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INTRODUCTION OF PANELS

A INTERNSHIP REPORT

Submitted by

BAROT JAYKUMAR JAGDISHBHAI

220943109003

Under subject of

SUMMER INTERNSHIP
B.E. IV, Semester– VII

in

Electrical Engineering Department

Vidhyadeep Institute of Engineering & Technology, Anita, Kim

Gujarat Technological University, Ahmedabad

[July, 2024]

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VIDHYADEEP INSTITUTE OF
ENGINEERING & TECHNOLOGY
ANITA, KIM.

CERTIFICATE

This is to certify that the Summer Internship report submitted along with the
project entitled Introduction Of Panels At Astek electricals india pvt limited
has been carried out by Barot Jaykumar Jagdishbhai under my guidance in
the subject of Summer Internship in Electrical Engineering, 7th Semester of
Gujarat Technological University, Ahmedabad during the academic year
2024-25.

Sign Sign
Prof. Chetan K Chodavadiya Prof. Sanjay R Bhanderi
Internal Guide Head of the Department

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COMPANY CERTIFICATE

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VIDHYADEEP INSTITUTE OF
ENGINEERING & TECHNOLOGY
ANITA, KIM.

DECLARATION

I hereby declare that the Summer Internship report submitted along with the
Summer Internship entitled Introduction Of Panels submitted in partial
fulfillment for the subject Summer Internship in Electrical Engineering to
Gujarat Technological University, Ahmedabad, is a bonafide record of
original project work carried out by me at Astek Electricals India Pvt
Limited under the supervision of Prof. Chetan K Chodavadiya and that no
part of this report has been directly copied from any students’ reports or taken
from any other source, without providing due reference.

Name of the Student Sign of Student

Barot Jaykumar Jagdishbhai _________________________

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ACKNOWLEDGEMENT

It is a matter of extreme honor and privilege for us to offer our grateful acknowledgement
to our guide Prof. Dr. Chetan K Chodavadiya, Vidhyadeep Institute of Engineering &
Technology, Anita for providing us a chance to work under their guidance and supervision.
I am thankful to the Astek Electricals India Pvt Limited for providing us an opportunity
for the summer internship. I express my sincere appreciation and thanks to Mr.Nilesh
Dubey sir for constant encouragement and needful help during various stages of work.
I express my sincere appreciation and thanks to Prof. Chaitanya Singh (Principal,
VIEAT) and Prof. S. R. Bhanderi (HOD, Electrcial Engg. Dept.) for constant
encouragement and needful help during various stages of work. I am thankful to the
institute for providing all kind of required resources.
I appreciate all my colleagues whose direct and indirect contribution helped me a lot to
accomplish this report and who made the period of project more pleasant and fruitful. I
would also like to thank all the teaching and non-teaching staff for cooperating with me
and providing valuable advice which helped me in the completion of this report.

Finally, I would like to express my deepest thanks to all the members of my family,
who gives me strength and support to aspire for this level of education.

Name of the Student Sign of Student

Barot Jaykumar Jagdishbhai _________________________

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ABSTRACT

Practical aspects of any content/topic are equally important as the conceptual aspects of it.
The theoretical knowledge would be useless if the student doesn’t know the practical
application and utilization of it. On this account summer training is golden opportunity for
the technical students to get face to face with working environment of an industry.
With undergoing training at ASTEK ELECTRICALS INDIA PVT LIMITED, Surat, we
learned a lot about the control panel manufacturing along with the components used in it.
For preparing this report we have had visited to every detailed location inside the company,
with responsible person.
This training has helped us to perceive the basic concepts of control panel manufacturing.
During this period, we became aware about the industry’s working environment and
recognize the needfulness/precautions of safety measurement inside & outside the
company.

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LIST OF FIGURES

Fig 1.1 Company’s Logo and Names 4

Fig 1.2 Journey of Astek Electrical India Pvt Ltd 5
Fig. 1.5.1 Engineering and Steel Sector’s Clients 8
Fig. 2.3.2 Designing of Panel from All Views 10
Fig. 2.3.3 Estimation Sheet for DG-PCC Panels 14
Fig. 2.4.1a CRCA Cabinet Before Powder Coating 15
Fig. 2.4.1b Powder Coating Work on The Panel Body 15
Fig. 2.4.1c Final Fabricated Cabinet of MCC Panel 16
Fig. 2.5.1 SLD of MCC Panel having DOL starter 17
Fig. 2.5.2 MLD of MCC Panels having Star-Delta starter 17
Fig. 2.6 Title Pages of Drawing 19
Fig. 3.1 SLD of Uses of Panels in Industries 20
Fig. 3.6 Classification of LT Panel 23
Fig. 3.6.1 PCC panel 24
Fig. 3.7.1 DG-PCC Panels 25
Fig. 4 Busbar Figure 26
Fig. 5.1 Components Used in Starters 28
Fig. 5.5 DOL Starter Feeder 30
Fig. 5.5.1 Power Circuit of DOL Starter 31
Fig. 5.5.2 Control Circuit of DOL Starter 32
Fig. 5.6.1a Power Circuit of Star-Delta Starter 33
Fig. 5.6.1b Power Circuit of Star-Delta Starter 33
Fig. 5.6.2 Control Circuit of Star-Delta Starter 34
Fig. 5.7a Power Circuit of Reverse-Forward Starter 35
Fig. 5.7b Control Circuit of Reverse-Forward Starters 35

