TYPES OF WIRING

The following types of wiring are commonly used;

a) Cleat wiring system.
b) Wooden casing caping wiring.
c) Lead sheathed wiring system
d) Conduit pipe wiring
e) C.T.S. /T.R.S. wiring.
f) P.V.C. casing and capingwiring
SYSTEM OF WIRING
Another classification of wiring system depends upon the method of supplying power to
points According to it there are two types of wiring, one is tree system and the other is
Distribution system.
a) Tree system. 1) This system is no more in the use because there is only one circuit and
numbers of
tappings are taken for various rooms. This system suffers from different type of trouble.
b) Distribution System. This is now very widely used for indoor wiring in building due to the
following advantages:
1) All the lamps are maintained almost at the same voltage.
2) The system is simple and is capable of further extension.
3) Each circuit is protected by a fuse.
4) The only disadvantages is that its initial cost is high.
In this system the leads from the meter are connected to the main distribution board,
which in turn supply to the lamps etc.
Golden rule for wiring,
1) Always treat the conductor as bare; however well insulated they may be so that under no
condition short circuit or leakage may occur.
2) Special care should be taken for the mechanical execution of work so that there is no
damage to the property.
3) The Joints should be perfect and the lines should appear neat and tidy.
4) All the boxes and boards should be set straight and in level. They should at same time be
secured.
5) Wires in the boxes and boards should be with out kinks and laid down in straight lines, so
that they may be traced out easily

HOUSE WIRING
INSULATION TEST OF THE HOUSE BEFORE COMMISSIONING A NEW
BUILDING
Insulation test of the internal wiring is carried out most conveniently by a 500 volts
megger and comparises mainly two parts;viz line to earth test and line to line test.beforing
starting the test ,switch off the supply , remove the main fuse and disconnect the neutral link.then
proceed as follows.
LINE TO EARTH TEST;
a) Insert all fuses at the fuse board ;insert all lamps;close all single pole tumbler switches;where
fans
are provided; close all the fans switches and put the regulator in on position.
b) Temporarily short the phase and neutral terminals on the dead side of the main switch and
connect
them to one terminal of the megger.The other terminal is connected to the earth,
c) Note and record the megger reading.
This give the total combined insulation resistance to earth of both the phase and neutral
conductor.
The minimum permissible resistance should be not less than
50
-------------------------no. of outlets
for instance, if there are 20 wiring points, the insulation resistance should not be less than
50/20 i.e.two and half mega ohms. If the resistance is below this value, it cannot be considered as
satisfactory .Each final sub-circuit shouls have a resistance of at least .5 Megaohms under the
wrost condition.i.e. during rainy seasons.
LINE TO LINE INSULATION TEST.
a)
Remove or disconnect all consuming devices such as lamps, fans or portable apparatus
plugged on to 2-pin 3-pin sockets, etc.
b)
Keep all single pole tumbler switches in on position.
c)
Remove all fuses in the fuse boards and open the neutral links.
d)
Take the insulation resistance between the phase and neutral lines of each final sub
circuits The insulation resistance between lines of each subcircuit should not be less than 5
Megaohms of ten wiring points. If the readings are lower, cause must be find out and rectified
The maximum permissible leakage on the consumer premises is 1/5000 part of the maximum
current
supplied to the consumer. Thus, if the maximum load of the premises is, say 5amp on a 230
volt system. Then permissible leakage current will be 5/5000 = 1 miliamphers
The test would reveal nearly all insulation defects in a wiring installation.

