlling both mains and generator contactors. To
the busbar the loads connected were 200HP and 100HP motors, two sub switch boards, a
capacitor panel and two spares.

CE 2.6

Another design task which I handled was the Sub-Switch Board (SSB) design. I connected the
SSB with MSB using a 3.5 core 95sq.mm AYFY cable. The SSB had a total connected load of
77KW and a maximum demand of 40KW. It consisted of five Vertical Distribution Boards
(VDB) and two spares for future expansion. For the design of SSB, I calculated the total
𝑀𝑎𝑥𝑖𝑚𝑖𝑚 𝑑𝑒𝑚𝑎𝑛𝑑
incoming current using the equation; 𝐶𝑢𝑟𝑟𝑒𝑛𝑡 = , which was about 140A.
3∗𝑉∗∅ √
Hence a 160A Switch Fuse Unit (SFU) was connected for protection and the current transformer
was 125/5A, CL1, 15VA. Considering the total current carried, I selected the busbar of 25𝑚𝑚 ∗
10𝑚𝑚 𝐴𝑙𝑢𝑚𝑖𝑛𝑖𝑢𝑚 conductor for phase and 25𝑚𝑚 ∗ 6𝑚𝑚 𝑎𝑙𝑢𝑚𝑖𝑛𝑖𝑢𝑚 conductor for neutral.
I then connected the VDBs to the busbar using 63A Switch Fuse Unit (SFU). I used single run of
3.5 core 35sq.mm aluminium cables for the connection. By this design calculation, I designed the
SSB and developed the single line diagram.

CE 2.7
For this project, I was responsible for designing and supervision activities. During supervision,
when the test run of the installation was carried out there a sudden drop in voltage was happened
or technically we might call it as an oscillatory transient. It caused the power to alternately swell
and then shrink. These transients occurred when the capacitive load, i.e. the highest rating motor
(200HP) was taken out from the circuit. Due to this the adjustable speed drive (ASD) used in the
installation also tripped. As soon as the problem was raised, I consulted the senior engineers in
the company and discussed the scenario. I came up with two solutions. First one was to install
line reactors or chokes that would damp the oscillatory transient to a manageable level. Second
one was to install the zero-crossing switch. Among the two, I suggested to use line reactors or
chokes. These reactors were installed ahead of the ASD to prevent the tripping.

CE 2.8

During the final test run of the project, I faced a problem of overheating of the neutral along with
nuisance tripping of the protective devices in the main switch board. Suddenly I advised the
technicians to switch off the installations and I started to look for the cause. In the main switch
board, I found that 2 circuits from same phase were sharing the same neutral. On investigating I
found that circuits 4 and 6 shared the same neutral. When the actual running load was brought,
about 200 A started to flow through the circuit which overheated the neutral and tripped the
circuit breaker. This phenomenon might have produced a fire in the system due to overheating
and continuous tripping of circuit breaker whenever it was running full load. Soon after
identifying the problem, I changed the 6th circuit and provided it with a separate neutral and the
test run was again performed. At that time, there were no signs of overheating and tripping of
protective devices.

CE 2.9
During the designing phase of the project, my newly joined colleague designed the fire alarm
system and I was responsible for the system drawings. When I inspected the designs before
submitting it to get sanction from the government authorities, as per his design the sounders
needed to be installed above the ceiling. That would highly reduce the required sound level of
the alarms. If the same design was used for the project then the alarm sound would have not been
noticeable in case of any fire occurred in the building, in turn resulting in fatal incidents. I re-
specified the sounders for avoiding the further delay at all locations by keeping in mind the
smoke barrier’s effects in the ceiling void and the acoustic fill to the ceiling tiles at specific
locations. Also, before taking the designs for sanction I showed it my senior engineer to check
for inconsistencies.

CE 2.10

I planned the efficient utilization of labor, material, and equipment as I was in charge of the
project. I gave special attention to cost reduction methods. Observing the latest trends and
changes in the market, I procured the raw materials and equipment directly from the
manufacturers in a very low cost direct from the factory. Since the project was the installation
addition for an IT firm, the major economical step taken was the installation of branch circuits
underground. Use of less expensive PVC conduit and eliminating overhead supports reduced the
cost to a great extent. The use of 3∅, 3 wire system instead of 4 conductor feeders also became a
cost-effective solution. An estimated amount of INR 900,000 was saved by adapting the solution
I suggested.

CE 2.11
In the project site, the ventilation provided was very minimal. The use of normal LED acid
batteries was not safe as it vented gasses during charging and discharging. Also, it required
periodic addition of water to the electrolyte. So I suggested using a sealed maintenance free and
valve regulated LED acid battery. It effectively controlled gas generation and allowed
recombination of gasses within the battery. No electrolyte leakage occurred from the terminals
of the battery as it was sealed. This suggestion helped the client to eliminate the risk of poor
ventilation in UPS room.

