OPERATION AND MAINTENANCE OF

ELECTRICAL SYSTEMS REPORT FOR

LEARNING.
 ABSTRACT
This report summarises all the activities done during internship in electrical operation
and maintenance of the plant.

Chapter One gives a brief introduction to the company, highlights the aims and
objectives of the internship training, and the methods of tasks done.
Chapter Two is the literature review giving additional knowledge on all equipment
and methods used in the internship training.
Chapter Three explains all the activities done in detail.
Chapter Four highlights the skills gained over the period of training. It also contains
the conclusions, recommendations, appendices and references.

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 TABLE OF CONTENTS
DECLARATION...........................................................................................................2
ACKNOWLEDGEMENT.............................................................................................3
ABSTRACT...................................................................................................................4
TABLE OF CONTENTS...............................................................................................5
LIST OF FIGURES........................................................................................................7
CHAPTER ONE............................................................................................................8
1.1 INTRODUCTION............................................................................................8
1.1.1 Brief background...................................................................................8
1.1.2 Tiles making process.............................................................................8
1.2 METHODOLOGY.........................................................................................10
1.2.1 Aims of the training.............................................................................10
1.2.2 Methods of tasks done.........................................................................10
CHAPTER TWO..........................................................................................................11
1.3 LITERATURE REVIEW...............................................................................11
1.3.1 Pliers....................................................................................................11
1.3.2 Cables..................................................................................................11
1.3.3 Junction boxes.....................................................................................12
1.3.4 Conduit pipes.......................................................................................13
1.3.5 Tester...................................................................................................13
1.3.6 Screw drivers.......................................................................................13
1.3.7 Saddlers...............................................................................................14
1.3.8 Circuit breakers...................................................................................14
1.3.9 Overload relay.....................................................................................15
1.3.10 Motors...............................................................................................16
1.3.11 Contactor...........................................................................................17
1.3.12 Timers................................................................................................17
1.3.13 Variable frequency drive...................................................................18
1.3.14 Push buttons......................................................................................19
1.3.15 Indicator lamps..................................................................................19
1.3.16 Relay..................................................................................................19
1.3.17 Connectors.........................................................................................20
1.3.18 Cable gland........................................................................................20
1.3.19 Cable lags..........................................................................................20
1.3.20 Crimping tool....................................................................................21
CHAPTER THREE......................................................................................................22
1.4 ACTIVITIES DONE IN DETAIL.................................................................22
1.4.1 Repairing faulty grinder......................................................................22
1.4.2 Installing new submersible water pump..............................................22
1.4.3 Troubleshooting variable frequency drive (VFD)...............................22
1.4.4 Earthing of control panels in briquette making facility.......................23
1.4.5 Installing indicator lamp for the water pump......................................24
1.4.6 Installing limit switch for the rotary....................................................24
1.4.7 Direct on line starter (DOL)................................................................25
1.4.8 Forward reverse starter........................................................................27
1.4.9 Star delta starter...................................................................................29

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 1.4.10 Replacing a faulty motor in wood cutting section.............................30
1.4.11 Installing a surveillance camera........................................................31
1.4.12 Troubleshooting arc welding machine..............................................31
1.4.13 Installing a variable frequency drive(VFD)......................................32
1.4.14 Troubleshooting security lights.........................................................33
1.4.15 Connecting a single phase motor(incomplete)..................................34
1.4.16 Tripping of overload relay.................................................................35
1.4.17 Single phasing of motor....................................................................36
1.4.18 Designing a circuit for 50 pieces of 70w lamps................................36
1.4.19 Cable glanding and lagging in a busbar panel...................................37
1.4.20 Installing industrial socket outlets.....................................................38
1.4.21 Installing pilot lamps.........................................................................38
1.4.22 Troubleshooting building lights in stone ball mill............................39
1.4.23 Replacing a faulty overload relay......................................................39
1.4.24 Mounting and wiring of vfds in a vfd panel......................................40
CHAPTER FOUR........................................................................................................42
1.5 SKILL GAINED FROM INDUSTRIAL TRAINING...................................42
1.6 CONCLUSIONS............................................................................................42
1.7 RECOMMENDATIONS...............................................................................42
APPENDIX..................................................................................................................43

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 LIST OF FIGURES
Figure 1 : Water pump control panel....................................................................23
Figure 2 : Variable frequency drive.....................................................................24
Figure 3 : Earthing of control panels....................................................................24
Figure 4 : Indicator light of water pump..............................................................25
Figure 5 : Limit switch and Stop button connection............................................26
Figure 6 : Power circuit and control circuit diagram of Direct On Line starter...26
Figure 7 : Control circuit wiring of Direct On Line.............................................27
Figure 8 : Direct On Line with indicator lights....................................................27
Figure 9 : Power circuit and Control circuit diagrams for Forward Reverse
Starter...........................................................................................................28
Figure 10 : Forward Reverse Control circuit wiring............................................29
Figure 11 : Power circuit and Control circuit diagrams for Star Delta Starter.....30
Figure 12 : Star Delta power and control circuit wiring.......................................31
Figure 13 : Delta connection for induction motor................................................31
Figure 14 : Installation of surveillance camera....................................................32
Figure 15 : Inside an arc welding machine...........................................................33
Figure 16 : Variable frequency drive terminal connections.................................33
Figure 17 : Street lights troubleshooting..............................................................35
Figure 18 : Single phase motor............................................................................36
Figure 19 : Busbar panel cable connections.........................................................38
Figure 20 : Indicator lights for control panels......................................................39
Figure 21 : Forward Reverse control panel where the overload relay was replaced
......................................................................................................................41
Figure 22 : Variable frequency drive panel wiring..............................................42

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 CHAPTER ONE
1.1 INTRODUCTION
1.1.1 Brief background
It manufactures quality ceramic, porcelain and vitrified tiles. They have a well
equipped modern and imported infrastructure facility, with a production capacity of
producing a very large number of tiles per day.