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LIST OF TABELS

Fig. 4.1 Current Carrying Capacity of Various Busbar Materials 27

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ABBREVIATIONS

PCC Power control center

MCC Motor control center
APFC Automatic power factor control
IMCC Intelligent motor control center
PDB Power distribution box
LDB Lighting distribution box
VCB Vacuum circuit breaker
ACB Air circuit breaker
MCCB Molded case circuit breaker
MCB Miniature circuit breaker
PT Potential transformer
CT Current transformer
MFM Multi-function meter
TB Terminal block
HT & LT High tension & low tension
SLD Single line diagram
GA General arrangement
VFD Variable frequency drive
SFU Switch fuse unit
CMM Current measuring module

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TABLE OF CONTENT
Acknowledgement………………………………………………………………………... i
Abstract……………………………………………………………………………………ii
List of Figures……………………………………………………....……….…………....iii
List of Tables…………………………………………………………………………….. iv
List of Abbreviations………………….…………………………………………………. v
CHAPTER 1 Overview of Company…………………………………………………....04

1.1 Introduction ..............................................................................................................04

1.2 History ....................................................................................................................05

1.3 Mission, Vision, and Values .....................................................................................06

1.3.1 Mission ............................................................................................................06

1.3.2 Vision ..............................................................................................................06

1.3.3 Values..............................................................................................................06

1.4 Different Product and Services .................................................................................07

1.4.1 Product Offered ...............................................................................................07

1.4.2 Services Offered ..............................................................................................07

1.5 Company’s Happy Clients ........................................................................................08

1.5.1 Engineering and Steel Sector ...........................................................................08

1.6 Company Contacts Details ........................................................................................08

CHAPTER 2 Stages of Productions ..............................................................................09

2.1 Introduction ..............................................................................................................09

2.2 Project Acquisitions or Marketing ............................................................................09

2.3 Planning Designing and Estimation ..........................................................................09

2.3.1 Planning...........................................................................................................09

2.3.2 Designing ........................................................................................................10

2.3.3 Estimation........................................................................................................13

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2.4 Fabrication and Purchasing………………………………………………………… 14

2.4.1 Fabrications .....................................................................................................14

2.4.2 Purchasing .......................................................................................................16

2.5 Wiring Diagram........................................................................................................16

2.5.1 Single Line Diagram (SLD) .............................................................................17

2.5.2 Multiple Line Diagram (MLD) ........................................................................17

2.6 Final Drawing Preparation ........................................................................................18

CHAPTER 3 Introduction of Control Panels .................................................................20

3.1 Introduction ..............................................................................................................20

3.2 General Classification of Panels ...............................................................................20

3.3 HT Panels .................................................................................................................21

3.3.1 Main Function of HT Panels ............................................................................21

3.4 MV Panels ................................................................................................................21

3.5 LT Panels .................................................................................................................22

3.6 Classification of Panels.............................................................................................23

3.6.1 PCC Panels ......................................................................................................23

3.7 Working of PCC Panels ............................................................................................24

3.7.1 DG-PCC Panels ...............................................................................................24

3.7.2 Process of DG Synchronization ........................................................................25

3.8 Working of DG Synchronization Of Panel…………….…………………………….25

CHAPTER 4 Busbar………… ………………………………………………………….26

4.1 Current Carrying Capacity of Various Busbar Materials…………………………27

CHAPTER 5 Starters………………………………………………...…………………..28

5.1 Introduction ……………..……………………………………………………………28

5.2 Need of Starters……………………………………………………………………….28

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5.3 Working of Starters………..………………………………………………………….29

5.4 Classification of Starters…………………………………………………..………….30

5.5 Direct Online Starters(DOL)…………...…………………………………………......30

5.6 Star Delta Starters………….………………………………………………………....33

5.6.1 Power Circuit of Star-Delta Starters……………..……………………………..33

5.6.2 Control Circuit of Star-Delta Starters…………………………..………………34

5.7 Reverse-Forward Starters (RDOL)..……………………………………………….....34

CHAPTER 6 Conciusion..…………………………………………………………….....36

CHAPTER 7 Reference………………………………………………………………….37

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CHAPTER 1: OVERVIEW OF THE COMPANY

1.1 INTRODUONCTION

Astek electricals India pvt ltd was established in year 2009 at Surat Gujarat, which was

formally known as Astek electricals. Control panels are the heart to run of any kinds of

industries. Specially in surat the textile, Dimond cutting and polishing, and chemicals

manufacturing industries as well as lots of international conglomerates established their

operations in surat. The well-connected port through rest of India as well as the

international water. After watching this opportunity, they turn their electricals components

sales business into the panels manufacturing business. They provide the HT and LT panels

solution towards industries as well as the engineering services as per their client’s

requirements.

