INDUSTRIAL TRAINING PROJECT REPORT

ON
ELECTRICAL PANELS
ESSWIN ELECTRO CONTROLS PVT. LTD.
RUDRAPUR UTTARAKHAND
DURATION- 07.08.2022 - 07-09-2022
SUBMITTED BY- ANKIT JOSHI
COURSE- B TECH(EEE)
 DECLARATION
Mr. Ankit ,hereby declare that this project is being submitted
to fulfilment of Industrial Training Programme in Esswin
Electro Controls, and is result of self done work carried out
by me under the various guidance of engineers and other
officers.

I further declare that my knowledge, the structure and

content of the projected are original and ghave not been
submitted before any purpose.
Mr. Ankit
B Tech 4 year(7 sem)
EEE
Amrapali Institute
 ACKNOWLEDGEMENT
I would like to express my special thanks of gratitude to my
INDUSTRIAL PROJECT teacher as well as our school principal
who gave me the excellent opportunity to do this wonderful
project which also helped me in doing a lot of Research and I
came to know about so many new things, like how Electrical
Panel works.
I am really thankful to them. Secondly, I would also like to thank
my teachers who helped me a lot in finishing this project within
the limited time. Just because of them I was able to create my
project and make it good and enjoyable experience.
I am making this project not only for marks but to also to improve
my knowledge.

ANKIT JOSHI
OBJECTIVE OF INDUSTRIAL TRAINING
• To provide comprehensive learning platform to students where they
can enhance their employ ability skills and become job ready along
with real corporate exposure.
• To enhance students’ knowledge in one particular technology.
• To Increase self-confidence of students and helps in finding their
own proficiency
• To cultivate student’s leadership ability and responsibility to
perform or execute the given task.
• To provide learners hands on practice within a real job situation.
 WHAT IS ELECTRICAL
An electrical panel is nothing but a load control
PANEL
center. All the electrical actions such as power
distribution, power transmission, power system
protection are performed by using electrical
panel only. The electrical scheme (wiring
diagram) will be established using electrical
panel & Electrical panels are the practical
installation of electrical wiring diagram. It
consists of trip circuit, closing circuits, busbars,
cables, MCCBs, MCBs, MPCBs, NO & NCs,
etc. Electrical panels are ensuring the safe
power distribution to the load. Electrical panels
are manufactured by rolled steel and well-
shaped either rectangle or square. Electrical
panel are classified different types as per
application.
HOW ELECTRICAL PANEL ARE ASSEMBLED?
Order Entry
• When we convert a quote to a control panel manufacturing order several things occur automatically:
1. Store a snapshot of all as sold data in our database
2. Create a new Job Order in our database
3. Create a new Job Directory on our File Server
4. Move as sold Quote files into the new Job Directory
5. Send an Order Acknowledgement email to selected customer contacts.
Design and Submittal Generation
• With many of our customers, this step occurs before we receive an order.
1. During design preparation, we review estimated panel components and revise as appropriate. Next, we
automatically create blank panel drawings in our panel design software. Next, we automatically load
panel components into our panel design software. In short, we automatically create the sandbox
(drawings) and fill them with toys (components).
2. During drawing design, we place (locate) all panel components on the Layout drawings and interconnect
them on the Power, Control, and Field drawings. Our panel design software automatically keeps track of
each component and adds drawing cross reference (line number) data.
3. After drawing design, we automatically produce an engineering submittal by clicking Produce Submittal.
The resulting bookmarked PDF document includes the following 1) Cover Sheet, 2) Table of Contents, 3)
Product Datasheets for each provided part, 4) Enclosure Layout, Power Schematic, Control Schematic,
Field Connection drawings for each panel, 5) Bill of Material for each panel.
4. We email the engineering submittal for review and approval.
• 3 • Pre-Production Review
1. After Engineering Submittal approval, Quality Control reviews the panel design one last time to insure it’s production ready. This
reduces production delays by solving problems before the parts are ordered.
2. After Quality Control review, we determine the earliest potential production start date. Then we send quote requests to all parts
vendors with our earliest potential production start date as the desired delivery date. We allow each vendor to confirm our parts
pricing is correct and our requested delivery can be met or advise us otherwise.
3. After all vendor responses are received, we schedule production and send purchase orders to all parts vendors with confirmed
pricing and the desired delivery date as one week prior to start of production.
4. An Automated Order Delivery Schedule email is sent to selected customer contacts.
•
• All required control panel manufacturing data has already been prepared, so we can begin (prepare for final assembly) before
the parts arrive. This allows us to shift when certain aspects of control panel manufacturing occur to facilitate a quick delivery
schedule or to normalize production loading.
• Prepare Wires for Final Assembly
• We use industrial wire processing equipment to produce all wires 14 Gauge or smaller.
• After the shortest distance wiring calculation program has been run in our panel design software to determine all required wire
lengths by type (color, gauge), we import the wiring data into our wire machine and produce all required wires in sequence by
type (color, gauge) as follows:
• Wire End A – Cut the wire. Strip the wire. Print directly on the wire insulation (Wire No, From Device ID: Terminal No) at a programmed
position from the end
• Wire Middle – Print directly on the wire insulation (Wire No) at a programmed interval.
• Wire End B – Cut the wire. Strip the wire. Print directly on the wire insulation (Wire No, From Device ID: Terminal No) at a programmed
position from the end