1.1.2 Tiles making process

The tiles making process begins in the Slip house

1) Slip house
Materials are mixed with water in the ball mills which are continuously turning by the
help of pulley systems driven by large motors, to make a smooth paste called slip. The
slip is then stored in underground storage tanks that are also continuously stirred to
prevent the slip particles settling at the bottom.

From the storage, a piston pump is used to pump the slip under high pressure to the
spray drier building.

2) Spray drier
In this section, the slip is converted to fine powder.
When the slip reaches the spray drier building, a second piston pump is used to pump
the slip under high pressure into the silos (a tall tower used for storage).
The slip is sprayed at high pressure to be dried into powder by the heat produced from
a nearby furnace.
The silos release the powder to conveyors.
There are halogen lamps of 1000W that produce heat to dry the powder further before
being taken to the press.

3) Press machine
Using a hydraulic system, the powder is pressed using the press machine to form the
tiles. The powder has little water content in it to help with binding.
After the press, the tiles are loaded onto rollers that transport them to the kiln.
There are photo sensors on the rollers that detect defective tiles such that they are
removed.

4) Kiln (single layer entry and exit)

The tiles pass through the kilns where they are dried, then taken to the glaze area.

5) Glaze area
Here, a smooth top layer is added to the tiles.

6) Digital Printer
The digital printer adds a printed decorative pattern on the tiles to give them their
design.

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7) Kiln (Double layer entry)
The tiles then go to a second kiln to be hardened. There is also a compensator where
some tiles are stored to be used later in case of a shortage.
The last stage of the kiln is red hot for further hardening of the tiles.

8) Sizing and packaging.

In this section, the tiles are shaped and packaged.

9) Gasifire
The heat that is used in the kilns is produced at the gasifire section, where coal is
burned together with wood and briquettes to produce heat at very high temperatures.
The coal is mixed with wood and briquettes to reduce the use of coal therefore
minimizing expenses.
The briquettes are made from the briquette building before being sent to the gasifire.

10) Briquette building

This is where the briquettes are made. The material used for making these briquettes
are groundnut husks.
These husks are sent by a conveyor belt to the Rotary where they are dried and sifted
(sifting: using a sieve or mesh to separate the finer particles of soil from larger
materials). The rotary is turned by a gear system that is driven by a motor. The
product is fed to the briquette making machines, where the husks are mixed with
water and then compacted to form the briquettes.
1.2 METHODOLOGY
(Aims, objectives, and methods of tasks done)
1.2.1 Aims of the training
a) To get more skills and knowledge in operation and maintenance of electrical
systems to complement the theoretical knowledge of the university.
b) To obtain problem solving abilities through exposure to different tasks that need
to be handled in different ways.
c) To know the different requirements needed in the working field, for example,
safety and protection, tools and equipment.
d) To learn communication skills and team work that will be helpful in the working
field.
1.2.2 Methods of tasks done
a) The methods used to obtain knowledge and skills during the training include the
following;
b) Theoretical studies on the different equipment
c) Hands on demonstration and practice while doing maintenance and repairs.
Maintenance types include Preventive maintenance and Corrective maintenance.
d) Preventative Maintenance: This is regularly performed on an equipment(s) to
reduce its likelihood of failure. Preventive maintenance is performed while the
equipment is still working, so that it does not break down unexpectedly. This type
of maintenance is planned so that any required resources or material can be made
available.

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e) Corrective Maintenance: This is performed to identify, isolate, and rectify a fault
so that the failed equipment, machine, or system can be restored to an operational
condition within the tolerances or limits established for in-service

CHAPTER TWO
1.3 LITERATURE REVIEW

In this chapter, I have described the tools used and also the methods used during the
training.

1.3.1 Pliers
Pliers are hand-operated tool for holding and gripping small articles or for stripping
and cutting wire.

1.3.2 Cables
An electric cable is measured in volts and, depending on these, they are categorized
into one group or another:
Low voltage cables (up to 750 V): in a variety of applications, and with thermoplastic
and thermoset coatings. They are designed and built according to harmonized
standards.
Low Voltage cables (up to 1,000 V): (also called (0.6/1 kV) The cables in this section
are used for industrial power installations in various fields (general industry, public
installations, infrastructures, etc.). They are designed according to international
standards (UNE, IEC, BS, UL).
Medium Voltage cables: from 1 kV to 36 kV. They are used to distribute electricity
from electrical substations to transformer stations.
High Voltage cables: from 36 kV. They are used to transport electricity from the
generating plants to the electrical substations.

