190513109009 Designing and Maintenance of Control

Chapter 1

INTRODUCTION

1.1 INTRODUCTION OF COMPANY

➢ Established in the year 2017, “MINAL ELECTRICALS” has successfully

emerged as a major manufacturer of Control Panel, and many more. There range
has gained acknowledge due to the excellent features like highly durable,
excellent functionality, highly efficient, easy usability, and optimum strength.

➢ Under the headship of mentor Mr. Kalpesh Patel, the organization is moving
ahead in this cutting-edge competition. He possesses deep knowledge and
experience of this domain, which has continuously helped the company design
immaculate products for the clients.

➢ Basic Information
Nature of Business: Manufacturer
Company Owner: Kalpesh Patel Registered Address: 10,Karma Estate,Vatva
GIDC Phase-4,Vatva,Ahmedabad- 382445
Total Number of Employees: Up to 7 People
Year of Establishment: 2017
Legal Status of Firm: Individuals Firm
Annual Turnover: Rs.12-13 lakh

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190513109009 Designing and Maintenance of Control

1.2 AIM AND OBJECTIVE

➢ This Internship helps students to acquire practical skills related or supplementary

to the theories and knowledge obtained in lectures during the time at the
university and to gain work experience from the field to improve interpersonal
skills and teamwork.

➢ It helps to know how to operate & maintain the different machines and to know
different tools & equipment’s in industries.

➢ The Internship is also done to fulfill the requirement for the award of a bachelor’s
degree in mechanical engineering. To learn the different cultures of different
workers and their way of solving issues and problems.

➢ To experience the various challenges and situations that occurs in the field so
that I may think of alternative solutions.

➢ To participate actively in areas deemed relative to internee's scope and To Relate

with bosses in form of supervisors and inspector.

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190513109009 Designing and Maintenance of Control

1.3 INTRODUCTION OF CONTROL PANEL

1.3.1 "What Is Control Panel and why we use?

➢
➢ In its simplest terms, an electrical control panel is a combination of electrical
devices which use electrical power to control the various mechanical functions
of industrial equipment or machinery. An electrical control panel includes two
main categories: panel structure and electrical components.

➢ This makes the safe operation of panels a desirable skill for both electrical and
non-electrical workers.

➢ Similarly, an electrical control panel is a metal box which contains

important electrical devices that control and monitor a mechanical process.

➢ Control Panel and cabinet design is fundamental in allowing the user to interact
efficiently with the industrial process right on the front line. Industrial control
panels consist of power circuits or control circuits (or both) which provide
signals that direct the performance of machinery or equipment. Industrial
control panels don’t include the main power, nor do they include the controlled
equipment; rather, the panel is mounted on a back panel (or subpanel) or in an
enclosure, depending on the application.

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190513109009 Designing and Maintenance of Control

Chapter 2

TYPES OF CONTROL PANELS

2.1 Types of control panel

➢ Power control center (PCC Panel): It contains all of the electrical switchgear
like an air circuit breaker, MCC's, mcb, and suitable size aluminium or copper
bus bar.

Fig.2.1 PCC(Power control center)

Panel
➢ Motor Control center (MCC Panel): It has a control from a remote or local
that is called a motor control panel. It can control the motor from generation to
production.

Fig 2.2 MCC (Motor Control Panel )

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190513109009 Designing and Maintenance of Control

➢ Automation Panel (SCADA PLC Panel): Automation panel is a

Programmable digital computer also known as PLC Automation Panel is one
of the most important and efficient kinds of control panels. Which are generally
used in a variety of electronic and electrical circuit fittings.

Fig 2.3 Automation Panel (SCADA PLC Panel)

➢ H.T, Panel (High Tension Panel) : 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.

Fig 2.4 H.T, Panel (High Tension Panel)

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190513109009 Designing and Maintenance of Control

➢ L.T.Panel ( Low Tension Panel ) : LT Control Panel receives the main power
supply either from Generator or Transformer and distributes the same to
various electronic devices and distribution boards. With the help of
protective switch gears, they are used for controlling and monitoring the mains
supply from a centralized location.

Fig 2.5 L.T.Panel ( Low Tension Panel )

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190513109009 Designing and Maintenance of Control

2.1.1 Advantages, Disadvantage and Application

➢ Advantages:

1. Number of wires needed for connection is reduced by 80%.

2. Consumption is greatly reduced.
3. Allow for fast and easy detection.
4. Change in operating sequence or application of PLC controller to a different
operating process can easily be accomplished.
5. Needs fewer spare parts
6. It is much cheaper compared to a conventional system.
7. Reliability of a PLC is greater than of an electro-mechanical relay or a timer.

➢ Disadvantage:

1. The system require uninterrupted power supply with no voltage

fluctuations.
2. Standby batteries required in case of power failure.
3. There is risk of fire due to overheating.
4. Moisture may cause damage to the system.
5. Damage readily occurs in the event of a fire

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190513109009 Designing and Maintenance of Control

➢ Applications:

1. Industrial electrical control panels are designed and utilized for the
control of mechanical machinery and equipment. Industrial control panel
units are designed to handle a particular equipment arrangement and
include certain devices that enable the industrial operator to control the
equipment.
2. Electrical control panels are essential for industrial automation. They
provide higher-level monitoring and control of the various functions of
production machinery, allowing manufacturers to define, organize, and
meet production objectives.

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190513109009 Designing and Maintenance of Control

2.1 Components of Control Panel

➢ There are some of the components which is used in Control Panels.

1. Main circuit breaker

➢ When the overflow of current takes place through MCB – Miniature Circuit
Breaker, the bimetallic strip gets heated and it deflects by bending. The
deflection of the bi-metallic strip releases a latch. The latch causes the MCB to
turn off by stopping the flow of the current in the circuit.