Fig 1.1 Company’s Logo and Names.

Further they increase their expertise and get certificate for SIEMENS authorized system

house. They also get lots of certificate, these certificates are mentioned in further section.

Based on this expertise and dedication towards manufacturing they got their own ISO

certification in 2017, that is ISO 9001:2015. In addition, they are specialized manufacturer

of all kinds of electricals control planes.

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1.2 HISTORY

Fig 1.2 Journey of Astek Electrical India Pvt Ltd.

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1.3 MISSION, VISSION AND QUALITY

1.3.1 Mission:
● Innovation.
● Adapting change.
● Implementation of kaizen.
● Faster product introduction.
● To exploit untapped market.
● To achieve international standard.

1.3.2 Vision:
● Astek electricals India pvt Ltd. Strives to be a world class manufacturing
organization for electrical control panels and electrical services by imbibing the best
work practices and caring for its customers, employees, society and environment.
● Become a global market leader in electrical control panels manufacturing.
● Become a world class manufacturing company.
● Achieve highest customer satisfaction.

1.3.3 Values:
● Our values represent the basis for the development of our business.
● Focus on consumer is a fundamental ingredient for our success.
● Developing people is fundamental to sustain our growth.
● Quality in our products and excellence in our processes.
● High performance is what we strive for permanently.
● Respect for people makes us even stronger.
● Integrity as the basis of any relationship.
● Constant innovative spirit.
● Sustainable growth

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1.4 DIFFERENT PRODUCT AND SERVICES

Whole industries throughout the world run by the electrical control panels. Because of
cost effective and highly effective the scope of the electrical control panels is bright the
demand will be increase exponentially in coming year. Keeping, this in mind sagar
electricals create variety of product under “ASTEK” brand name all are mention below.

1.4.1 Product Offered:

● L.T. Switch Board SIEPAN-IEC 61439
● H.T. Switch Board
● Ring man unit (RMU) 8DJH ST
● Compact Substation (CSS)
● L.T. Switch Board CPRI-IS-8623
● Power control center (PCC)
● Motor control center (MCC)
● Automatic power factor correction panels (LV APFC PANEL)
● LV/HV Busduct (up to 6300A)
● AUTO DG Synchronizing panels
● AMF panels etc.

1.4.2 Services Offered:

● Work (With Torrent Power, DGVCL, etc.)
● H.T. / L.T. Panels Installation, Testing & Commissioning.
● H.T Structure Installations.
● H.T./L.T. Cable Laying, Cable Termination, Cable Jointing.
● Fabrication Work
● Earthing Work.
● Bus duct Installation.
● Relay Testing.
● Retrofitting Jobs.
● Industrial and Commercial Turnkey Project Work etc.

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1.5 COMPANY’S HAPPY CLIENTS

Fig. 1.5.1 Engineering and Steel Sector’s Clients

1.6 COMPANY CONTACTS DETAILS

Astek Electricals India Pvt. Ltd.

Location: Plot No. 202-204, Unity Estate,
Near Batliboi Ltd., Bhestan, Surat - 395 023, Gujarat, India.

Mobile No:
+91 9727980082
+91 9825080082

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CHAPTER 2: STAGES OF PRODUCTION

2.1 INTRODUCTION

Production is the process of making or manufacturing goods and products from raw
materials or components. In other words, production takes inputs and uses them to create
an output which is fit for consumption a good or product which has value to an end-user or
customer. In this chapter we are going to know he whole process of manufacturing from
the project acquisition to dispatch of product from workshop. The whole process of
manufacturing involves like project acquisition, planning, designing, estimation, busbar
sizing and fitting, power wiring and control wiring, quality check, testing, and finally
wrapping and dispatch.

2.2 PROJECT ACQUESTION OR MARKETING

The very first step towards electrical control panels manufacturing is project acquisition.
There is different way of project acquisition like company showcase their past project to
their clients to get project, another way that customer firm release tender for panel and
manufacturing company fill the tender to get project, another way is directly from referral,
another way is third party marketing on bases of commissions etc. these few ways of getting
the project. Also, they use the digital medium for getting the project and showcase their
project on various digital platforms.

2.3 PLANNING DESIGNING AND ESTIMATION

2.3.1 Planning:
After getting the project from the client the planning are takes place among all the peoples
who are going to become part of that manufacturing process. The project manager Allocate
the work to all people like the designing work allocated to the designing people, fabrication
of panel allocated to fabrication team, estimation work gets the estimation engineer, the
wiring and dressing of panel are gets by technician other like name plate fitting, cleaning,
drilling mounting of components, making of busbar and fitting it into the panels are also
awarded to respective peoples.