• Prepare Nameplate / Device ID / Terminal labels

• We use industrial color graphic printing equipment (Multi Color Printer, Adhesive Laminator, Precision Cutter) and industrial label
material (NEMA 4X label face, color foils, adhesive) rated -50F to 150F to produce all labels.
• Panel Identification labels
• Manufacturer Identification labels – using our customer’s brand (colors / logo)
• Operator Device labels
• Component Device labels
• Terminal Block labels
• Final Assembly
• Punch or drill all required holes to accommodate all components, DIN Rail and wire duct per the design drawings. Install DIN Rail and wire duct. Mount all
components, pre-produced component Device ID labels, Terminal Block labels, and Door mounted Device labels.
• Install all pre-produced wires per the data printed on each wire and per the design drawings.

• 5 • Quality Control
• After production is complete, we schedule Quality Control testing. Because Quality Control reviewed the design prior to produ ction, the focus is insuring each
control panel was final assembled per the design drawings.
• All physical aspects of the panel are inspected. The placement of all physical devices are compared to the design drawings an d inspected to verify they are
mounted per the manufacturer’s recommendations. The Device ID, Terminal Block, Panel ID and Operator Device labels are inspected to insure they’re mounted
and oriented properly.
• All electrical aspects of the panel are inspected. Because wire connection data is pre-printed on each end and each end is pre-stripped to the manufacturer’s
recommended strip length, the focus is insuring each wire is landed properly. Point to point wire testing is performed to verify visual inspection. Then power
connections are tightened per the manufacturer’s torque recommendations. Then function testing is performed to insure panel f unctions as specified.
• When UL508A third party safety certification is requested, we apply a serialized UL508A label and log the serial number in the UL log file against the Job No.
• As-Built drawings are produced from the marked up (redlined) production drawings and a copy is placed in each control panel. All production and quality control
documentation is stored in the Job file.

• 6 • Shipping
• When QC testing is complete, we send an automated Release to Shipping email. This notifies our customer that we’re preparing their control panel manufacturing
order for shipment. This also gives them an opportunity to change the Shipping Address.
• We take detailed photos of all panels in the shipment. This verifies how everything looked prior to shipment, and helps us provide better troubleshooting assistance
if a problem occurs in the field.
• We package the shipment based on the shipment type and weigh it. We apply Drop N’ Tell indicators and labels so our customer can determine if the shipment was
dropped during transport. If the shipment is tall, we ship it direct (one truck, secured with a no tamper seal, with no terminal transfers) to insure it doesn’t have an
opportunity to be mishandled (tip over) during shipment. We also apply Tip N’ Tell Indicators and labels so our customer can determine if the shipment was tipped
over during shipment.
• We determine the best shipping option through our shipping broker and schedule pick up. When the shipment is picked up, we send an automated Shipping
Notification email. This identifies the Shipper Name, Shipper Tracking No, and Shipper Tracking Website Link so our customer can track the shipment.
TYPES OF ELECTRICAL PANEL
1. Power control center (PCC Panel)
2. Motor Control center (MCC Panel)
3. Automation Panel (SCADA PLC Panel)
4. Auto Power Factor Correction Panel(APFC
Panel)
5. DISTRIBUTION BOARD PANEL
 PCC PANEL
• 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 used in refineries, chemical plants,
pharmaceuticals and Solar Industries.
MCC PANEL
• MCC Panel (Motor Control Center) that is a device used to
control and actualize the performance of an electric motor.
These MCC Panels are offered in a wide variety such as
compartmentalized with ACB/ MCCB SFU, DOL, ATS, Star
Delta Starters& VFD STARTERS.
• MCC panel is known as Accurate motor control centre
(MCC) that assembly of one or more Electrical
Component containing MCCB, Contactor, Overload
relay, and MPCB. A motor control centre can include
variable frequency drives, programmable controllers,
and metering and may also be Intelligent Controller
(eAccu- IMCC Panel). eAccu-MCC Containing Very
Advance Most trusted technology as per IEC standard
and Indian standard with intelligent drawing designs.
 STARTERS IN MCC PANEL
• Various types of starter are used depending upon
requirement/capacity:
• DOL Starter
• Star Delta Starter
• Auto Transformer Starter
• Soft Starter

