TRAINING CERTIFICATE

This is to certify that Mr.Ishan Paul, a student of MAHARAJA SURAJMAL INSTITUTE OF TECHNOLOGY,NEW DELHI,has completed eight weeks Summer/Implant training starting from 4th June,2010 to 30th July,2010 on “Switchgear and Control System” in C&S Electric,Noida.

His work and conduct during training period have been very good.

Sub Divisional Engineer

ACKNOWEDGEMENT

I would like to extend my sincere thanks to Mr.Vishal Bolia and Dr. Sachin Goel for their encouragement & valuable contributions to the project throughout its various phases.

I express my sincere thanks to Mr.Ankit Arora, Ms.Sonia Badhan , Mr.Gulab for their full support, constant cooperation & continuous guidance throughout training period.

Being a part of C&S Electric has enabled me to get an overall picture of the switchgear

and components. The study of electrical components has been a very interesting learning

experience and has nourished my interest in nanotechnology.

Ishan PaulB.tech (4th year) EEE

Maharaja Surajmal Institute Of Technology

PREFACE

With the ongoing revolution in electronics and communication where innovations are

taking place at the blink of eye, it is impossible to keep pace with the emerging trends.

Excellence is an attitude that the whole of the human race is born with. It is the

environment that makes sure that whether the result of this attitude is visible or

otherwise. A well planned, properly executed and evaluated industrial training helps a lot

in collating a professional attitude. It provides a linkage between a student and industry to

develop an awareness of industrial approach to problem solving, based on a broad

understanding of process and mode of operation of organization.

During this period, the student gets the real experience for working in the industry

environment. Most of the theoretical knowledge that has been gained during the course of

their studies is put to test here. Apart from this the student gets an opportunity to learn the

latest technology, which immensely helps in them in building their career.

I had the opportunity to have a real experience on many ventures, which increased my

sphere of knowledge to great extent. I got a chance to learn many new technologies and

also interfaced too many instruments. And all this credit goes to organization C&S

Electric Limited.

INTRODUCTION

C&S Electric Ltd. is amongst the leading suppliers of electrical equipment in India and is India’s largest exporter of industrial switchgear. It’s wide range of electrical and electronic products find application in power generation, distribution, control, protection and final consumption.

The business operations of C&S Electric are divided in the following 3 strategic business units (SBUs)

1. Switchgear & Protection SBU2. Power Busbars SBU3. Lighting & Wiring Accessories SBU

C&S employs over 3000 people including 400 engineers, and has 16 state-of-the art manufacturing plants. It has 22 sales office across India and its products are exported to 73 countries. C&S Electric also has several joint venture companies and a 100% owned subsidiary.

HISTORY

Our CMD, Mr. R N Khanna after graduating from IIT Kharagpur, gets his first taste of the switchgear business as a Design Engineer in a leading German company.

1966 R N Khanna returns to India after spending 4 years with FANAL as a switchgear design engineer. Controls & Switchgear Company is founded in a garage by R N Khanna, who is soon joined by his younger brother Ashok Khanna (IIT Madras).

1966 - 1982

The company goes on to become amongst the largest LV switchboards manufacturer in India, executing prestigious and challenging jobs. Enters Busduct business, with technology from Simelectro France, to build on its strong relationships with power generation utilities.

1982 In a short time enters the switchgear components

- 1985

business by technology transfer from Terasaki Japan (Air Circuit Breakers); ABB Stromberg Finland (Switches and Switch Fuse Units) and France (Contactors, Overload Relays and Motor Starters). Thus becomes a major LV Switchgear Player.

1992 - 1994

Diversities with 3 joint ventures: Wago (Terminals), RS (Mail Orders) and AVK-SEG (Alternator and Relays until 2004 restructuring).

1998 - 2007

Second Generation join the business. Big thrust on exports. Entry into Lighting and Wiring Accessories. Establishment of EOU and SEZ facilities.  Acknowledged as India’s #1 Busbar Company. Growth of almost 40% for three years in a row 2005 to 2008. JV with Himoinsa of Spain to manufacture Diesel Generating Sets.