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2.3.2 Designing:
The actual work of panel manufacturing is started from the designing, the designing team
design the electric panels according to the client’s requirement. The designer design all the
possible views like front view, rear view, top view, bottom view, intern top view, internal
rear view and L. side view, R. side view, etc. these all-design work performed on the
AUTO-CAD design software. This is also known as GA drawing.

Fig. 2.3.2 Designing of Panel from All Views.

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2.3.3 Estimation:
In estimation section the estimation engineer estimates the rating of all components as well
as the cost of components used in that panel. For example, the figure mentioned above in
that panel we required the MFM, ACB, TNC, Indicator lamp, C.T, Busbar wire with
different rating. They calculate all the rating according to requirements and finally they
make an estimation sheet like mention below. This estimation sheet also known as Bill of
materials (BOM). In estimation the wait of panels is also calculate.

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Fig. 2.3.3 Estimation Sheet for DG-PCC Panels.

2.4 FABRICATIONS AND PURCHASING

2.4.1 Fabrications:
After approval of GA drawing from the clients as well as the manufacturer. The next step
is fabricating the body according to GA drawing. This body is manufactured by CRCA
steel sheet, this sheet is strong in build quality and scratch free. After selection of sheet this
sheet is cut according to required dimension, and band according to requirement, after that
the worker make hole for components fitting according to requirement, also they make
whole for Nut-Bolt for assembling. After that, the welding work done takes place. After
that, the chemical spray is used in part to remove the dust so the powder coating work will
be properly. After doing all this work the whole components are heated at 200 degrees
Celsius to dry the parts. After that, the assembling work takes place. The whole process

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mentions below, cutting the metal sheet weld it and make cabinet type structure in which
the protective switchgear easily mounting.

Fig. 2.4.1a CRCA Cabinet Before Powder Coating.

Now, the several chemical layer will spray on the body so dust can be avoided, and the
powder coating will shine according to the requirement. There are two type of powder
coating are generally spray on body that is 7032 and 7035. In panels industries the 7032-
color coding is widely used and acceptable. 7035 came in silver color tis color coding is
less used in industries.

Fig. 2.4.1b Powder Coating Work on The Panel Body.

After cutting, welding, and powder coating the all component are assembled and the final
product is ready as shown below, this is full fabricated of MCC panel according to design

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and GA drawing.

Fig. 2.4.1c Final Fabricated Cabinet of MCC Panel.

2.4.2 Purchasing:
Before, purchasing the estimation engineer estimate the rating and price of that components
according to that rating and make the estimation sheet as mentioned in above figure 2.3.3.
According to that sheet and client’s requirement the purchase engineer talk to supplier and
purchase with best quality and price. In electrical control panel industries use different
types of switch gear for same rating, for example the ACB coming in same rating with
various makes. The ACB with 5000A rating come with L&T, siemens, Schneider, ABB
etc.

2.5 WIRING DIAGRAM

Wiring is core part of panels manufacturing. There are different types of wiring used in

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various panel. In HT panels used different wiring, in LT panels used different kind of
wiring. In LT panels there are various like PCC, MCC, IMCC, DG-PCC and APFC etc.
these all-LT panels having there its own SLD and MLD. SLD stands for single line
diagram, and MLD stands for multiline diagram
both type of wiring used for showing the whole wiring of panels in a single page. These
both type of wiring is prepared with EPLAN software.

2.5.1 Single Line Diagram (SLD):

Single line diagram is used for showing all kind of equipment and switchgear in a single
line so component mounting people easily understand and mount switchgear in a line and
technician can understand the way of wiring. Below shown SLD figure belongs to The
MCC panels in which shown ACB in incomer and DOL starter in outgoing section.

Fig. 2.5.1 SLD of MCC Panel having DOL starter.

2.5.2 Multiple Line Diagram (MLD)

Multiple line diagram is used to show the SLD into enlarge. MLD are generally used in the
control wiring, in PCC, MCC, IMCC, APFC, etc. in this wiring diagram all components of
control circuit are mentioned, so the technician can understand it easily and perform wiring
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according to diagram. MLD are also very helpful during testing.

Fig. 2.5.2 MLD of MCC Panels having Star-Delta starter.

2.6 FINAL DRAWING PREPRATION

In final step of pre-production stages, the drawing of whole panel is prepared, in which all
the data are include which is very essential for panel manufacturing. The data include in
drawing is mentioned below, which are also given in above section. Cover pages contain
the data like client name, manufacturer name, project name, panel type HT or LT name of
panel as mentioned in below cover page of MCC panel. Cover pages is the first page under
the cover pages more than 20 pages are include. This all things mentioned in drawing are
shown below,
● Cover pages/ Title page

● Technical Datasheet

● General Arrangement (GA)

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● Equipment Details

● Single Line Diagram (SLD)

● Wiring Diagram (MLD)

● Bill of Materials (BOM)

Fig. 2.6 Title Pages of Drawing.