Types of electric cable by their use

Low voltage cables
Cables for electric panels
Flexible cables for wiring electric cabinets. These electric cables are especially
suitable for domestic use, for installation in public places and for internal wiring of
electrical cabinets, switch boxes and small electrical appliances.

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Power cables
Energy cables for industrial facilities and public places. It is common to find power
cables in applications for power transmission in all types of low voltage connections,
for industrial use and for variable frequency drive (VFD).
Armoured cables
Cables with aluminium or steel reinforcement for installations with risk of mechanical
aggression. It is also common to find armoured cables in places where rodents are
present, as well as in installations in premises with a risk of fire and explosion
(ATEX).

1.3.3 Junction boxes

An electrical junction box (also known as a ‘jbox’) is an enclosure housing electrical
connections.[1] Junction boxes protect the electrical connections from the weather, as
well as prevent people from accidental electric shocks.

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1.3.4 Conduit pipes
The electrical conduits are used to protect the electrical cables. Conduit are where the
electric wires pass during installation.

Pvc conduits

Flexible conduits

1.3.5 Tester
It is used to test for the presence of the power in a circuit.

1.3.6 Screw drivers

A screwdriver is a tool, manual or powered, used for screwing (installing) and
unscrewing (removing) screws.

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1.3.7 Saddlers
These are used for holding conduits firmly in place on the wall or ceiling.

1.3.8 Circuit breakers

A circuit breaker is an automatically operated electrical switch designed to protect
an electrical circuit from damage caused by excess current from an overload or short
circuit. Its basic function is to interrupt current flow after a fault is detected. Unlike
a fuse, which operates once and then must be replaced, a circuit breaker can be reset
(either manually or automatically) to resume normal operation.

Types of circuit breakers

MCB
MCB stands for Miniature Circuit Breaker. It automatically switches OFF electrical
circuit during any abnormal condition in the electrical network such as overload &
short circuit conditions.

MCCB
MCCB stands for Molded Case Circuit Breaker. It is another type of electrical
protection device which is used when load current exceeds the limit of a miniature
circuit breaker. The MCCB provides protection against overload, short circuit faults
and is also used for switching the circuits. The wide current ratings and high breaking
capacity in MCCB find their use in industrial applications. MCCB can be used for

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protection of capacitor bank, generator protection and main electric feeder
distribution.

MPCB
Motor Protection Circuit Breaker is referred to as an electrical MPCB. The MPCB is a
circuit breaker created to safeguard electric motors from thermal overload, short
circuit faults, unbalanced loads,
Application: Induction Motor starting (DOL/Star-delta), Lighting circuit applications,
Direct starting applications

1.3.9 Overload relay

An overload relay is a device that protects an electric motor against overloads and
phase failure.
It senses the overloading of the motor and interrupts the power flow to the motor, thus
protecting it from overheating and winding damages. Apart from overloads, it can
also protect the motor from phase loss/ failures and phase imbalance. They are very
commonly known as OLR.
A thermal overload relay works in the principle of electro-thermal properties in a
bimetallic strip. It is placed in the motor circuit in such a way that the current to the
motor flows through its poles. The bimetallic strip gets heated up by the current
directly or indirectly and when the current flow exceeds the set value, it bends.

They always work in combination with contactors.

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1.3.10 Motors
An electric motor is a device used to convert electricity into mechanical energy—
opposite to an electric generator. They operate using principles of electromagnetism,
which shows that a force is applied when an electric current is present in a magnetic
field. This force creates a torque on a loop of wire present in the magnetic field, which
causes the motor to spin and perform useful work. Motors are used in a wide range of
applications, such as fans, power tools, appliances, electric vehicles, and hybrid cars.

How does an AC induction motor work?

Electromagnet coils, are energized in turn by an AC supply. Since it's AC, the current
in each coil doesn't switch on and off abruptly, but rises and falls smoothly in the
shape of a sine wave.
As the coils are energized, the magnetic field they produce between them induces an
electric current in the rotor. This current produces its own magnetic field that tries to
oppose the thing that caused it (the magnetic field from the outer coils). The
interaction between the two fields causes the rotor to turn.
As the magnetic field alternates, it effectively rotates around the motor. The rotating
magnetic field makes the rotor spin in the same direction and (in theory) at almost the
same speed.

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1.3.11 Contactor
A contactor is an electrically controlled switch used for switching an electrical power
circuit. A contactor has three components:

The contacts: are the current-carrying part of the contactor. This includes power
contacts (L1 L2 L3, T1 T2 T3), auxiliary contacts (NO, NC), and contact springs (A1
A2).
The electromagnet (or "coil"): provides the driving force to close the contacts.
The enclosure: is a frame housing the contacts and the electromagnet. It protects and
insulates the contacts and provides some measure of protection against personnel
touching the contacts.

Operating principle
When current passes through the electromagnet, a magnetic field is produced, which
attracts the moving core of the contactor. The electromagnet coil draws more current
initially, until its inductance increases when the metal core enters the coil. The force
developed by the electromagnet holds the moving and fixed contacts together. When
the contactor coil is de-energized, gravity or a spring returns the electromagnet core to
its initial position and opens the contacts.