2008 Enters Medium Voltage business through a JV with Efacec of Portugal. Raises private equity from GE Commercial Finance with intention to grow even more aggressively through organic and inorganic means. Merges three main companies into a single entity  –  C&S Electric Ltd.

VISION AND MISSION

Our Vision

C&S shall be the most trusted, respected and preferred brand, for electrical and electronic equipment that finds application in power generation, distribution, control and final consumption.

In its major businesses C&S shall not only command a domestic market share ranging from 12% to 50% or more, but be known widely as the company “closest to its customers”

C&S products shall be used to manage power in India’s biggest industries, in its highest buildings, in its most critical infrastructure and in millions of its homes.

The C&S name shall be recognized widely as a benchmark, and shall serve as a role model and an inspiration to other Indian engineering products companies.

C&S shall be cited as a company that played an important role in making “Made in India” a label that is trusted and respected the world over.

Our Mission

To create a unique alchemy of outstanding products, operational excellence, path breaking customer service, and compelling marketing.

To create and relish a vibrant workplace where employees are empowered, cared for, developed, and most of all, provided unlimited opportunity to discover their full potential.

To continuously enhance our core technologies, and develop new world class technologies and products to expand our offering to customers.

To consolidate and strengthen our position as India’s largest exporter of Industrial power distribution and control equipment.

To earn a healthy return on investment for the shareholders. To everyday experience, the sheer joy of delighting our internal and external

customers, and to relish the thrill of participation in India’s infrastructure boom.

VALUES

STRETCH FOR YOUR CUSTOMER Fully understand and fulfill needs of internal and external customers

Do not tolerate mediocrity. Stretch, Excel and Exceed

BE FRANK, BE HONEST Be frank, fair and non-political and expect the same treatment for yourself

Do not be afraid of conflict, when it is required and is just

BE OBSESSED WITH QUALITY Display attention to quality every single day, from the very top down, and from

the bottom up

Remember and teach that small things lead to perfection, but perfection is not a small thing

WORK HARD, SMART & SWIFT Nurture a culture of tenacity, perseverance and sheer hard work Be innovative Opportunities to innovate are everywhere, everyday. Grab them Take responsibility for your own agenda and priorities

Take some risks. If you are not making mistakes, you are not trying hard enough

SUCCEED AS A TEAM AND AS AN INDIVIDUAL Strike a balance between people and task orientation

Empower and delegate, but don't over delegate

DISCOVER YOUR STRENGTHS & THOSE OF OTHERS While we are bonded by shared values we must encourage and respect rich

diversity in skills, experiences, knowledge, talents and personal styles

Success comes more from exploiting strengths than from overcoming weaknesses

MARKETS SERVED

Industry         Power

Paper

Petrochemical

F&B

Metals

OthersBuildings    

IT Parks

Hospitals

Hotels

Group Housing

Others

Infrastructure     Railway

Water

Telecom

Airports Others

OEMs    

Material Handling

Lifts

Compressors

Telecom Power Supplies

Machine Tools

Others

Homes         Apartments

Villas 

SWITCHGEAR AND PROTECTION

The term switchgear, used in association with the electric power system, or grid, refers

to the combination of electrical disconnects, fuses and/or circuit breakers used to isolate

electrical equipment. Switchgear is used both to de-energize equipment to allow work to

be done and to clear faults downstream. This type of equipment is important because it is

directly linked to the reliability of the electricity supply.

The very earliest central power stations used simple open knife switches, mounted on

insulating panels of marble or asbestos. Power levels and voltages rapidly escalated,

making open manually-operated switches too dangerous to use for anything other than

isolation of a de-energized circuit. Oil-filled equipment allowed arc energy to be

contained and safely controlled. By the early 20th century, a switchgear line-up would be

a metal-enclosed structure with electrically-operated switching elements, using oil circuit

breakers. Today, oil-filled equipment has largely been replaced by air-blast, vacuum,

or SF6 equipment, allowing large currents and power levels to be safely controlled by

automatic equipment incorporating digital controls, protection, metering and

communications.

High voltage switchgear was invented at the end of the 19th century for

operating motors and others electric machines. The technology has been improved over

time and can be used with voltages up to 1,100 kV.