FUSE
DIFINATION ; Fuse is essentially a short piece of metal (or a fusible material)inserted in a
circuit which melts when a predetermined value of current flows through it and thus breaks the
circuit.
Rated carrying current ; of a fuse is the maximum current which it can carry without undue
heating and melting.
Fusing current ; is the maximum current at which a fuse elements melts ,SchwartZ and James
have defined the fusing current as the minimum currents to fuse the wire in such a time
interval as shall be necessary for the wire to have attained its steady temperature.
The fusing current depends upon various factors such as;
a) Materials.
b) Length-the shorter the fuse the greater the current ( because all heat is easilyconducted )
c) Diameter.
d) Shape of cross section of the fuse elements .
e) Size &Location of the terminals.
f) The type of enclosed employed.
e) Whether the fuse is stranded or not.The fusing current for a stranded fuse will be less than the
product of the fusing current for one strand and the numbers of strand as shown in table.
No.of wires
1
2
3
4
7
Fusing
1
1 2/3
2. 1/4
2. 2/3
4
current
If the strands are twisted together the fusing current will be reduced further on account of local
heat produced which will cause melting of fuse earlier .
FUSE ELEMENT MATERIAL: - Experience has shown that the most generally suitable material
for the fuse element is low melting point such as tin, lead or zinc. A low melting point however
available with high specific resistance metals.
METAL
Sp.Resistance in micro Melting point
ohm.cm
Tin
11
231.850 C
Zinc
.6
419 C
Lead
21.7
327 C
Cupper
1.66
1084 C
Silver
1.557
960.5 C
Aluminum 2.788
658.7C
TYPES OF FUSES : Fuses may be low voltage or high voltage type. Low voltage fuse can be
further subdivided into two classes namely the semi-enclosed rewirable fuses and the cartridge
type fuses.
a) Semi-enclosed rewirable fuses have one or more strand of fuse wire stretched between
terminals blocks and are mounted on a molded or porcelain handle. This of fuse have limited use
usually at power points where very low value of fault current to handled Fuses of this type are
made upon about 500A rated current, but their breaking capacity is generally too low for modern
needs e.g. 400V system it is limited about 40.
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These fuses suffer from following disadvantages

i) The protective capacity is uncertain this means that no dependence can be placed upon the
wire to interrupt the circuit where a given current flows. For instance although theoretically a
No-15SWG tinned copper wire fuse should interrupt a circuit when a current of 197 amps is
flowing, the circuit may interrupt when a lower current flows or at other circumstances when
only a much higher current flows.
ii) The fuse wire is subjected to deterioration due to oxidation through the continuous heating up
of the element after a relativity short period the current comes to the metal to deteriorate and the
fuse operate at a lower current.
iii) Accurate calibration of the fuse wire is impossible to determine accurately the amount of
current which a fuse will carry before it operates. For instance, a longer fuse operated earlier than
one of shorter length, should the actual wire of the fuse be 2 in for example it will carry a high
current before it operated than if the wire 12 in long.
SWG

Dia. In inches

40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13

0.0048
0.0052
0.0060
0.0068
0.0076
0.0084
0.0092
0.0100
0.0108
0.0116
0.0124
0.0136
0.0148
0.0164
0.0180
0.020
0.022
0.024
0.028
0.032
0.036
0.040
0.488
0.056
0.064
0.072
0.080
0.092

Current rating
of fuse in amps.
1.5
2.5
3.0
3.5
4.5
5.0
5.5
6.0
7.0
8.0
8.5
10.0
12.0
13.0
14.0
15.0
17.0
20.0
24.0
29.0
34.0
38.0
45.0
65.0
73.0
78.0
102.2
130.0

Approximate
fusing current.
3
4
5
6
7
8
9
10
11
12
13
16
18
23
28
30
33
38
48
58
70
81
106
135
166
197
230
295

The above figures are an approximate guide only and the current at which the fuse will
blow which depend upon the construction of fuse holder in which the wire is used.
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H.R.C. CATRIDGE FUSE:where large construction of power are consumed, as the modern distribution system, it is
essential that fuses should here definite known breaking capacity and also that than breaking
capacity should have a high value, intensive research by manufacturers and supply engineers in
this directions has resumed the high rupturing capacity cartridge fuse.
In its simplest form an HRC cartridge fuse as shown in figure consist of a ceramic body
having metal end caps to which are welded fusible silver ( or bi metallic current carrying
elements. The space which body surrounding the elements is complete packed with filling
powder usually quartz .Which has excellent arc extinguishing properties.
The operation of the fuse consists of the following steps:
1. Melting of the silver elements.
2. Vaporisation of the elements.
3. Fusion of silver vapor and filling powder leading to powder roping
4. Extinction of the arc due to (3)
The electrical phenomena associated with the operation of the fuse are:
1. Creation of high resistance as a result of the chemical reaction between the silver vapor and
filling powder.
2. Change over of the high resistance in to an insulator as the current is cut off.
3. Creation of transient voltage which in the fuse at the instant of breaking fault current due to
the sudden change of energy.
The physical phenomena associated which the fuse operation include a sudden rise of
temperature and the generation of a high internal pressure derived from the released energy
consequent on one interruption of fault current.
The main advantages of cartridge fuse are:
i) Ability to clear high values of short circuit.
ii) Non-deteriorating (If correctly selected for rating)
iii) High speed operation.
iv)Consistent performance.
v) Increase time /current characteristic.
vi)Low cost compared with other form of circuit interrupter of equal breaking capacity.
v) Reliable discrimination.
The main disadvantages are:
I) Must be replace after operation.
II) Arc, by their nature, subjected to relativity high temperature rises. This is not disadvantage in
the fuse but may affect associated switches etc.Unless properly cared for.
Discrimination means the breaking of the faulty section of the line to an extent
restricted to minimum sound parts of the circuit remain in operation and are not cut off
from the energy supply.