1.3.12 Timers
Timers are used in the industries to control the process/operation with specified time
interval of repetitive nature. It is basically a time-clock with an arrangement for on/
off operation/process at a pre- determined specified time-intervals.

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1.3.13 Variable frequency drive
A variable frequency drive is a type of motor controller that drives an electric motor
by varying the frequency and voltage of its power supply.
VFD consists of mainly four sections, those are rectifier, intermedialte DC link,
inverter, and controlling circuit.

Rectifier:
It is the first stage of a variable frequency drive. It converts AC power fed from the
mains to DC power. It utilizes diodes and other electronic switches. A number of 6
diodes are required for the 3 phase conversion, so the rectifier unit is considered as a 6
pulse converter.

DC bus:
DC power from the rectifier section is fed to the DC link. This section consists of
capacitors and inductors to smooth against ripples and store the DC power. The main
function of the DC Link is to receive, store and deliver DC power.

Inverter:
This section consists of electronic switches like transistors, thyristors, but most
especially IGBTs are used. It receives DC power and converts it into AC power using
pulse width modulation technique to vary output frequency for controlling the speed
of the induction motor.

Control circuit:
It consists of a microprocessor unit and performs various functions like controlling,
configuring drive settings, fault conditions, and interfacing communication protocols.
It receives a feedback signal from the motor as current speed refernce and accordingly
regulates the ratio of voltage to frequency to control motor speed.

1.3.14 Push buttons

A push button is a mechanical device used to control an electrical circuit in which the
operator manually presses a button to actuate an internal switching mechanism to
control a machine or a process.
There are Start (NO) and Stop (NC) Push buttons that send a command to start or stop
a process respectively.

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1.3.15 Indicator lamps
These are used to make the operation status (ON, OFF, FAULT) of the machine on
which they are installed visible from the outside by means of a small light.

1.3.16 Relay
A relay is an electrically operated switch. A relay consists of a coil which receives an
electric signal, and converts it into a mechanical action that causes its contacts to open
or close. It is used for remote or automatic control that is actuated by various
conditions of an electric circuit.

1.3.17 Connectors
These are used to create an electrical connection between parts of an electrical circuit.
They are sometimes called links.

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1.3.18 Cable gland
Is a device that attaches to the end of an electrical cable to secure it to a piece of
equipment.

1.3.19 Cable lags

Are used to provide a secure and reliable connection between a cable and the
terminal, reducing the risk of loose connection and damage.

1.3.20 Crimping tool

A crimping tool is used to conjoin two metals by deforming one or both of them in a
way that causes them to hold tightly together. It is used to make lags tight on cables.

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 CHAPTER THREE
1.4 ACTIVITIES DONE IN DETAIL
1.4.1 Repairing faulty grinder
When a grinder stops working, these are the first things to look at:
i. Is there power at the supply
ii. Are the carbon brushes damaged
iii. Is the switch working.
If all these are fine, then it could be a motor problem.

For this case, when a tester was used to determine the continuity of supply, it was
found out that power was not reaching the switch. With further examinations, the
wires supplying the switch had burned out and created an open circuit. This prevented
the power from reaching the motor.
The switch was rewired and the grinder tested. It worked after the repair.

1.4.2 Installing new submersible water pump

The water pump is used to pump water from an underground storage for use in the
factory. It is operated by a Direct On Line control circuit in the control panel.

Steps taken:
a) The 3 phase 3 core motor supply cable was terminated to the submersible pump
and the other end to the overload relay output terminals on the Direct On Line
control.
b) The pump was then tested to find out if it was functioning properly and if the
motor for the pump was moving in the right direction by powering it from the
circuit breaker.

Figure 1: Water pump control panel

1.4.3 Troubleshooting variable frequency drive (VFD)

The circuit breaker for the VFD had tripped and could not re-energize.
Upon further visual inspection, the VFD was not damaged but 2 out of the 3 phases
supplying the circuit breaker had come into contact and created a short circuit,
causing the circuit breaker to trip. This happened where there was a joint.

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Steps taken to solve problem:
a) The main power was cut off first to stop power from going to the tripped circuit
breaker.
b) The joint was re-wired and more insulation used on the joint.
c) The circuit was then tested for functionality.

Figure 2: Variable frequency drive

1.4.4 Earthing of control panels in briquette making facility.

Earthing is done to provide a low resistance path to ground for leakage current.
Earthing of the control panels protects personnel from electric shock when they touch
the metal body of the control panel.Such that in case of a fault, the fault current flows
to the ground.

Steps taken:
a) A location for the earth rod was chosen near the equipment to be earthed.
b) A hole was drilled into the ground depending on the length of the earth rod,
which for this case was 7 ft.
c) The earth rod was placed into the ground and the gaps filled with a mixture of
soil, earth composite and water.
d) The length of each earth wire to the earthing point on the control panels was
estimated and cut for terminations.
e) The earth wires were connected in parallel and then joined together to be
connected to the earth rod.

Figure 3: Earthing of control panels

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1.4.5 Installing indicator lamp for the water pump
The indicator lamp is supposed to light when the water pump is running.
Components needed are:
a) Lamp
b) 2 core flexible cable to act as Live and Neutral

Steps taken:
a) Since the water pump is operated by a Direct On Line (DOL) control, the Live of
the indicator lamp was connected to the output of the NO contacts of the
contactor in the DOL circuit.
b) The Neutral of the indicator lamp was connected to any neutral point on the
control panel.
c) The connection was then tested to see if it was working as required.