TYPES

 A piece of switchgear may be a simple open air isolator switch or it may be insulated by

some other substance. An effective although more costly form of switchgear is gas

insulated switchgear (GIS), where the conductors and contacts are insulated by

pressurized sulfur hexafluoride gas (SF6). Other common types are oil [or vacuum]

insulated switchgear.

The combination of equipment within the switchgear enclosure allows them to interrupt

fault currents of many hundreds or thousands of amps. A circuit breaker (within a

switchgear enclosure) is the primary component that interrupts fault currents. The

quenching of the arc when the ciruit breaker pulls apart the contacts open (disconnects

the circuit) requires careful design. Circuit breakers fall into these four types:

Oil circuit breakers rely upon vaporization of some of the oil to blast a jet of oil

through the arc.

Gas (SF6) circuit breakers sometimes stretch the arc using a magnetic field, and

then rely upon the dielectric strength of the SF6 to quench the stretched arc.

Vacuum circuit breakers have minimal arcing (as there is nothing to ionize other

than the contact material), so the arc quenches when it is stretched a very small

amount (<2–3 mm). Vacuum circuit breakers are frequently used in modern medium-

voltage switchgear to 35,000 volts.

Air circuit breakers may use compressed air (puff) to blow out the arc, or

alternatively, the contacts are rapidly swung into a small sealed chamber, the escaping

of the displaced air thus blowing out the arc.

Circuit breakers are usually able to terminate all current flow very quickly: typically

between 30 ms and 150 ms depending upon the age and construction of the device.

Several different classifications of switchgear can be made[3]:

By the current rating.

By interrupting rating (maximum short circuit current that the device can

safely interrupt)

Circuit breakers can open and close on fault currents

Load-break/Load-make switches can switch normal system load currents

Isolators may only be operated while the circuit is dead, or the load current

is very small.

By voltage class:

Low voltage (less than 1,000 volts AC)

Medium voltage (1,000–35,000 volts AC)

High voltage (more than 35,000 volts AC)

By insulating medium:

Air

Gas (SF6 or mixtures)

Oil

Vacuum

By construction type:

Indoor (further classified by IP (Ingress Protection) class or NEMA

enclosure type)

Outdoor

Industrial

Utility

Marine

Draw-out elements (removable without many tools)

Fixed elements (bolted fasteners)

Live-front

Dead-front

Open

Metal-enclosed

Metal-clad

Metal enclose & Metal clad

Arc-resistant

By interrupting device:

Fuses

Air Blast Circuit Breaker

Minimum Oil Circuit Breaker

Oil Circuit Breaker

Vacuum Circuit Breaker

Gas (SF 6) Circuit breaker

By operating method:

Manually-operated

Motor-operated

Solenoid/stored energy operated

By type of current:

Alternating current

Direct current

By application:

Transmission system

Distribution

By purpose

Isolating switches (disconnectors)

Load-break switches.

Grounding (earthing) switches

A single line-up may incorporate several different types of devices, for example, air-

insulated bus, vacuum circuit breakers, and manually-operated switches may all exist in

the same row of cubicles.

Ratings, design, specifications and details of switchgear are set by a multitude of

standards. In North America mostly IEEE and ANSI standards are used, much of the rest

of the world uses IEC standards, sometimes with local national derivatives or variations.

C&S LV PANEL NOIDA

The Noida Unit of C&S Electric manufactures LOW VOLTAGE Switchgear Panels.The range is approximately upto 1000A,These Panels Employ certain components which are responsible for the detection and successful recovery of the normal operation.The Following Components are Used :

COMPONENTS

Power Distribution Components

Air Circuit Breakers : 630A ~ 6300AMoulded Case Circuit Breakers : 5A ~ 1200ASwitch Disconnector Fuses : 32A ~ 800ASwitch Disconnectors : 25A ~ 3150ACompact Changeover & Bypass Switches : 63A ~ 3150AHRC Fuse Links & Bases : up to 800A

The LV components division of C&S electric supplies a comprehensive range of switchgear and controlgear components. In the eighties, C&S acquired sophisticated technology for these high technology products from companies such as Terasaki of Japan (Air Circuit Breakers),

ABB Stromberg of Finland (Switches, Switch Fuse Units), and a large French multinational (Contactors, Overload Relays). However, today C&S Electric is a major investor in R&D for new generation circuit breakers and contactors. It exports these products to 73 countries. A world class expertise in the field of switchgear and controlgear components has been developed over the years, and the division is poised to expand its already substantial share of the domestic market and expand its fast growing exports.