HIGH VOLTAGE H.R.C FUSESCartridge type ; Similar in general construction to the low volt designs, are used upto33 KV
with short circuit capacities of about (500 MVA three phase).
Some designs are employed fuse elements wound to helix, so as to avoid
corona effect at high voltages, Rating of the order of 200A at 6.6 KV. And 11KV. And 50A at 33
KV. are available. Some designs have two fuse elements in parallel one of low resistance carries
the normal current other is of higher resistance and after the low resistance elements has blown
reduce the short circuit currents and finally breaks the circuit.
APPLICATION OF H.R.C. FUSE ;
1) The normal application of low voltage HRC Fuse is on low voltage distribution system against
overload and short circuit condition.
2) Another application of H.R.C.Fuse is for the back-up protection to the circuit breakers whose
short circuit capacity has been increased owning to extension of generation plant or inter
connection to a value beyond their rated MVA. The fuses are arranged to deal with short circuit
exceeding a certain magnitude while the circuit breakers continue to interrupt short circuits with
their breaking capacity. The correct operation is ensured by adjusting suitably the time
Characteristics of the fuses to that of eliminate the necessity of replacing the circuit breakers.
SELECTION OF FUSE :
1) Steady load ; If the fuse is required to give both overload and short circuit protection then it
should have a steady current rating not greatly in excess of the full load current of the circuit in
order to give close protection, However, if the fuse is required to give only short circuit
protection then fuse of mush greater rating than the normal load current can be selected, such a
fuse will run cooler have a longer life and have a good margin in hand for some temporary
overload without rise of deterioration.
2 ) Fluctuating load ;
1) Switching of transformer, Fluorescent lighting, the fuse selected should have such a rating as
will withstand the transient current surge on switching in. the general practice is to select a fuse
which has a normal rating 25 to 50% above the normal full load current of the apparatus to be
protected.
2)Switching capacitor circuit ; similar selection as above is recommended for capacitor circuit
but here the tendency should always be towards higher percentage. This type of circuit is
particularly difficult because on switching in there is heavy current surge of highly transient
nature and of higher frequency.
3) Motor load ; H.R.C. Protects motors the cables and the starter itself from damage due to short
circuit, protection against overload should be provided by separate devices like overload trips.
The use of separate overload devices assured that these take care of the relatively more
frequently occurrences without causing fuse renewed each time an overload occurs.

ADVANTAGES AND DISADVANTAGES OF FUSE

ADVANTAGES
1. It is cheapest form of protection.
2. It affords currents limiting effect under
short circuit condition.
3. The minimum time of operation can be
made much smaller than that with circuit
breaker.
4. The inverse time current characteristics of a
fuse enable it to be used for overload
protection.
5. It requires no maintenance.
6. It interrupts enormous short circuit current
without noise and also without flames &gas
or smoke.

DISADVANTAGES
1. On heavy short circuit discrimination
between fuses in series can not be obtained
unless there is considerable difference in the
relative sizes of the fuses concerned
Discrimination between two protective
devices (such as two fuses a fuse and an
over current relays or fuse and circuit
breaker) is said to occur when on incidence
of a short circuit or an over current only
desired protective device operate.
2.Time is lost in replacing fuses after
operation.
3. It is impossible to employ secondary
protection to fuse.

Inspection Frequency
Hourly

Item to be Inspected
i)Load in Amphere
ii)Temperatutre
iii)Voltage

Inspection Notes

Action to be taken

Inspection Frequency
Hourly

Item to be Inspected
i)Load in Amphere
ii)Temperatutre
iii)Voltage

Inspection Notes
Check against rated
figure
Check oil temperature
&ambient
temperature.
Check against rated
figure.