The motor can be controlled manually by using start/stop push

button or automatically by providing external signals from
sensors in the field/PLC in the same panel.
 APFC PANEL
APFC or Automatic Power Factor Control
Panels are predominantly used for sustainment
of Power Factor as per State Electricity Board.
Power Factor is defined as ratio of active power
to apparent power and it is mainly a key factor in
measuring electrical consumption. Everyone
knows that how costly electricity is computed
now-a-days. Therefore it becomes very much
important to reduce on electrical consumption for
reducing expenditure and economizing the utility
expenses by harnessing electrical utility by
operation at desired power factor to curtail
unwanted electricity penalty rising because of
continuous power factor drop.
WHAT IS POWER FACTOR
• ower factor is an expression of energy
efficiency. It is usually expressed as a
percentage—and the lower the
percentage, the less efficient power
usage is.
• Power factor (PF) is the ratio of working
power, measured in kilowatts (kW), to
apparent power, measured in kilovolt
amperes (kVA). Apparent power, also
known as demand, is the measure of
the amount of power used to run
machinery and equipment during a
certain period. It is found by multiplying
(kVA = V x A). The result is expressed
as kVA units.
 APFC RELAY EPCOS
• APFC Relay - Automatic Power
Factor Controller Relay. Low Power
Factor - Harms. In industries we've
differing kinds of loads viz. resistive,
inductive & capacitive. To improve the
facility factor it's required to attach a
hard and fast capacitor or capacitor
bank at the LT side of the Transformer.
 AUTOMATION PANEL(PLC & SCADA)
• They are used to monitor and control heavy-duty and large-scale
machinery in industrial and commercial applications. Automation
control panels can perform both simple and complex processes by
employing relays, timers, sensors, starters, and controllers. The main
advantage of automation control panels is that they provide more
control over the industrial equipment in a facility. One can enjoy the
comfort of a hands-free approach and experience high efficiency,
functionality, and flexibility with automation control panels.
• Convenient systems are everyone’s favorite. That is exactly what
automation control panels offer. They offer flexibility in modification of
logic, have a reduced frame, and provide an edge over control of the
various automated equipment in the facility. They will also help in
accomplishing tasks efficiently and with impressive speed.
Types Of Automation Control Panels

• Sectors that rely on consistent productivity and production greatly benefit

from using automation control panels. Industries belonging to manufacturing,
mining, agriculture are only a few such sectors that rely heavily on automation
control panels. There are many varieties of automation control panels, but
Spike Electric mainly deals with the supply of PLC Control Panels. Why? Spike
Electric has always prioritized quality over every other factor. PLC automation
control panels are of reduced size, flexible to use, are user-friendly, and are
most reliable and efficient than other convention automation control panels.
 PLC Control Panels (Programmable Logic
Controller)
• Programmable logic controller
(PLC) control panels or also
known as PLC Automation
Panel are one of the most
important and efficient kinds of
control panels. Which are
generally used in variety of
electronic and electrical circuit
fittings. PLC Control Panels we
manufacture are highly capable of
giving higher output at less power
consumption. Integrated with solid
PLC logic and flawless PLC
hardware programming.
SWITCHGEAR
• Switchgear is an integral part of an electric power system.
Switchgear includes fuses, switches, relays, isolators, circuit
breaker, potential and current transformer, indicating device,
lightning arresters, etc. that protects electrical hardware from
faulty conditions.
 Components of Switchgear
• Switchgear essentially consists of switching and protecting
devices such as switches, fuses, isolators, circuit
breakers, protective relays, control panels, lightning
arrestors, current transformers, potential transformers, auto
reclosures, and various associated equipment.
TYPES OF SWITCHGEAR
• There are three different classes of switchgear systems: low-
voltage, medium-voltage, and high-voltage

• Low-Voltage Switchgear
• Low-voltage switchgear are designed to regulate systems of up
to 1KV. These are commonly found on the low-voltage sides of
power-distribution transformers and are used across a variety of
industries.
• High-Voltage Switchgears
High-voltage switchgears are those that control 75KV of power
or more. Because these breakers are designed for high-voltage
use, they often include improved safety features