The production of these sophisticated products demands an extensive infrastructure. The plants are equipped with sophisticated machinery and equipment. This includes the latest CAD/CAM/CAE softwares, power presses, molding machines, runnerless molding tools, sophisticated measurement and testing machines as well as several computerized test and calibration benches. The standards of quality are keeping in line with the basic values of C&S where product quality speaks for itself. It is the result of this that C&S products find favor with customers like the worlds largest manufacturer of wind turbines, the largest American locomotive producer, the top drives manufacturer in the world, and the world’s largest elevator company, amongst others. In India, C&S LV components have served for many years now, India's largest power plants, refineries, buildings and thousands of its OEMs manufacturing anything from compressors to elevators.

o Power Control Components

Power Contactors T & F Range : 9A ~ 800AMini Contactors : 9A ~ 16ACapacitor Duty Contactors : 10kVAR ~ 60kVARMotor Protection Circuit Breakers : 32A ~ 100AControl & Signalling DevicesIndustrial Motor Starter up to 350HPSubmersible Pump Control Unit up to 57A

The LV components division of C&S electric supplies a comprehensive range of switchgear and controlgear components. In the eighties, C&S acquired sophisticated technology for these high technology products from companies such as Terasaki of Japan (Air Circuit Breakers), ABB Stromberg of Finland (Switches, Switch Fuse Units), and a large French multinational (Contactors, Overload Relays). However, today C&S Electric is a major investor in R&D for new generation circuit breakers and contactors. It exports these products to 73 countries. A world class expertise in the field of switchgear and controlgear components has been developed over the years, and the division is poised to expand its already substantial share of the domestic market and expand its fast growing exports.

The production of these sophisticated products demands an extensive infrastructure. The plants are equipped with sophisticated machinery and equipment. This includes the latest CAD/CAM/CAE softwares, power presses, molding machines, runnerless molding tools,

sophisticated measurement and testing machines as well as several computerized test and calibration benches. The standards of quality are keeping in line with the basic values of C&S where product quality speaks for itself. It is the result of this that C&S products find favor with customers like the worlds largest manufacturer of wind turbines, the largest American locomotive producer, the top drives manufacturer in the world, and the world’s largest elevator company, amongst others. In India, C&S LV components have served for many years now, India's largest power plants, refineries, buildings and thousands of its OEMs manufacturing anything from compressors to elevators.

o Final Power Distribution Components

Miniature Circuit Breakers :1P, 1P+N, 2P, 3P, 3P+N & 4PTrip Type B, C & DDC MCB : 1P & 2P; 0.5A ~ 63AIsolator : 1P, 2P, 3P & 4P; 25A, 40A & 60AISI & CE Marked

Distribution Boards :Single Phase Neutral Horizontal Distribution BoardSingle & Double Door - 4, 8, 12 & 16 waysThree Phase Neutral Horizontal Distribution BoardSingle & Double Door - 4, 6, 8, 12 & 16 ways with 8 way as the incomer

Residual Current Circuit Breakers :Complete range - 2P & 4P 25A, 40A & 63A in 30, 100 & 300mA

The LV components division of C&S electric supplies a comprehensive range of switchgear and controlgear components. In the eighties, C&S acquired sophisticated technology for these high technology products from companies such as Terasaki of Japan (Air Circuit Breakers), ABB Stromberg of Finland (Switches, Switch Fuse Units), and a large French multinational (Contactors, Overload Relays). However, today C&S Electric is a major investor in R&D for new generation circuit breakers and contactors. It exports these products to 73 countries. A world class expertise in the field of switchgear and controlgear components has been developed over the years, and the division is poised to

expand its already substantial share of the domestic market and expand its fast growing exports.