Action to be taken
Reduce load if higher
Switch off if the oil
temp.is high Take
corrective action.s

MAINTENANCE OF OVER HEAD LINE

GENERALS ; The over head line should be inspected periodically for maintenance purpose to
detect any fault which may lead to break down of electric supply and necessary repairs should be
done immediately.
PATRROLING OF OVER HEAD LINES FROM GROUND : All over head lines should be
patrolled periodically at interval not exceeding 3 months from the ground when the line is live.
The main points to be noted while patrolling are as follows:
Metal pole: Tilted poles, deformed cross arms and earth wire supports, settled or bugling soil
around pole foundation, yielding foundation cracks or breaks in the pole above the ground levels
etc.
Conductors or earth wire: Kite strings and other extraneous matters excessive or loose sags,
improper clearance and broken strands loose or broken binding wire, clearance with line etc.
Insulators: - Broken porcelain, burnt and fused spots on the glaze, burning and tilting of
insulator and fittings, and dirty insulator and rusty fittings.
Earth Equipment:- Damaged or broken earthwire at the ground level, missing conductor, fixing
staples on supports, and missing clamps at the tops.
Stays:- Loose and over tight stays.
Trees:- The trees which have become dangerous for the lines and require felling or trimming.
Bird Nests: - Bird Nests coming on the over head lines.
Jumpers:-Loose jumpers, jumblers jumbling on the poles, and overheated jumpers.
Inspection of overhead lines from pole Tops: Many breakdowns including slipping of
conductor due to loose clamps, cracks in the porcelain insulator and defects on the suspension
fittings can only be discovered or seen by going of top of every pole. This inspection fittings can
only be discovered or seen by going on top of every pole. This inspection should be carried out
by taking a shout down of the line at least once a year and should be done in a little time as
possible. Along with such inspection should be carried out and replacement of cracked insulator,
etc,be also made. Other points which cannot be examined from the ground, such as defective
clamps sleeves and connectors, missing bolts, washers sign of overheating on the clampsor
connectors, loose earth wire and loose binding of conductor with insulators and lighting arrestor
should be checked and repairs carried out.
Special Inspection: - A special inspection of the overhead lines should be carried out after wind
storm, heavy rains,thunder storms,etc.The purpose of such inspection is to defect any damage or
breakage on the lines and to effect necessary repairs.
Emergency Inspection: - When an overhead line trips on fault frequently it should be inspected
to find out the nature of the fault such as loose sag and faults caused by birds and tree branches
touching the line and to find out the amount of repairs involved with a view to avoid
reoccurrence of such faults in future.
Emergency Inspection :- When an overhead line trips on fault frequently it should inspected to
find out the nature of the fault such as loose sag and faults caused by birds and tree branches
touching the line and to find out the amount of repairs involved with a view to avoid
reoccurrence of such faults in future.

Maintenance Tests on Overhead lines In addition to the above mentioned inspection, over
head line should be give regular tests and checks as part of preventive maintenance.After 5 Years
of service, the poles and cross arms should be tested for corrosion& rust
The metal poles should be checked at random after every 5 years to detect any rust at the
joints. The underground parts are also liable to corrosion and, therefore, should be inspected for
effecting any repairs or replacement.
Measurement of Clearance of overhead lines: - The conductor clearance should be checked
periodically least once in a year as they will be changed due to variety of service conditions. The
clearance may change due to unequal tension in adjacent spans, due to elongation with time, or
due to displacement of poles after a repair or construction of new roads and earth filling under or
near line.
Inspection of Insulators:- The insulators of an overhead line are subject to mechanical and
electrical stress which shorten their life.Deteration of insyulators is also caused by vibration and
temperature changes stressing mechanically beyond their design strength or over voltage lead to
the failure of the insulator.
Inspection of joints :- The joints in conductors deteriorate in service with time and loose some
of their conductivity due to short circuits which cause considerable heating and impairs the joint.
Poor electric contact or low mechanical strength in a joint may lead to overheating and breaking
of the conductor.
Line Repairs: The overhead lines should be repaired periodically after each inspection and
overhauled once a year. The schedule of line repairs should include the following:
a) Replacement of defective poles as a whole.
b) Painting of metal poles and parts.
c) Replacement of damaged insulators and string.
d) Replacement of line fittings.
e) Cutting out and replacement damaged conductor sections.
f) Sag adjustment on conductor and earthwire.
g) Repair of lighting arrestors.
h) Tightening of clamps.
i) Replacement of overheated and weather-beaten jumpers.
j) Removing of kite string and extraneous matters over the lines, and
k) Trimming of tree branches fouling or likely to foul in the near future with lines.