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CHAPTER 3: INTRODUCTION OF CONTROL PANELS

3.1 INTRODUCTION

An electrical control panel is an enclosure, typically a metal box or plastic molding which
contains important electrical components that control and monitor several mechanical
processes. The introduction of panels is shown below with SLD.

Fig. 3.1 SLD of Uses of Panels in Industries.

3.2 GENERAL CLASSIFICATION OF PANELS

According to voltages level the panels are classified into three parts. The panels which work
on very high voltage is known as high voltage panels, its voltage level can be given as
11KV, 22KV, 33KV this panels also known as high tension panels or HT panels. The panels
which work on voltages level 600V to >11KV is known as the medium voltage panels. And
similarly, the panels which works on voltages level below >600V (To specific 400V) is
known as low tension panels. The classification of this kind of panels can be given as,

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● HV panels (High Voltage panels).

● MV panels (Medium voltage Panels)
● LV panels (Low voltage Panels)

3.3 HT PANELS

Full form of HT Panel – The full form of HT panel is High Tension panel.
Definition – HT panel is a metal enclosure fitted with HT Circuit Breakers, relays &
metering that is used to receive 11KV/33KV supply (from one or more source) & distribute
the power through its outgoing feeders. Outgoing feeder may be one or more it depends on
the load of the building.
HT Panels is a high-powered unit that is specially designed for power distribution centers
to control large currents and voltages to ensure higher safety within the power lines. It is
designed and developed as per electrical engineering standards that make it highly efficient
as well as robust in construction.
HT panels mean high tension panels. It distributes high voltage power that cab be
11KV/22KV/33KV etc.HT panel is a metal enclosure fitted with HT Circuit Breakers,
relays & metering that is used to receive 11KV/33KV supply (from one or more source) &
distribute the power through its outgoing feeders. Outgoing feeder may be one or more it
depends on the load of the building. It is installed in Electrical substations of Commercial
complexes, residential colonies, factories, schools, hospitals etc. to receive & distribute HT
supply.

3.3.1Main Functions of HT Panel

● To make & break HT supply (or switch on or switch off
supply).
● To receive & distribute HT supply.
● To provide protection against faults such as short circuit, overload, earth fault,
overheating of transformers winding, overheating of transformer oil.
● To provide metering to monitor various parameters.

3.4 MV PANELS
Full form of MV Panel – The full form of MV panel is Medium Voltage panel.
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Definition – MV panel is a metal enclosure fitted with MV Circuit Breakers, relays &
metering that is used to receive 600V/1.1KV/3.3KV/6.6KV supply (from one or more
source) & distribute the power through its outgoing feeders. Outgoing feeder may be one
or more it depends on the load of the industries.
MV panels are similar to HT panels so in general the HT panels are widely use in all
industries. MV panels has less application in industries more or less the MV panels are use
only having load more than 440V and less than 11KV, but in industries the load between
600V to 11KV are very less and it is not economical to operate medium voltage panels in
industries, but somehow a small number of this kid of panels are also in uses in industries.

3.5 LT PANELS

Full form of LT Panel – The full form of LT panel is Low Tension panel.
Definition – LT panel is a metal enclosure fitted with LT Circuit Breakers (ACB), MCCB,
MCB relays & metering that is used to receive less than 440V supply (from one or more
source say transformer and DG-sets) & distribute the power through its outgoing feeders.
Outgoing feeder may be one or more it depends on the load of the industries.
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. Our LT panels are designed to work
with low electricity consumption that makes them cost effective. The following section
incorporate in LT panels, which is mentioned below.

● Feeders: Feeder is a section of panels which connects electricals source/Power with

load through cable or bus ducts.
● Incoming Feeders: In this section of panels where electricals power is received by
ACB/MCCB/MCB from the source like transformer or /and DG sets and connected
with outgoing feeder such as ACB/MCCB/MCB through internal busbar. The capacity
of incomer feeder should always be more than all outgoing feeder of that panels.
● Outgoing Feeders: It is section of panels where loads or sub panels are connected
through the cables with our main incomer feeders.
● Bus-bars: Bus-bar are made up of either aluminum or copper (Al or Cu). These are of
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rectangular in shape. Incoming and outgoing feeders are connected through these
busbars. The capacity of bus-bar is depending on the loads which is to connected with
it.
● Cable Alley or Cable Ducts: This is the section of panels where cables from
incoming or outgoing section are connected with panel feeder.

