Career Episode 1

a) Introduction:

CE 1.1

This career episode is the narrative of my project “Installation of 200 kVA DG Set and
regularization of electrical load in the premises of PMS College of Dental Science and
Research”. The project was carried out by the company “M.K Electricals” where I worked as an
Electrical Engineer. The project was started in May 2016 and accomplished in Mar 2017. It was
based in Trivandrum, India.

b) Background:

CE 1.2

M.K Electricals is a self-performing engineering firm specialized in electrical design and

implementation. With an experienced team, M.K Electricals had exposure in a wide range of
project types that included government entities, I.T Companies, health care sectors, commercial
buildings, etc. The client of this project was PMS College of Dental Science and Research,
Trivandrum, Kerala, India. The project was the installation of 200 kVA DG Set and
regularization of electrical load at the premises of PMS College of Dental Science and Research.

CE 1.3

The scope of this 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 200 kVA DG Set 400 kVA 11kV/433V 50 Hz 3
phase copper wound indoor oil type transformer, regularization of electrical load at the customer
premises, implementing standards that matched the identity and corporate guidelines of PMS
College of Dental Science and Research, and overall design and implementation within the
estimated deadline and cost.

CE 1.4

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

• Planned and designed the power stations or electric power installations

• Determined the types and designed the arrangements of circuits, transformers, circuit
breakers, and transmission lines
• Interpreted specifications, drawings, and standards and regulations relevant to electric
power equipment and their uses
• Supervised the operation and maintenance of the installation work
 • Identified the customer requirements and provided appropriate solutions and technical
drawings
• Prepared documentations and presentations
• 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 1.5

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

Proprietor

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 1.6

Considering the location of the site, I developed a detailed scheme of the installation using
AutoCAD software. This project was in a hilly terrain and the scheme was prepared considering
its geographical location. To perform this particular task, I determined the total power
requirement. I calculated the total power consumption by determining the total connected load.
The total connected load was calculated by adding all individual loads. The total connected load
was 493kVA. After analyzing all available information, I developed the electrical schematic
diagram. To start with the diagram, I first selected the mode of supply by determining the total
connected load. Hence 11kV, 3phase, and 50 Hz supply was selected. For the right choose of
transformer, firstly I calculated the maximum demand using the equationMaximum Demand =
Total connected load/ Diversity factor. I assumed the Diversity Factor as 1.5 and the
maximum demand was obtained as 328kVA. Taking into consideration the future expansion, a
20% extra was also provided, which modified the maximum demand to 394 kVA. Then I
calculated the transformer rating using the equation; Transformer rating = Constant of starter x
Motor rating in HP. Constant of starter was 2.5 and the highest rated motor was 20HP. So, the
transformer rating obtained was 50HP, which was approximately 37 kVA.

CE 1.7

Hence based on the calculation a 400kVA, 11kV/430V, 50Hz, 3 phase copper wound indoor oil
type star-delta transformer was selected to serve the purpose. I used aluminium conductor as
busbar having a density of 0.8. Hence the busbar selected was 50𝑚𝑚 ∗ 12𝑚𝑚 copper conductor
for phase and 50𝑚𝑚 ∗ 6𝑚𝑚 copper conductor for neutral. The generator of 200 KVA was
selected based on maximum demand and highest rating motor which I calculated. I selected the
generator cable selected of measurement 2 ∗ 3.5 ∗ 200𝑠𝑞. 𝑚𝑚 AYFY cable. The required
protection was MCCB with O/L and E/F release and standby low set earth fault relay using
current transformer in neutral earthling conductor.