CE 2.12

While working on this project, I calculated the mode of supply used for the building. As a first
step, I determined the total connected load. The loads were given in Horse Power (HP), I
converted it into kiloWatt (kW) and then I determined the total load in kW. Then taking into
account the power factor, I calculated the total kilo Volt Ampere (kVA) by dividing kW by
power factor. Hence, I selected the mode of supply. Another calculation was for selecting the
protective device for the MSB. I calculated the total load connected to MSB by adding all
individual loads. I found the maximum demand using the equation relating diversity factor and
total connected load. I obtained the full load current through the MSB using the equation
connecting maximum demand and current. As full load current was found, I selected the proper
protection. The protective device used was an MCCB.

CE 2.13
The software which I used for this project was AutoCAD, PC Schematic, Electrical Estimating
Software, DIALux, Microsoft Office (MS-Word, Excel, and Powerpoint). I worked on AutoCAD
and PC Schematic for preparing the electrical design. I used Electrical Estimating Software for
estimation purpose. I prepared documents using MS Word and Excel and presentations using
PowerPoint. I planned the lighting inside the individual room using DIALux.

CE 2.14

During the project, I followed a set of safety precautions. I used appropriately insulated rubber
gloves, goggles, and safety shoes while working on any electrical circuit. Since this particular
project was an additional work, I periodically used to check whether caps were provided to the
live wires while working on service panel. Also, extra care was given to the selection of circuit
breakers and fuses used. I considered myself responsible and accountable for the environment
safety. I took special care to recover used goods from the worksites by the concerned team.
During the selection of air conditioners, I procured environmental friendly units available in the
market which best suited the client’s budget. Also during the air conditioners’ installation work, I
educated the workers on the harmful effects of a gas leakage to the environment.
CE 2.15

During this project, I attended training at Transformers and Electricals Kerala Limited (TELK),
Kerala. The training focussed on how a work is performed on a transformer. I also completed a
course in Primavera, management software in that time period. I referred to the internet as well
as a lot of books like journals and technical magazine enhancing my engineering knowledge. I
used to read a monthly magazine provided by the Institute of Electrical and Electronics
Engineers (IEEE) to update my technical knowledge. Moreover, I also got help from my senior
engineers and colleagues to resolve the technical issues.

CE 2.16
I followed the codes and standards of the Bureau of Indian Standards (BIS) during the project.
Some important regulations of the Central Electricity Authority Regulations 2010 which I
applied included; Regulation 12 which insisted on following standards, codes of practice and
National Electric Code, 2011 of the BIS, Regulation 32 which insisted approval and sanction for
generators, Regulation 35 insisted on providing primary and secondary switchgear for
transformer and motor, Regulation 36 which insisted approval and sanction for multi-storied
buildings having heights more than 15 metre, Regulation 41 regarding earthling of installations
below 650 V, Rule 3 of IE, and Regulation 43 which insisted approval and sanction for
installations of voltage 650 V and above, etc. I followed the IE Rule 36 that is on safe work
procedures.
CE 2.17
I led a team of seven members consisting of 2 junior engineers, 2 draftsman, and 3 technicians
while working on the project. I frequently interacted with my colleagues and subordinates. I was
responsible for management of the team, which ensured continuous development of individuals
and the team. With my technical expertise and administrative skills, I managed my team very
well. I organized the weekly meetings with my team to discuss on the project milestones and
process improvements. I was open to any kind of suggestion from my team members which
could help in the betterment of the project.

CE 2.18

During this project, I attended the weekly meetings organized by the management. Mainly the
discussion points included process improvements, awareness of shifting company initiatives, and
latest trends in technology. These meetings were held for 10 minutes. I also arranged the weekly
meetings with the team to discuss the assigned tasks when required. I shared the present status of
the works with them. I discussed employee performances, quality issues, standard
implementations, etc. with my senior manager. I also had the meeting with the chief engineer
regarding the drawings, quality control, and challenges or issues in worksites. I was responsible
for preparing reports and documents for the project. I developed reports on time management,
scheduling, task delegation, materials procured, missing data, incorrect blueprint, escalated
project cost, reworks, etc. I also provided the project documentation. I prepared engineering
documentation, quality assurance documentation, and assembly documentation. I also prepared a
presentation which included the electrical principles, wiring methods, grounding methods, etc. In
this project, I was a part of inspection and assessment team. It was my responsibility to inspect
all procured instruments before transporting it to the work site. I was in charge of maintaining
the ERP system of the company. Also, I was responsible to supply Electrical Safety Manual to
promote an electrically safe workplace.
d) Summary

CE 2.19

I was responsible for planning, scheduling, and implementing the project. The successful
completion of the project made me really elated and felt accomplished. I considered it was my
biggest achievement to complete the project on time with an exorbitant quality. Proper planning
and conscious action helped me to complete the project successfully on time. Proper resource
management and allocation made it easy for me to complete the task on time. The project
presented me a platform to showcase my engineering and management skills to a great extent.
The previous experiences in design development and estimation helped me a lot to achieve my
goal without much of a haze.