The production of these sophisticated products demands an extensive infrastructure. The plants are equipped with sophisticated machinery and equipment. This includes the latest CAD/CAM/CAE softwares, power presses, molding machines, runnerless molding tools, sophisticated measurement and testing machines as well as several computerized test and calibration benches. The standards of quality are keeping in line with the basic values of C&S where product quality speaks for itself. It is the result of this that C&S products find favor with customers like the worlds largest manufacturer of wind turbines, the largest American locomotive producer, the top drives manufacturer in the world, and the world’s largest elevator company, amongst others. In India, C&S LV components have served for many years now, Indias largest power plants, refineries, buildings and thousands of its OEMs manufacturing anything from compressors to elevators.

PANEL MANUFACTURING

The Panels Used for the switchgear is also manufactured at the LV Panel units at the Powder Coating Plant located in the C&S NOIDA UNIT..

The following process are taken in order to obtain a clean,nuetral and powder coated panel:

Action of Various Chemicals on the panels Roasting panels

Powder coating(both automatic and manual)

Roasting

Action of Various Chemicals on the panels

The Panels required for the switchboard needs to be clean and properly painted so that no voltage leakage is observed,although they are properly grounded.The Panels are dipped in various solvents which ensure that the panels coming at the output are free from rust,Grease,and any other unwanted chemical substance.

PROCESS

1. DEGREASING

2. RINSE

3. DERUSTING

4. RINSE

5. ACTIVATION

6. PHOSPHATING

7. PASSIVATION

CHEMICAL

REDOLINE

NORMAL WATER(PH-7)

RUSTOKEN

WATER(PH 8)

FIXODINE

CAUSTIC SODA

DEOXYLYTE

TEMPERATURE

50-60 C

ROOM TEMP

35-40C

ROOM TEMP

40-50 C

25-35 C

35-40 C

TIME TAKEN

6-8 MINS

5 MINS

6-8 MINS

5 MINS

1 MIN

6-8 MINS

1 MIN

ROASTING:

After the action of various chemicals on the panels,these are fed to a roster which runs at 100 C.The basic function of the roaster is to remove or evaporate any left out chemical/water..

PAINT:

The panels are then fed to a enclosed room in which automatic spray paint machine paints the panels in the respected colours needed.The paint time,quality,speed of the conveyor belt etc are controlled by an official seated in the powder coating plant.

The machines are capable of changing the amount of powder coat to be painted on the panels.therefore the paint as required by the contractor is painted on to the panels.

ROASTING:

The panels are finally fed to a roaster which dries the paint and makes it firm.the temperature of the roaster is higher than the previous roaster ie its above 100 C.

The entire process is automatic,where the panels and other metals to be painted are hung upon a conveyor belt which passes 1st through the roaster which evaporates any left out chemical by the previous process.

After that the panels are fed to the paint room,where they are painted by the machines which are automatic.Any further portions left out by the machine can be filled by the workers also.

Finally the roaster ,roasts the paint and makes it firm on the panels.

FEATURES:

Booth-8 sqm/min. Conveyor speed-2.5M/min

No of Panels-1200 sqM/shift.

Variable speed of the conveyor with auto lubrication

Press chamber with 1200 m/hr.

Warner Autopaint Guns with touch screen

Air emission conforming to EU-EN norms.

CONCLUSION

The role of switchgear is:

Electrical protection

Safe isolation from live parts

Local or remote switching

Electrical protection at low voltage is (apart from fuses) normally incorporated in circuit-

breakers, in the form of thermal-magnetic devices and/or residual-current-operated

tripping devices (less-commonly, residual voltage- operated devices - acceptable to, but

not recommended by IEC).

Electrical protection assures:

Protection of circuit elements against the thermal and mechanical stresses of

short-circuit currents

Protection of persons in the event of insulation failure

Protection of appliances and apparatus being supplied (e.g. motors, etc.)

The aim is to avoid or to limit the destructive or dangerous consequences of excessive

(short-circuit) currents, or those due to overloading and insulation failure, and to

separate the defective circuit from the rest of the installation.

A distinction is made between the protection of:

The elements of the installation (cables, wires, switchgear…)

Persons and animals

Equipment and appliances supplied from the installation

The protection of circuits

 -  Against overload; a condition of excessive current being drawn from a healthy

(unfaulted) installation

 -  Against short-circuit currents due to complete failure of insulation between conductors

of different phases or (in TN systems) between 

    a phase and neutral (or PE) conductor

Protection in these cases is provided either by fuses or circuit-breaker, in the distribution

board at the origin of the final circuit (i.e. the circuit to which the load is connected).