MAINTENANCE AND PERIODICAL CHECKS OF AC MOTOR

General: When an electric motor has been properly installed, it requires little attention later on to
keep it working properly. If the motor is kept clean and dry, and properly lubricated periodically,
it will give trouble free service for long time. All maintenance work should be done correctly
under the supervision of an experienced electrician having in mind the fine clearances and the
precision construction of the modern motor.
The main aim of maintenance work should be to prevent trouble rather than allow it to
occur and then deal with it.
Protection of Exposed Surface: Protective point and varnish should be maintained in good
condition by repainting or revarnishing when necessary. In many instances, such as that of
windings, spraying is the only effective means of application of such protection.
MOTOR
1) Cleaning of motor:-Motor should be cleaned by blowing air at regular intervals to keep their
ventilating passages clear, it being emphasized that many types of totally enclosed motors also
require such attention, particularly when operating in dusty atmospheres.
Note: The most satisfactory way of cleaning is to blow the dust out with hot air blower. Violent
air jets from compressor tanks are likely to carry excessive moisture and may damage the
windings.
2) Moisture, oil, dirt, grease and carbon, and metallic dust are the principal cause of breakdown.
The motor should, therefore be kept clean and dry; water dropped on the machine will soon
cause trouble, unless the motor has been designed to withstand such conditions. The starter and
rotor winding should be kept free from oil, grease dampness and dirt. Periodic cleaning with dry
compressed air bellows or a brush is very necessary.
3) All motors require be examining and dismantling from time to time and the frequency of
successive cleaning will depend upon the conditions under which the machine operates. During
periodic cleanings care should be taken to clear air passages in the stator and rotor of any
accumulated dirt.
4) Terminals and screw connections should be kept clean and tight. If they should be
disconnected and all contact surfaces made clean and smooth. Bad contact leads to sparking and
ultimate breakdown.
5) After reassembly, the gaps shall be tested as a precautionary measure by means of a feeler
gauge.
6) If it is found that the air gap measurements of two diametrically opposite points differ by
about 25 percent or more, the motor shall be examined, because the brackets or bearing housing
may not be correctly aligned. Gap measurement should always follow reassembly, since rubbing
between stator and rotor will cause extensive damage.
Insulation Resistance: The insulation resistance of the winding shall be tested periodically during
service and where this found to drop below 1 Mega ohm / KV with a minimum of 1 Mega ohm,
the motor should be dried out and then put into service. If weak winding insulation becomes a
regular feature, the winding should be given a coat of good insulating varnish after the machine
has been dried out.

10

Note; Extra care in respect of insulation resistance is necessary in case where the motor is
subjected to dampness,etc .
Ball and Roller Bearing : climatic condition affect the lubrication and it is necessary to ensure
that the bearing do not run hot. Increasing temperature or noise are sure sign that the bearing
need immediate attention; it may be that the addition a small amount of grease arrest cures the
trouble.
Every three years the complete grease charge should be removed, the bearing housing
washed with petrol to which a few drop of oil have been added and thoroughly dried.
When opening up bearing for inspection and cleaning all dirt and foreign matter should
be removed.
Only the required quantity of grease should be put into the bearing as too much grease
may also cause overheating in the same ways as too little grease.
Slip ring and Brush gear ; These should require careful inspection and attention. Dust, oil and
moisture should be allowed to accumulate. The brush should slide freely in the holder with being
slack; The tension should be press squarely on the tops of the brushes and their operating
mechanism should function freely.
1) The slip rings shall be smooth and free from oil and dirt. If roughened by sparking, they shall
be cleaned with fine glass paper mounted on a wooden block shaped to the curvature of the rings.
Emery cloth should not be used.
2) When a new brushes are to be fitted, they shall be bedded to the surface of the slip rings by
placing them in their holders and interposing between them and the slip rings a strip of glass
paper, rough side outward. The strip should be worked backward and forward until the brush
face has acquired the curvature of the ring.
3)The correct brush pressure is of paramount importance from the point of view of brush and
ring wear. If the pressure is too light the brushes will chatter and cause sparking, disintegration of
the brushes and blackening and burning of the rings. Too much pressure will produce scoring and
overheating from frictional losses. The current pressure is about 0.15 to 0.2 kg/cm square of
brush area and this should be tested occasionally by means of spring balance attached as near as
possible to the end of the brush spring that makes contact with the brush.
4) Sparking at the slip rings is harmful and should be eliminated.
5) Fuse contacts and terminals shall be examined periodically for cleanliness and tightness.
When a fuse wire or strip has to be renewed, care should be taken that the new one is of the
correct metal and size.

11

RDSO : RESEARCH DESIGN & STANDARD ORGATION :

The RDSO is head quarter at Luckhnow and is headed by a Director General with a team
of specialist from different field of Railway working and function as technical advisory and
consultant to Railway Board.
RITES : Which is a gorvent of India Undertaking Under Ministry of Railways Provides
consultancy service on all aspect of Railways from concept to compeletion

12