Figure 4: Indicator light of water pump

1.4.6 Installing limit switch for the rotary.

The rotary rotates as it dries the husks used for making briquettes. A limit switch is
essential for disconnecting power and stopping the rotary movement in case of a
deviation to either side. This is a safety measure to prevent any complications or
accidents.

Procedure:
a) The limit switch is connected in series with the stop push button.
b) The stop push button is a normally closed (NC) contact while the limit switch is a
normally open(NO) sensor.
c) When the movement of the rotary deviates and moves the hinge of the limit
switch, it closes and completes the stop circuit, hence the rotary is stopped.

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Figure 5: Limit switch and Stop button connection

1.4.7 Direct on line starter (DOL)

The DOL is a motor starting method that connects the motor windings directly to the
full supply voltage. The DOL provides high starting current, which may damage the
windings of the motor. Thus motors having low power rating are connected through
the DOL starter. These are motors below 5HP. It is used for motors below 5HP. It
consists of a circuit breaker, main contactor and overload relay. It provides both over-
current and overload protection. The circuit breaker is used for protection against
over-current while the overload relay protects the motor from overloading.
It consists of a power circuit and a control circuit. The power circuit is responsible for
providing the power supplied to the motor. The switching of this circuit is controlled
by the control circuit.

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Figure 6: Power circuit and control circuit diagram of Direct On Line starter

When the Start push button is pressed, current will flow from one phase to the
contactor coil back to the neutral wire. The contactor coil (A1 A2) gets energized,
which causes the contactor to close its contacts. As a result, the 3 phase supply is
connected to the motor.
Even if the start push button is released, the control circuit continues working due to
the Hold On circuit that is connected parallel to the start push button through the NO
auxiliary contacts (13, 14). With this connection, when the contactor is energized the
NO auxiliary contacts become normally closed, hence providing power to the
contactor coil even when the start push button is released.
The current flow to the contactor coil (A1, A2) will only break when the stop push
button is pressed. This action de energizes the contactor hence stopping power supply
to the motor.
An emergency stop switch (remote) is connected in series with the stop push button to
shut down the whole electrical circuit in case the control circuit is not responding to
commands due to faulty machine or accidents.

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Figure 7: Control circuit wiring of Direct On Line

Direct on line with indicator lamps

1) On
This indicates that the motor is running.
2) Trip
This indicates that the overload relay has tripped due to overloading.

3) Off
This indicates that the motor is not currently in operation.

Figure 8: Direct On Line with indicator lights

1.4.8 Forward reverse starter

This kind of motor starter is required if a motor is to be driven in two directions. It
consists of the forward and reverse contactors. When the forward contactor is
energized , the motor moves in the forward direction, and when the Reverse contactor
is energized, the motor turns in the opposite direction. The forward reverse starter is

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electrically interlocked using two normally closed auxiliary contacts. This prevents
one contactor coil from being energized if the other is already engaged.

Figure 9: Power circuit and Control circuit diagrams for Forward Reverse Starter

When the Forward Start pushbutton is pressed, current will flow through the contactor
coil (A1, A2) of the Forward contactor, energizing it. As a result, the 3 phase supply
is connected to the motor through the forward contactor hence the motor turns in the
forward direction. When the Forward Start push button is released, the control circuit
continues operating due to the Hold On circuit connected on NO (13, 14). When the
stop push button is pressed, it cuts current flow to the contactor coil of the forward
contactor hence cutting power supply to the motor.
To turn the motor in the Reverse direction, the Reverse Start push button is pressed.
The Forward and Reverse circuits are electrically interlocked by connecting the
Forward contactor coil through the NC auxiliary contacts of the Reverse contactor and
vice-versa, such that when the Forward circuit is in operation, the Reverse circuit
cannot be connected simultaneously. This is because the Reverse contactor coil is
connected through the NC auxiliary contacts of the Forward contactor, which
becomes normally open when the Forward contactor is energized. As a result, it does
not allow current flow to the Reverse contactor coil.

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Figure 10: Forward Reverse Control circuit wiring

1.4.9 Star delta starter

The Star Delta Starter is used for large induction motors with high power ratings. It is
used to reduce the starting current of the motor without using any external device. The
motor is connected in a star connection through the starting period. Then once the
motor reaches the required speed, the motor is connected in delta connection. The
connection can be changed from star to delta manually or automatically using a timer.
The power circuit consists of three contactors which are the Main, Star and Delta
contactors, a thermal overload and a timer.

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Figure 11: Power circuit and Control circuit diagrams for Star Delta Starter

Manual mode:
In this mode, start and stop push buttons are used.

Press the start pushbutton then the star contactor coil will be energized.
Due to electromagnetic induction, the star contactor will hold.

After holding the star contactor auxiliary contact NO (normal open) will be
converted into the normal close (NC). Holding supply of contactor coil is
received from the input terminal of start button and coil will hold continue
and start push button will free from pressing.

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Same time the power supply is received from the star NO output point and
is connected into the main contactor holding coil through delta NC
auxiliary contact. After that main contractor is held.