Fig. 2.6 Main Circuit Breaker

2. Earthing
➢ Equipment in automotive industries where control panels are situated are of high
frequencies which when interfere with other electrical components cause
malfunction. Generally, devices like controllers, communication devices and
digital measuring devices when exposed to electromagnetic interference fail to
provide effective output & pose threats of electric shocks during fault conditions.

Fig. 2.7 Earthing

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190513109009 Designing and Maintenance of Control

3. Transformer
➢ How Does the Transformer Work : The concept of a step-down transformer is
actually quite simple. The transfer has more turns of wire on the primary coil as
compared to the turns on the secondary coil. This reduces the induced voltage
running through the secondary coil, which ultimately reduces the output voltage

Fig. 2.8 Transeformer

➢ A step-down transformer is a type of transformer that converts the high voltage

(HV) and low current from the primary side of the transformer to the low voltage
(LV) and high current value on the secondary side of the transformer. The
reverse of this is known as a step up transformer.

Fig. 2.9 Step Down Transformer

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190513109009 Designing and Maintenance of Control

4. Terminal
➢ Terminals is used for the various types of electrical wire connectors used to end
a wire or cable and connect it to an electrical system or terminate it completely.

Fig. 2.10 Terminal Fig. 2.11 Cross sectional view of

Terminal
5. Programmable Logic Controller (PLC)
➢ A PROGRAMMABLE LOGIC CONTROLLER (PLC) is an industrial
computer control system that continuously monitors the state of input devices
and makes decisions based upon a custom program to control the state of output
devices.
➢ PLCs are used to expedite these industrial machine operations. PLCs monitor
machine inputs, make appropriate decisions based on their programs, and control
outputs to trigger machine and process automation. PLCs are made up of input
points or modules, output points or modules, and a CPU (central processing
unit).
➢ The primary function of a PLC’s input circuitry is to convert the signals
provided by these various switches and sensors into logic signals that can be
used by the CPU.The CPU evaluates the status of inputs, outputs, and other
variables as it executes a stored program. The CPU (Central Processing Unit)
sends signals to update the status of outputs. As above PLC Works.

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190513109009 Designing and Maintenance of Control

➢ The programming device is used to enter or change the PLC’s program or to

monitor or change stored values. Once entered, the program and associated
variables are stored in the CPU. In addition to these basic elements, a PLC
system may also incorporate an operator interface device of some sort to
simplify monitoring of the machine or process.

Fig. 2.12 PLC

6. Relays and contactors

➢ Relays are switches that open and close circuits electromechanically or
electronically. Relays control one electrical circuit by opening and closing
contacts in another circuit.

Fig. 2.13 Relays Fig. 2.14 Contactor

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190513109009 Designing and Maintenance of Control

7. Ferrol
➢ It is used for numbering the wires so we identify the wiring.

Fig. 2.15 Ferrol

8. Lugs
➢ Most common use of lugs includes connecting one cable with another cable or
connection more than two cables.
➢ It is also used in connecting fuse sockets, load switches and electrical appliances,
other than for connecting cables and power lines.

Fig. 2.16 Lugs

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190513109009 Designing and Maintenance of Control

9. Circuit Breakers
➢ An electrical circuit breaker is a switching device which can be operated
manually and automatically for controlling and protecting a. As the modern
power system deals with huge currents, special attention should be given during
designing of a circuit breaker to ensure it is able to safely interrupt the arc
produced during the closing of a circuit breaker. This was the basic definition of
circuit breaker.

Fig. 2.17 Circuit Breaker

10. Limit Switch

➢ A limit switch is an electromechanical device operated by a physical force
applied to it by an object. Limit switches are used to detect the presence or
absence of an object. These switches were originally used to define the limit of
travel of an object, and as a result, they were named Limit Switch.

Fig. 2.18 Limit switch

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190513109009 Designing and Maintenance of Control

11. Fuse
➢ In electronics and electrical engineering, a fuse is an electrical safety device that
operates to provide over current protection of an electrical circuit. Its essential
component is a metal wire or strip that melts when too much current flows
through it, thereby stopping or interrupting the current.

Fig. 2.19 Fuse

12. HMI ( Human Machine Interface )

A Human-Machine Interface (HMI) is a user interface or dashboard that connects

a person to a machine, system, or device. While the term can technically be applied
to any screen that allows a user to interact with a device, HMI is most commonly
used in the context of an industrial process.

Fig 2.20 HMI ( Human Machine Interface)

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190513109009 Designing and Maintenance of Control

Chapter 3

GENERAL TOPIC OF MAKING CONTROL PANEL

❖ Enclosures and Space Requirements

➢ The intended environment largely dictates the appropriate type of enclosure for
an industrial control panel. You’ll need enough space to install and wire
components, and it’s also wise to plan for several receptacles to reduce the need
for extension cords when it’s necessary to power test equipment or appliances.
➢ Placement is another consideration related to enclosures. Depending on where
the panel will be located, you may need to account for swing requirements of
cabinet doors (if a cabinet enclosure is being used). If a control panel will be
located in an area with a high ambient temperature, a ventilation fan or air
conditioning may be required to keep the control panel within an ideal operating
temperature range. If temperature control applies, it’s necessary to allow for easy
access to air intakes and exhaust vents (which makes it easier to access and
replace filters). Both NEC required clearance around power wiring and UL
required clearance around heat producing devices must be considered to allow
adequate room for ventilation.

➢ Space considerations are paramount, as one of the most common NEC

violations involves control panels that are too small or too confined to allow for
the proper space for wiring and wire bending. It’s also wise to consider space
requirements not only for the current configuration but possible future needs, as
restricted space is a common challenge for retrofits.

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