3.6 CLASSIFICATION OF LT PANELS

The classification of LT panels depends on its industrial uses so, according to its uses or
application the LT panes are classified into the following mention below,

1.PCC panels

1.MPDB/PDB 1.DG-PCC
panels panels

1.MCC/IMCC
panels

1.APFC 1.MLDB/LDB
panels panels

SFU UNIT

Fig. 3.6 Classification of LT Panel

3.6.1 PCC PANEL

PCC stand for power control center it is also known as the main power distribution panels.
PCC Panels are the most essential part of electrical system of an industry from where the
power of the industry is controlled. PCC Panel is a power distribution board to control the
Electrical power supplied to HT Panels, MCC panels and transformers who play vital role
in all electrical control system. Power Control Centre is used for distribution and control of
various power source used in industry. Normally Power Control Centers is installed near
power source hence fault level is high. Various protections viz short circuit, overload, earth
fault, under voltage etc. are provided to protect source and equipment. PCC Panels widely

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used in refineries, chemical plants, pharmaceuticals and Solar Industries.

Fig. 3.6.1 PCC panel

3.7 WORKING OF PCC PANELS

PCC Panel stand for Power Control Center also known as Main power Panel, The Power
Control Center Panel works by combine circuits from several places into a single central
hub. This enables access to the whole electrical connections of a grid, Industry from a single
place. The electricity for all circuits is controlled by a single main power switch in a PCC
panel. When the main Circuit Breaker switch is turned off, the entire electric supply might
be temporarily shut down. There are situations, though, when you may need to manage the
power for individual components or places. As a result, each circuit will be divided into its
own switch by a PCC panel. If you need to turn off the electricity in just one part of your
business, you may do so without cutting off the power to other parts of the industry that
needs it. It would be quite risky to power up your Plant or Commercial Place without a
PCC panel. Basically, to protect and control power distribution for large manufacturing
unit PCC Panels are used.

3.7.1 DG-PCC PANELS

DG-PCC stand for Diesel Generator-power control center. DG synchronizing panel
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controls the functionality of a number of diesel generator sets. In Industries, more than one
DG sets have to be used in parallel to share the total load on the system. Basically DG
Synchronization panels are mainly designed for meeting critical aspects of Power system
requirements which primarily includes uninterrupted or flashing restoration of Power
supply along with DG and circuitry protection for an infrastructure of social or commercial
values and repute ( like Hospitals , Malls , Multistore residential societies, Hotels,
Telecommunication sectors and Industries with varied loads of power implementation )
D.G. Synchronization panels work both manually and with an automatic synchronizing
function using PLC for two or more generators or breakers. They are pre-dominantly used
in electro-mechanical synchronizing of Diesel generators and provide multiplex solutions.

3.7.2 PROCESS OF DG SYNCHRONIZATION:

Process of Diesel Generator synchronization basically constitutes matching the
undermentioned parameters of an alternator (Diesel Generator) with an existing healthy
running power system. It is done before connecting DG to the healthy power system.
Technical parameters which are matched during DG Synchronization are,

1.Frequency

1.ofWaveform 1.angle
Diesel
Generator
1.Voltage Phase

1. Phase
Sequence

3.8 WORKING OF DG SYNCHRONIZATION PANELS

Diesel Generator synchronization is the process of matching technical electrical parameters
such as voltage, frequency, phase angle, phase sequence, and waveform of Diesel generator
with a healthy or running power system. This is required to be done just before the generator
is reconnected to the power system.

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CHAPTER: 4 BUSBAR

Fig : 4 Busbar Figure

Based on current carrying capacity the busbar is classified into primarily five types these
types are mentioned in below table. While selecting busbar one should kept in mind that
the application, current carrying capacity, and budget as under size busbar can cause
heating and damage in busbar while over size busbar can affect the cost of project. By
keeping this all thing in mind, the busbar is divided into five part these are mention below,
● Copper
● Aluminum
● Galvanized Steel
● Iron Steel
● Silver Steel

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Table 4.1 Current Carrying Capacity of Various Busbar Materials

S Materials Current Carrying Applications

r.
Capacity Per mm2
N
o.
1 Copper 1.2 Amp/ mm2 Panels and Board
.
2 Aluminum 0.8 Amp/ mm2 Panels and Board
.
3 Galvanized 0.6 Amp/ mm2 Electrical
. Steel Earthing
4 Iron Steel 0.6 Amp/ mm2 Trolleys,
. unloader
and Traction
5 Silver Steel 1.6 Amp/ mm2 Rarely Used due
. to
High Cost

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CHAPTER 5: STARTERS

5.1 INTRODUCTION
A motor starter is an electrical device that is used to start & stop a motor safely. Similar to
a relay, the motor starter switches the power ON/OFF & unlike a relay, it also provides a
low voltage & overcurrent protection. Starter is the fundamental components of MCC
panels. In this chapter we are going to study the various type of starter like DOL starter,
Star-Delta starter, Reverse-Forward starter RDOL starter, VFD starter, soft starter.