Main contactor power supply and star contactor power is received in

motor and motor starts. Due to low voltage as one-third the motor moves
slowly and also starting load will be decreased.

 After crossing the set time, the timer changes the power supply star to
delta connection, and the delta holding coil receives holding power
through star NC points.
 During timer changing connection star to delta, the star contactor is
stopped and delta is started. Now the motor is moved at normal speed
in delta connection and it will take normal current.
 The power supply is received in holding coil of the delta through star
NC point from timer.
 Motor will take a heavy current in starting period but it is reduced in
star connection. after changing connection in delta, the motor speed
will increase. After getting full speed the motor will take normal current
as per load.
 Motor overload relay will check running load as per load setting on the
relay. If the load is more as set load, then the control supply will be
braked by the overload relay and the motor will stop.
 If we want to stop the motor then we will have to press the stop button
after that the contactor coil will be de-energized. Contactor terminal
points will be disconnected and the motor will stop.

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Figure 12: Star Delta power and control circuit wiring

1.4.10 Replacing a faulty motor in wood cutting section

The delta connected motor stopped running and upon further inspection, it was
determined that the problem could be burned windings.
For reconnecting the new motor, the supply wire from the circuit breaker is
terminated in the terminal box of the motor.
Since the replaced motor was delta connected, caution is taken to ensure the new
motor is connected the same way.

Figure 13: Delta connection for induction motor

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1.4.11 Installing a surveillance camera
Steps taken:
a) The communication cable from the cabinet was pulled to the point of connection
of the camera.
b) The junction box for the camera was screwed onto the metal frame to be used to
hold the camera.
c) The communication cable was then connected to the camera through an RJ45 and
tested to see if it was working.

Figure 14: Installation of surveillance camera

1.4.12 Troubleshooting arc welding machine

The arc welding machine stopped working and had the yellow indicator light on(an
indication for standby mode).
The electrical circuit for the arc welding machine has a low voltage lockdown that
detects a low voltage in the system and puts the machine on standby mode for
protection of the electronic components.

Steps taken to troubleshoot:

a) Standby mode means could mean the IC is faulty or one of the transistors or
diodes is faulty. Therefore to check the transistors and diodes, a clamp meter was
used. And the arc welding machine is not connected to supply.
b) The clamp meter was set to continuity and its probes placed on the transistor/
diode terminals.
c) If the resistance value on the display screen of the clamp meter was 400 - 700
Ohms, transistor/diode was working properly.
d) If the resistance value on the display screen of the clamp meter was 300 Ohms
and below, transistor/diode was faulty.
e) If the resistance value on the display screen of the clamp meter was or close to 0
Ohms, transistor/diode was shorted and now acting as a wire.
f) Faulty transistors and diodes were then replaced and arc welding machine tested
again.

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g) The arc welding machine still remained on standby mode and the problem could
not be determined.

Figure 15: Inside an arc welding machine

1.4.13 Installing a variable frequency drive(VFD)

The VFD was to be used to control one of the motors operating in the rotary section
for briquette making facility.
The VFD drives the motor by changing the frequency and voltage supplied to the
motor. Frequency is directly related to the motor speed, therefore the faster the
frequency, the faster the speed of the motor.

Steps taken:
a) The left side of the VFD is always the Supply terminals and the right side is the
motor terminals.
b) The connection is as below.

Figure 16: Variable frequency drive terminal connections

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1.4.14 Troubleshooting security lights
There are security lights along the fence of the factory and some of lights had stopped
working.
The section with non working lights was isolated from the circuit breaker point.
A continuity test was done on the supply wires using a clamp meter to determine the
possible problem.

Understanding why a continuity test is performed:

A continuity test verifies the presence of a complete path for current in an electric
circuit. A low resistance (close to or equal to 0) between two points indicates that the
circuit is closed and there is electrical continuity. While a high resistance indicates
that the circuit is open and continuity is lacking. Most short circuits result in lower
resistances, which result in higher currents, and those higher currents trip the breaker.
When testing a circuit, one will not have access to both ends of the wire at once to test
continuity, therefore the following can be done according to the test being performed.

1) Open circuit test

Isolate both ends of the cable, short one end, measure between two wires on the other
end. This should show continuity

2) Short circuit test

Isolate both ends of the cable, test between two wires on one end. This should show
OL (open).

On two different occasions, findings were obtained as follows:

Finding 1:
The supply cable between two security lights was faulty.
Steps taken to determine this:
a) One end of the cable was isolated.
b) Continuity test was done between any two phases ie Red and Yellow
c) The meter showed a resistance of 0 Ohms, indicating that there is continuity
between the two phases.
d) The continuity test is repeated for Red and Blue, Yellow and Blue combinations.
e) Continuity was also detected for these combinations.

This indicated that all the three phases were shorted at a certain point along the length
of the cable.
The cable was replaced with a new one to solve the problem.

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Figure 17: Street lights troubleshooting

Finding 2
For this ocassion, the circuit breaker supplying the security lights tripped and could
not allow to be re-energised.
Here, the continuity test was performed between each phase and a neutral, at the joint
where the supply cable branches to two different circuits. The following values were
obtained.
Phase and Neutral Resistance value
RN 0Ω
YN 1,816 Ω
BN 1,746 Ω

From these values, it was concluded that the there could be water at one of the other
joints that is making the Y and B phases to come into contact. When water comes into
contact with electrical wiring, it causes a short circuit, which can trip the breaker.