CE 1.8

As this particular project site was a hospital, there were various small loads mixed with large
loads. This resulted in a heavy load change at times. So, I designed an automatic power factor
control (APFC) panel for the improvement of power factor by keeping the higher power factor
consistent. Poor power efficiency is caused by low power factor. Therefore, I used APFC to
prevent the voltage drop and flickering. For the design, I first performed calculation for required
𝑘𝑉𝐴𝑟 by multiplying the 𝑂𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 𝐾𝑊 𝑤𝑖𝑡ℎ [𝑇𝑎𝑛 (𝐴1 ) − 𝑇𝑎𝑛 ( 𝐴2 )] where A1 is the inverse
cosine of present power factor having value of 38.739 and 𝐴2 is the inverse cosine of desired
power factor with value of 11.478. I got the value as 30𝑘𝑉𝐴𝑟. So, considering the future
expansion I took 50𝑘𝑉𝐴𝑅. Therefore, the capacitor bank was divided into four; 20kVAR,
15kVAR, 10kVAR, and 5kVAR. I designed the protection for each unit by calculating the full
load current through each unit. The full load current would be 1.4 times the kVAR. The switch
rating would be twice the full load current and the fuse rating would be 1.5 times the full load
current. Hence, MCBs of 50A, 40A, 25A and 16A were selected respectively. The AFC panel
was connected to the MSB using 3.5 ∗ 50𝑠𝑞. 𝑚𝑚 Aluminium cable. The phase to phase gap was
25mm and phase to earth was 19mm. The bus bar used for banking was 1.8 ∗
𝑟𝑎𝑡𝑒𝑑 𝑏𝑎𝑛𝑘 𝑐𝑢𝑟𝑟𝑒𝑛𝑡.

CE 1.9

Every calculation, design, and estimation of the project was based on a predesigned cable route.
This predesigned cable route was through a private property. After completing all designs, it was
critical to get sanction from the property owner. After discussing this problem with the senior
manager and chief engineer, I put forward a suggestion. I proposed to find a new cable route
which was through the government property located nearby. During the planning phase of the
project, the strategy was to take power supply from the Kerala State Electricity Board (KSEB)
line for the transformer in the hospital premises using an aluminium conductor that runs through
a private property. In the first design that I prepared, the aluminium conductor was supposed to
be through a private property that measured 95m long overhead. Due to the disagreement from
the property owner, a new cable route was designed through the government property, cutting a
service road using a 3 ∗ 150𝑠𝑞. 𝑚𝑚 XLPE cable that measured 160m long. So in the previous
scheme the incoming line was marked as 95m long aluminium conductor (overhead) and in the
redesigned scheme the incoming cable was changed to 160m long XLPE cable (underground).
Instead of the aluminium conductor, new XLPE cable was incorporated.

CE 1.10

During the testing of the installation work, the breaker tripped instantaneously. Soon after
witnessing the problem, I carried out an effective inspection which helped me to identify the cause.
The connection under circuit breaker was loose. An 800A, 50kA, 4P, MCCB, set at 533A which
was connected to the secondary side of the transformer, tripped during the test run. The screws
were tightened too loosely so the heat generated by this high resistance connection during the
operation found its way into the breaker's overload mechanism which tripped the breaker. To
rectify the same, I turned off the branch circuit before turning off the main breaker as there were
electrical loads, including motor circuits which didn’t come on at the same time. Then the
connections were tightened and turned the main breaker back on. Even though it was simple
mistake from worker’s side it could have made great lose like overheating which would lead to
electrical flash, sparks, explosion blowing, etc.
CE 1.11

Another problem that I faced during the local power outage, when the utility power was back on
the generator, was still feeding the load connected to it. After a detailed investigation, I found
that there was a problem with the timer unit in the Automatic Transfer Switch (ATS) that kept
the generator online even after the utility power was back. The timer was usually set between 15
to 30 minutes as any glitch in power within that time will restart the timer. This fault condition
could have caused serious impacts like increased operating cost, improper network stability,
deteriorating system reliability, etc. To solve the issue I gave instructions for removing the ATS
from the circuit after disconnecting all AC power and ensured the generator was off. It was then
replaced with new ATC in working condition having the timer set to the proper delay needed.