Fig. 5.1 Components Used in Starters

5.2 NEED OF STARTERS:

A motor starter is essential for starting an induction motor. It is because of its low rotor
impedance. The rotor impedance depends on the slip of the induction motor which is the
relative speed between the rotor & stator. The impedance varies inversely with the slip. The
slip of the induction motor is at maximum i.e., 1 at standstill (rest position), thus the
impedance is at its minimum & it draws a huge amount of current called inrush current.
The high inrush current magnetizes the air gap between the rotor & stator that induces an
EMF in the rotor winding. This EMF produces an electrical current in rotor winding that
creates a magnetic field to generate torque in the rotor. As the rotor speed increases the slip
of the motor decreases & the current drawn by the motor is reduced.
The high inrush current is 5-8 times the normal rated full load current. So, such amount of
current can damage or burn the windings of the motor that will render the machine useless

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& it can cause a huge dip in voltage of the supply line that can damage other appliances
connected to the same line. In order to protect the motor from such a huge number of
currents, we use a starter that limits the initial current for a short duration at startup & once
the motor attains a certain speed, the normal power supply to the motor is resumed. They
also provide protection against fault conditions such as low voltage & overcurrent during
normal operation.

5.3 WORKING OF STARTERS:

A starter is a control device that is used for switching the motor either manually or
automatically. It is used for safe ON/OFF control of electrical motors by making or
breaking its contacts. The manual starter is used for smaller motors where the hand operated
lever is manually operated (move the contacts position) to the ON or OFF position. The
disadvantage of these kinds of starters is that they need to switch ON after power frailer. In
other words, they need manual control for each (ON or OFF) operation. Sometimes, this
operation may lead to flow high currents in the motor winding which may burn the motor.
This is why it is not recommended in most cases where other alternative motor starters with
protection are used such as automatic starters.
On the other hand, the automatic starters which consist of electromechanical relays and
contactors are used to switch the motor ON/OFF operation. When current passes through
the contactor coils, it energizes and produces the electromagnetic field which pulls or
pushes the contacts to make the connection of motor windings to the power supply. The
start and stop push buttons connected to the motor and starter can be used for ON and OFF
operation of motors. The contactor coils can be de-energize by pushing the stop button
which leads to de-energize the coil. This way, the contactor contacts move back due to
spring arrangement to its normal position which leads to switch off the motor. In case of
power failure or manual switch-off operation, the motor won’t start automatically until we
manually start the motor by pressing the “start push button”. The following diagram shows
that how a DOL motor starter operates for ON/OFF operation.

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5.4 CLASSIFICATION OF STARTERS

Starter is very essential part of MCC panels the various type of starter is used by the
industries so based on starting method the starters are classified into several type but in
industries these five types of starters are widely used in working. In which DOL is widely
used starters for lower rating motor then after Star-Delta is equally using for higher rating
motor.

1. Direct online starter (DOL)

2. Star-Delta Starter (S/D)
3. Reverse-Forward starter (RDOL)

5.5 DIRECT ONLINE STARTERS (DOL)

A simple DOL Starter has mainly two parts, one is Contactor and another is Thermal
Overload Relay. The Contactor is used to switching purpose and the thermal overload relay
is used to prevent overcurrent fault. The DOL starter cannot reduce the voltage or current
during starting of the motor like other starters. When we close the Contactor, the motor will
get the power supply and it will start. When the motor draws overcurrent, the thermal
overcurrent relay will trip the circuit and the motor disconnect from the supply. Actually,
the DOL Starter which is used with motor required additional circuits and equipment for
its operation. In the above paragraph, only the basic concept explained. Now we are going
to know actually how the DOL starter is operated.

Fig.5.5 DOL Starter Feeder

The connection or circuit to drive the motor is called Power Circuit and the connection or
circuit to operate the DOL starter is called Control Circuit or Pilot Circuit. In the power
circuit, three devices or equipment are connected. First the Main switch. We mainly use
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MCB as the Main switch. Next, the Contactor is connected. The Overload Relay is
connected after the Contactor. The output of the Relay is connected to the Motor. When we
buy any DOL Starter from the market, it has Contactor and Overload Relay inside it. So,
we need extra MCB or Main switch which should be connected before the Starter. The
DOL Starter including Control circuit also available in the market. In the power circuit, we
can only operate the Main switch or MCB and rest of all operations are done in the Control
circuit. Remember that the power circuit contains the full voltage like 230V for single phase
and 440V for three phase supply but the control circuit always contains up to 230V single
phase supply.