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1.4.15 Connecting a single phase motor
A single phase motor has the main winding and the auxilliary winding. This is a self
starting motor because it has a capacitor connected to it, that acts as a Capacitor Start
when connected in series with the auxilliary winding and and acts as a Capacitor Run
When connected in parallel to the auxilliary winding.

Motor connections
The motor has 3 terminals, the Common, Start and Run terminals

Figure 18: Single phase motor

1.4.16 Tripping of overload relay

The overload relay trips because it senses a high current going to the motor, thereby
protecting the motor. It has different current rating selections depending on the
current rating of the motor.

While pumping oil from the oil storage into the oil tank (for truck), the overload relay
at the forward reverse control panel used for controlling the motor for the pump kept
on tripping within a short time of the motor operation, even when it was reset.

Reason for tripping:

The oil gets thicker as the levels lower, therefore the motor draws more current above
its rated current (11.7A). The overload relay is set at 12A, within the range of the
motor rated current. It is set not to allow a current more than 12A to prevent damage
of the motor windings from high currents. So once the current drawn by the motor
goes beyond 12A, the overload relay trips.

Possible solution:
The motor used for the pump could be changed to a bigger one that can handle the
load. The overload current rating is then adjusted to a higher one depending on the
new motor current rating.

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1.4.17 Single phasing of motor
What could be the problem if I turn the 3 phase motor on from the control panel, the
motor is vibrating but not working (turning).

For this problem, it means one of the phases is not reaching the motor, that is, the
motor is single phasing.
What to troubleshoot when this happens:
1) Check the L1, L2, L3 or the T1, T2, T3 terminals of the contactor to see if they
are working properly.
2) Check the motor terminals to see if all of them are receiving power.

1.4.18 Designing a circuit for 50 pieces of 70w lamps

This design is for a factory building.
Determining the cable size and circuit breaker rating.
Total wattage = 70W × 50 = 3500W
With supply voltage taken as 240V single phase
From Power, P = IV
P 3500
Load current ¿ V ¿ 240 =14.58A ≈ 15A

Theoretically, a safety factor of 1.25×Full load current is added for circuit breaker
rating, making it
Circuit breaker rating = 1.25 × 14.58A = 18.23A

Practically, the circuit breaker rating is taken as 16A as it should be a rating not far
away from the load current current.

Cable size
When the resistivity and length of the cable to be used are not known, this formular
can be used to determine cable size.
Load current
Cable size ¿
Multiplicationfactor
15
¿
6
= 2.5 sqmm
Where Multiplication factor for copper = 6 and for aluminium = 4

Materials:
1) 2.5sqmm 4 core copper cable
2) 16A Circuit breaker
3) Contactor
4) Timer
Since this design has many lamps, a two core cable (Live and Neutral) supplying
240V will not be enough as it will cause dimming of the lights. Therefore a 4 core
cable is chosen to provide 3 lives and one neutral such that the 50 lamps are divided
among the 3 lives (16 lamps, 17 lamps,17 lamps).
The contactor and timer are used for automation such that the lights go on during the
night and off during daytime by using a signal from the timer.

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1.4.19 Cable glanding and lagging in a busbar panel
The busbar panel is supplied by a 50sqmm 3 core armoured cable. Other control
panels get power from this busbar panel.
Cable gland is designed to permit the entry of cable in to electrical equipment or
panel. It provides mechanical supports for cables.

Procedure:
a) Check the gland pack to see if the size matches that of the cable.
b) Before starting the termination process, the length of the cable needed was
measured and a mark put on it to have an idea of the area to cut.
c) The outer sheath of the cable was cut with caution making sure not to cut the
armouring in the process or damage the conductors inside.
d) After, the armouring was cut at an extended length from where the sheath was
cut.
e) The gland set was then fixed, rotate the gland and nut in opposite directions to
tighten it.
f) For the cable lagging, the insulation if the Red, Yellow, Blue and Black wires
were stripped.
g) For each wire, a ring lag was fixed at the bare end.
h) A crimping tool was then used to press the lag firmly on the wire such that it
cannot move.
i) Since the lags are metallic, the part that does not touch the conductor is insulated
to prevent electric shocks in the future.
j) A set of adjustable spanners was used to screw the lugs to their respective
busbars.

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Figure 19: Busbar panel cable connections

1.4.20 Installing industrial socket outlets

The socket outlets are installed at points to help supply the different tools and
machines temporarily used in the building. The supply for the socket outlets is got
from the busbar panel. A 3 phase and single phase socket outlets were installed.

Procedure
a) For the 3 phase socket outlet, a 4 core cable is used for the 3 lives and a neutral.
b) One end of the cable was striped and lagged so that it could be used to tap power
from the busbar panel.
c) A spanner and nuts were used to fix the cable in the different buses on the busbar
panel, that is, the Red, Yellow and Blue wires on the respective Red, Yellow and
Blue buses while the Neutral wire on the Neutral bus.
d) The other end of the 4 core cable was stripped and terminated in a 4 pole circuit
breaker, from which the 3 phase socket outlet was to be connected on the output.
e) 2 wires were looped to the input of the 4 pole circuit breaker (one phase and a
neutral), in order to supply the 2 pole circuit breaker for the single phase socket
outlet.
f) The socket outlets were then screwed on metallic frames for support.