Certain derogations to this rule are authorized in some national standards, as noted in

chapter H1. 

The protection of persons

  -  Against insulation failures. According to the system of earthing for the installation

(TN, TT or IT) the protection will be provided by 

     fuses or circuit-breakers, residual current devices, and/or permanent monitoring of the

insulation resistance of the installation to earth 

The protection of electric motors

  -  Against overheating, due, for example, to long term overloading, stalled rotor, single-

phasing, etc. Thermal relays, specially designed 

     to match the particular characteristics of motors are used.

     Such relays may, if required, also protect the motor-circuit cable against overload.

Short-circuit protection is provided either by type   

     aM fuses or by a circuit-breaker from which the thermal (overload) protective element

has been removed, or otherwise made 

Switchgear control

Switchgear-control functions allow system operating personnel to modify a loaded system at any moment, according to requirements,and include:

Functional control (routine switching, etc.)

Emergency switching

Maintenance operations on the power system

In broad terms “control” signifies any facility for safely modifying a load-carrying power

system at all levels of an installation. The operation of switchgear is an important part of

power-system control.

]Functional control

This control relates to all switching operations in normal service conditions for

energizing or de-energizing a part of a system or installation, or an individual piece of

equipment, item of plant, etc.

Switchgear intended for such duty must be installed at least:

At the origin of any installation

At the final load circuit or circuits (one switch may control several loads)

Marking (of the circuits being controlled) must be clear and unambiguous.

In order to provide the maximum flexibility and continuity of operation, particularly

where the switching device also constitutes the protection (e.g. a circuit-breaker or

switch-fuse) it is preferable to include a switch at each level of distribution, i.e. on each

outgoing way of all distribution and subdistribution boards.

The manœuvre may be:

Either manual (by means of an operating lever on the switch) or

Electric, by push-button on the switch or at a remote location (load-shedding and

reconnection, for example)

These switches operate instantaneously (i.e. with no deliberate delay), and those that

provide protection are invariably omni-polar(1).

The main circuit-breaker for the entire installation, as well as any circuit-breakers used

for change-over (from one source to another) must be omni-polar units.

Emergency switching - emergency stop

An emergency switching is intended to de-energize a live circuit which is, or could

become, dangerous (electric shock or fire).

An emergency stop is intended to halt a movement which has become dangerous. 

In the two cases:

The emergency control device or its means of operation (local or at remote

location(s)) such as a large red mushroom-headed emergency-stop pushbutton must

be recognizable and readily accessible, in proximity to any position at which danger

could arise or be seen

A single action must result in a complete switching-off of all live conductors (2) (3)

A “break glass” emergency switching initiation device is authorized, but in

unmanned installations the re-energizing of the circuit can only be achieved by means

of a key held by an authorized person

It should be noted that in certain cases, an emergency system of braking, may require that

the auxiliary supply to the braking-system circuits be maintained until final stoppage of

the machinery.

Switching-off for mechanical maintenance work

This operation assures the stopping of a machine and its impossibility to be inadvertently

restarted while mechanical maintenance work is being carried out on the driven

machinery. The shutdown is generally carried out at the functional switching device, with

the use of a suitable safety lock and warning notice at the switch mechanism.

REFERENCES AND BIBLIOGRAPHY

1. http://www.electrical-installation.org/

2. WIKIPEDIA.ORG

3. Robert W. Smeaton (ed) Switchgear and Control Handbook 3rd Ed., Mc

Graw Hill, new York 1997

4. Lin Jiming et al., Transient characteristics of 1 100 kV circuit-

breakers, International Symposium on International Standards for Ultra

High Voltage, Beijing, Juillet 2007.

INDUSTRIAL TRAINING REPORT

(JUNE – JULY 2007)

Submitted in the partial fulfillment of the requirements

For the 8th Semester Curriculum Degree of

Bachelor of Technologyin

Electronics and Electrical Engineering

of

Maharaja Surajmal Institute of Technology, New Delhi

Submitted to:

H.O.D.,

Electrical Department

MSIT.

By

ISHAN PAUL

0591504907