CE 1.12

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 needed to be
completed within a span of 2 years, I decided to engage more workers and technicians to the
work site. They were assigned with a target every day. This helped me to complete the project
before the committed time.

CE 1.13

I used different software in the project such as AutoCAD, PC Schematic, Electrical Estimating
Software, DIALux, and Microsoft Office (MS-Word, Excel, and Powerpoint). I utilized
AutoCAD and PC Schematic for preparing the electrical design. I used Electrical Estimating
Software for the 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 1.14

I followed a set of safety precautions for all the projects which I handled. I used appropriately
insulated rubber gloves, goggles, and safety shoes while working on any electrical circuit. Before
starting the project, the workers were given a session on safety precautions and possible hazards
that could occur in the worksite. Since this particular project was to a dental hospital, I inspected
Residual Current Device/ Ground Fault Circuit Interrupter with special care. As an Electrical
Engineer, 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. I insisted suppliers
to use packaging which could be recycled. During the selection of air conditioners, I procured
environmental friendly units available in the market which best suited the client’s budget.

CE 1.15
I referred to the internet as well as a lot of books like journals, technical magazines etc. to
enhance my engineering knowledge. I 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 1.16

During this project, I attended training in Rajiv Gandhi Combined Cycle Power Project. I also
secured a supervisor grade ‘A’ license from Kerala State Electricity Licensing Board (KSELB).
This unique license was a permit which allowed me to work on All LT/MV electrical
installations, MV Generator up to 500 kVA, and HT installation up to 500 kVA transformers.

CE 1.17

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, Regulation 32, Regulation 35, Regulation 36, Regulation 41,
Regulation 43, Regulation 45, Regulation 48, and Regulation 52. I also followed CEA
Regulations 2006, CEA Amendment Regulations 2010, and CEA Amendment Regulations 2014
for installation of operation of Meters, CEA Regulations 2006 for procedure for transaction of
business, CEA Regulations 2007 and CEA Regulations 2014 for technical standards for
connectivity to the grid, and CEA Amendment Regulations 2015 for safety requirement, CEA
Regulations 2013 that is for connectivity of the Distributed Generation (DG) resources.

CE 1.18

While working on the project, I led a team consisting of one engineer, two draftsman, and two
technicians. 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 meeting with my team to discuss 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 1.19

During this project, I attended the weekly meeting organized by the management. Mainly the
discussion points included process improvements, awareness of shifting company initiatives, and
latest trends in technology. I scheduled the daily meeting with my subordinates briefing the daily
status. These meetings were held for 10 minutes. I also arranged the weekly meeting with the
team to discuss the assigned tasks. Being a part of the engineering team, I met my senior
manager and chief engineer on the daily basis before starting the work. I shared the present status
of the works. I discussed employee performances, quality issues, standard implementations, etc.
with my senior manager. I also had meetings with the chief engineer regarding the drawings,
quality control, and challenges or issues in worksites.

CE 1.20

I was responsible for preparing reports and documents for the project. I developed reports on
time management, scheduling, task delegation, materials procured, missing data, etc. I prepared
Engineering documentation included all the specification required for each part and equipment
and most feasible option for the same. The quality assurance documentation included the risk of
malfunction and failure, essential nature of all electrical components used in the project, etc. The
assembly documentation included the interconnection for individual electrical components and
safety measures associated with the assembly and testing of units. After receiving the complete
requirements from the client, I also prepared a presentation which included electrical principles,
wiring methods, grounding methods, about service entrance and service panels, the total energy
requirement of the entire building, standards followed, overall design, and safety awareness.

d) Summary

CE 1.21

I was responsible for planning, scheduling, and implementing the project. The successful
completion of the project made me really elated. I considered it was my biggest achievement to
complete the project on time with an exorbitant quality. The 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. I gained confidence in working with people and improved my intellectual and subject
knowledge.