1.4.21 Installing pilot lamps

The pilot lamps were necessary to indicate that the control panel is receiving power
supply.
Procedure:
a) 3 wires were stripped and connected to the input end of the MCCB supplying the
specific control panel. These wires are the RYB phases.
b) The wires were then connected to one terminal of each pilot lamp. The colour of
each lamp matches the Red Yellow Blue phase colours.
c) The other terminals of each lamp were looped together and connected to any
neutral terminal in the control panel.
d) The lamps were tested if they worked.

Figure 20: Indicator lights for control panels

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1.4.22 Troubleshooting building lights in stone ball mill
The stone ball mill building is where stones are converted to very fine powder to be
mixed with the other materials used for making tiles, such that the final product of the
tiles are of hard and durable quality. Broken tiles from the tile making process are
also mixed with the stones to avoid wastage.

The problem encountered in the stone ball mill building was that the building lights
that are automatically controlled by a timer were still on during day time yet they are
only supposed to be on at night time.
Upon further inspection, it was found that the 3 core cable supplying the lights was
connected to the output terminals of the circuit breaker instead of the contactor used
in the timer controlled circuit. Because of this, when the circuit breaker was switched
on, the lights were turned on without a signal from the timer.
The timer controlled circuit consists of a 6 cycle timer and a contactor. The timer
energizes the contactor coil through A1 ans A2 when required.

Steps taken to rectify the problem;

a) The output of the circuit breaker was connected to the L1, L2, L3 terminals of the
contactor.
b) The supply cable for the lights was then connected to the T1, T2, T3 terminals of
the contactor.
c) Therefore when the circuit breaker was switched on, nothing happened because
the contactor was not energized.
d) To check if the circuit was working, the timer was bypassed, sending a signal to
energize the contactor. This action caused the main contacts of the contactor to
close, thus powering the lights.
e) Therefore the lights were now controlled by the timer and not the circuit breaker.

1.4.23 Replacing a faulty overload relay

The faulty overload relay was on a forward reverse control panel. The overload relay
had tripped and while trying to reset it, the reset button was not functioning.

Steps taken to replace it:

a) All the ends of wire connected to the faulty overload relay were removed. They
are marked to know where they were connected.
b) The overload relay was removed by unscrewing it from the T1, T2. T3 terminals
of the forward contactor.
c) A new overload relay was screwed back to those same terminals and the wires
marked earlier connected back to the new overload relay.
d) The control circuit was tested if it worked. The overload relay was tripped on
command and then reset to see if it was working properly.

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Figure 21: Forward Reverse control panel where the overload relay was replaced

1.4.24 Mounting and wiring of vfds in a vfd panel

The VFD panel was being designed for the wood cutting section. The panel was to
contain VFDs controlling all the motors driving the wood cutting machines.

Requirements needed:
1) VFDs
2) MCCB
3) Circuit breakers for each VFD
4) Cables
5) Cable trays

Procedure:
a) The VFDs and MCCB were mounted in the empty panel.
b) Cable trays and mounting rail for circuit breakers were also screwed into the
panel.
c) The circuit breakers were attached to the mounting rail. 25A and 16A circuit
breakers are used depending on the rating of VFD maximum current and motor
full load current. Each VFD needs a circuit breaker.
d) Wires were connected from the output of the MCCB to the input of the circuit
breakers. Different supply wires were used for every 3 circuit breakers instead of
looping all from one supply. This was done to evenly distribute the load and
prevent overloading and overheating of the wires, which could potentially cause
wires to burn.
e) Wires were then used to connect the VFDs to the output of the circuit breakers.
All the wiring was made to pass inside the cable trays.
f) The wiring is checked for any design flaws.

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Figure 22: Variable frequency drive panel wiring

CHAPTER FOUR
1.5 SKILL GAINED FROM INDUSTRIAL TRAINING
a) I learned how to use the different test devices, for example, clamp meter.
b) I gained problem solving abilities when it comes to maintenance of equipment.
c) I learned to identify the different electrical components by sight.
d) I learned the functions of the different electrical equipment.
e) I learned the safety and protection measures and procedures that are undertaken
when dealing with power.

1.6 CONCLUSIONS
Operation and maintenance of electrical systems is one of the important activities
carried out in a factory because processes have to continue without delaying
production. This training provided a practical experience and involvement in the
different activities increased my skills.

1.7 RECOMMENDATIONS
To the students
I encourage my fellow students to put more effort in group participation and to always
be on time for the sessions so that they don’t miss a thing because the skills we get are
really helpful for future reference. I also encourage you to attend all days of practice
because it greatly impacts your progress.

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To the company
I appreciate the company for allowing students to do training and gain skills from the
company and I encourage them to continue doing so.

To the university
I encourage the University to continuously send supervisors to monitor our progress.

Reference
Log book

Ps: please use this report for learning only and I hope it helps you with what you need.
Chinchia.......

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