• Medium-Voltage Switchgear
• Medium-voltage switchgear are used in systems from 1KV up to
75KV. This switchgear is often found in systems involving
motors, feeder circuits, generators, and transmission and
distribution lines.
• Low Voltage Switchgear (LV)
• The power system which deals up to 1KV is called as LV or low
voltage switchgear. This kind of equipment mainly includes
switches, LV circuit breakers, HRC fuses, earth leakage (EL)
circuit breakers, offload electrical isolators, MCBs (miniature
circuit breakers) and MCCBs (molded case circuit breakers),
etc.
• Switchgear includes fuses, switches, relays, isolators, circuit
breaker, potential and current transformer, indicating
device, lightning arresters, etc.
FUSE AND SWITCHES
• The purpose of a switch or a fuse is to
break or connect an electric circuit, but
they must be correctly connected in the
home.
• A switch or a fuse in an electrical circuit
is always connected to the live wire so
that the socket or appliance is not live
when switched off.
• A fuse is an electric / electronic or
mechanical device, which is used to
protect circuits from over current,
overload and ensure the protection of
the circuit.
CIRCUIT BREAKERS
• An electrical circuit breaker is a switching device which can be
operated manually and automatically for controlling and
protecting an electrical power system.
• The modern power system deals with huge power network and
huge numbers of associated electrical equipment. During a
short circuit fault or any other type of electrical fault (such as
electric cable faults), a high fault current will flow through this
equipment as well as the power network itself. This high
current may damage the equipment and networks permanently.
 TYPES OF CIRCUIT BREAKER
•Air Circuit Breaker
•SF6 Circuit Breaker
•VacuumCircuit Breaker
•Oil Circuit Breaker
•MCCB/MCB
AIR CIRCUIT BREAKER

• This circuit breaker will operate in the

air; the quenching medium is an Arc at
atmospheric pressure. In many
countries, the air circuit breaker is
replaced by an oil circuit breaker. About
the oil circuit breaker, we will discuss
later in the article. Thus the importance
of ACB is still a preferable choice to use
an Air circuit breaker up to 15KV. This
is because; oil circuit breaker may
catch fire when used at 15V.
Vacuum Circuit Breaker
• A Vacuum circuit breaker is a circuit in
which a vacuum is used to extinct the arc.
It has dielectric recovery character,
excellent interruption, and can interrupt
the high-frequency current which results
from arc instability, superimposed on the
line frequency current.
• The principle of operation of VCB will
have two contacts called electrodes will
remain closed under normal operating
conditions. Suppose when a fault occurs
in any part of the system, then the trip coil
of the circuit breaker gets energized and
finally, the contact gets separated.
RELAYS
• A Relay is a simple electromechanical switch. While we use normal switches
to close or open a circuit manually, a Relay is also a switch that connects or
disconnects two circuits. But instead of a manual operation, a relay uses an
electrical signal to control an electromagnet, which in turn connects or
disconnects another circuit.
TYPES OF RELAYS
ELECTROMECHANICAL RELAY
• An electromechanical relay is a type of relay
which function using a magnetic field produced
by an electromagnetic coil when a control signal
is applied to it. It is called as electromechanical
since it has moving contacts in the output circuit
which are operated by applying an electrical
signal.
STATIC RELAY
• The relay which does not contain any
moving parts is known as the static relay. In
such type of relays, the output is obtained
by the static components like magnetic and
electronic circuit etc. The relay which
consists static and electromagnetic relay is
also called static relay because the static
units obtain the response and the
electromagnetic relay is only used for
switching operation
MICROPROCESSOR BASED RELAY
• Reliable and accurate protection schemes
are required for any system. Microprocessors
can fulfill these requirements without fail. In
addition to the system protection,
microprocessors can perform all control
operations, analysis as well as measurement.
The cost of a protective scheme should be
about 1% of the cost of the equipment to be
protected. When the microprocessor is used
to control the system in addition to system
protection, it will be very economical.
Presently, Microprocessor Based Protection
Relay schemes are developed.
CONTACTOR
• A contactor is an electromechanical control device
that used to make or break the connection
between the load and power supply. The use of a
contactor is similar to the relay. But the device
used for higher current carrying application is
known as a contactor and the device used for
lower current applications is known as Relay.
• A contactor has several contacts as per the
application and load. Generally, these contacts are
normally open (NO) contact. And hence the load is
shut off when the coil of the contactor is de-
energized. But the contactor can design for both
normally open and normally close applications.
The most common application of contactor is in the
starter that used to turn ON and OFF the
equipment like motor, transformer, etc.
ELECTRICAL PANEL ACCESORIES
• Cable Ducts
• LED Indicators
• Push Button
• Actuators & Stations
• Rotary & Load Break Switches
• Timers,
• Time Switches,
• Supply MonitorsTerminal Blocks,
• Relay Modules,
• Teknik For Push Buttons,
• Led Indicating Lamps,
• Plugs & Sockets