Fig. 5.5.1 Power Circuit of DOL Starter

The all-main operations are done in the control circuit. The control circuit is connected to
the Contactor Coil. When the coil of the Contactor is energized then the Contactor closes
the power circuit and the Motor gets the power supply. So, our main focus is to energize
the coil of the Contactor. If you see the power circuit and the control circuit carefully then
you will understand the operation of the DOL Starter. As you see in the above diagram

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after turning ON the MCB when we push the Start push button switch the Contactor coil
will be energized and the motor will start to run. After starting as the Contactor coil is
energized the Hold on contact will be closed and it keeps ON the control circuit even after
removing pressure on the Start Push Button switch. You can see the Overload Relay
operated switch is connected in series with the circuit which is Normally Closed. So, when
the motor draws overcurrent, the relay operated switch becomes open and the Contactor
also disconnected the Motor from the supply. The Overload indicator lamp is connected
through an overload relay operated a switch which is Normally Open so when the overload
occurs then the Switch become closed and the Lamp will be glow. We can stop the Motor
anytime by pressing the Stop push button switch which is Normally Closed. As you see in
the above figure the Power Circuit operating at 440V Three phase supply and the control
circuit is operating 230V single- phase supply.

Fig. 5.5.2 Control Circuit of DOL Starter

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5.6 STAR-DELTA STATER (S/D):

The whole STAR-DELTA starter circuit is divided into two parts,
● Power circuit
● Control circuit
5.6.1 Power Circuit of Star-Delta Starter:
You can see in the below I have shown the Star Delta Starter Connection with a Three
Phase Motor. First, a Main switch or MCB or MCCB is connected to give the power supply
to the Circuit. Then a Thermal Overload Relay is connected for the protection purpose. The
Thermal Over Load relay will trip the circuit if a short circuit or overload fault occurs in
the Motor. In the Power Circuit of Star Delta Starter, three contractors are used. One is the
main Contactor which will be always ON after starting the motor. The other Contactors are
Star Contactor and Delta Contactor. The star contactor is used to make Star connection.
Only during the starting time, the Star Contactor remain ON after a small time it will be
OFF and the Delta Contactor will be ON. Delta Contactor is used to make the delta
connection. It will be Turn ON after turning OFF the Star contactor and remain ON until
we stop the Total operation. Don't Confuse with the terms Star Contactor and Delta
Contactor. They are not any special types of Contactors. Here all contactors are the same
type of contactor. Here the terms Delta Contactor and Star contactor are used according to
their operation.

Fig. 5.6.1a Power Circuit of Star-Delta Fig. 5.6.1b Power Circuit of Star-Delta

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5.6.2 Control Circuit of Star-Delta Starter:

Here you can see the Control Circuit Diagram of Automatic Star Delta Starter. As you see
in the above Star Delta Starter Diagram, First, an NC push Button switch is connected to
Stop the operation. Next, the circuit goes through the NC terminals of the Thermal Over
Load Relay. When the fault occurs the thermal overload relay will trip the circuit. Next, a
NO Push Button switch is connected to start the operation. The NO terminals of the main
Contactor is connected across the NO Push Button switch for Holding. That means when
the NO push button switch is OFF, the circuit will remain ON. The Star Contactor is
Connected with the NC terminal of the Timer and the Delta Contactor is connected with
the NO terminal of the Timer. So, at the starting time, the Star contactor will be turned ON.
After a small time (which is to be set manually) the NC of the Timer will be NO and NO
will be NC so the Delta contactor will be turned ON and remain ON until we push NC Push
Button Switch for Stop. So, this was the total concept of the Star Delta Starter Diagram.

Fig. 5.6.2 Control Circuit of Star-Delta Starter

5.7 REVERSE-FORWARD STARTERS (RDOL):

The whole Reverse-Forward starter circuit is divided into two parts,
1. Power circuit
2. Control circuit
Forward Rotation or Clockwise (CW) Rotation:
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Generally, three-phase electrical motors are designed or their windings are connected in
such a way that when R, Y, and B phases are connected with motor terminals R, Y, B or
U, V, W or T1, T2, T3 respectively then they will run in Forward Direction or Clockwise.

Reverse Direction or Anti Clockwise (ACW) Rotation:

We know that in a three-phase electric motor if we interchange any two terminals of the
motor or power supply, it will rotate in the reverse direction. So, this basic concept is used
in this circuit diagram.

Fig. 5.7a Control Circuit of Fig. 5.7b Power Circuit of

Reverse-Forward Starter Reverse-Forward Starter

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CHAPTER 6 : CONCLUSION

After finishing my 15-day industrial training program or summer internship, I exposed

through different corporate action. Which is really amazing and first time in my life From
these days I learn about how a electrical control panel is built from scratched to finished. I
learn how to use lathe machine for cutting and drilling in the hard material. My work related
to electrical, I learn how to wiring the panel and design required for manufacturing. During
this industrial tanning I work with different people within origination they all are very
cooperative. They help me to understand everything which is very hard for me thanks to all
of them.

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CHAPTER 7: REFERENCES

Astek Electricals LT panels workshop Bhestan Surat

https://www.astekelectricals.com/in/en/
https://electrical-engineering-portal.com/
https://solutioncontrols.ca/products/motor-control-panels/vfd-panels/

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