C&S Electric Summer Training Report Electrical Engineering

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AN INDUSTRIAL TRAINING REPORT
PARAS PRATAP
REG.No. (11/IEE/066)
At
C&S ELECTRIC LTD
MV DIVISION
GREATER NOIDA
(UTTAR PRADESH)
Submitted to
DEPARTMENT OF ELECTRICAL ENGINEERING
SCHOOL OF ENGINEERING
GAUTAM BUDDHA UNIVERSITY
GREATER NOIDA

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BONAFIDE CERTIFICATE
It is certified that the Industrial Training report is a work of Paras Pratap Reg.No. 11/IEE/066
from Gautam Buddha University (Greater Noida) who carried out the work in C&S Electric
Ltd.(MV Division) Greater Noida (Uttar Pradesh).
DR.YOGESH KUMAR CHAUHAN
(HEAD OF DEPARTMENT)
ELECTRICAL ENGINEERING
SCHOOL OF ENGINEERING

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ACKNOWLEDGEMENT
It is always a pleasure to remind the fine people in the engineering program for their sincere
guidance I received to uphold my practical as well as theoretical skills in engineering.
Firstly I would like to thank Dr.Yogesh Kumar Chauhan (HOD) and Mr.Rupendra Kumar
Pachauri Electrical Engineering for the positive attitude they showed for my work, always
allows me to question them and giving prompts replies for my uncertainties in all the fields
including educational, social and managerial work.
I express my immense pleasure and deep sense of gratitude to Mrs.Niyati Singh(C&S Electric)
and C&S Employees for spending there valuable time with me and also helped me in completion
of task.
Finally, I would also like to thanks Mr.Shailash Srivastav (HR) C&S Electric for giving me this
opportunity and guiding me during the course of the training.

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CONTENTS
Chapter no Topic Page no.
1 Introduction
 Company Profile 6
2 About the Training
 Plant layout 9
 General plant layout
 Process of store
 Introduction to Ring main unit 14
 Parts of RMU
 Features of RMU
 Types of RMU-Indoor &Outdoor
 Types of welding 20
 Tank assembly 23
 Components of tank assembly
 Working of components
 Testing
 Leak Detection Test 31
 Final assembly of RMU 33
 Components of RMU
 Working of components
 Final RMU
3 Conclusion 45
4 Reference 46

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Introduction
Company profile:-
C&S Electric Ltd. is amongst the leading suppliers of electrical equipment in India and is India’s
largest exporter of industrial switchgear. Its wide range of electrical and electronic products find
application in power generation, distribution, control, protection and final consumption. C&S
Electric is amongst the top 4 players in the LV switchgear business & the market leader in the
Power Busbar Business. In addition the company also has product offerings for MV switchgear,
Energy Efficient Lighting solutions and Diesel Generating Sets. C&S Electric along with Solar
EPC business also has an electrical contracting business which performs turnkey solutions for
industrial and commercial electrification, substations and power plants. C&S Electric was also
the 2nd company in India to design and execute a grid connected solar PV power plant in India.

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We are pleased to introduce ourselves as one of India’s foremost manufacturers of electrical
equipment for power generation, distribution, protection and control. We have 20 manufacturing
units in and around Delhi employing about 4000 people including 500 qualified engineers. We
also export our products to more than 74 countries around the globe. A sizeable portion of our
turnover is exported to USA, Europe, Russia Kenya, Brazil, Malaysia, Middle East, Australia
and other countries.
C&S Electric Ltd., through its 100% owned subsidiary, C&S Electric International BV
incorporated in “The Netherlands” have acquired Eta-com Group of Companies having offices in
Boom-Belgium and Horsham RH 13 5BB-Great Britain.
SPECIALITIES:-
Market leader in busbar business with dominating market share in India. C&S is amongst the
largest exporters of electrical switchgear products from India. 4000+employees and million of
satisfied customers, Over 24% CAGR for last 10 years
 Website
http://www.cselectric.co.in
 Industry
Electrical/Electronic Manufacturing
 Type
Privately Held
 Headquarters
222 Okhla Industrial Estate Phase 3 New Delhi, New Delhi 110020India
 Company Size
1001-5000 employees
 Founded
1966

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General Plant Lay-out:-
Gate entry process
Store (Incoming)
M.R.N (Material Receipt Note/ Inspection Note)
I.Q.C (Incoming Quality Check/Control)
Sampling Norms (Check)
M.R.N Clearance & back to store

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General Plant Lay-out:-
GATE ENTRY PROCESS
STORE
MRM (MATERIAL RECEIPT CUM INSPECTION NOTE)
IQC (INCOMING QUALITY CHECK
SAMPLING NORMS
CHECK
MRM CLEARANCE & BACK TO STORE
GATE ENTRY
STORE
RAW MATERIAL

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Store:-
Bill, Order No
Gate check
Store
Rejected Rack
Ok
Store Rack
(Put location)
Stored in Computer
Product
Manufacturing
Material Receive
Note
Quality
Check

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I.Q.C (Incoming Quality Control) :-
Customer Requirement Based
purchase Order (P.O)
Material Receive
Verified By store
M.R.N Generated By store against
System Generated (ERP)

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Income Quality
Inspection of the components received against
Particular M.R.N on Drawing
OK Not OK
Store (Stock) (Rejected) R.G.N
(Rejection
Generating
Note)

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INTRODUCTION OF RING MAIN UNIT:-
Ring Main Unit is enabled to install on medium voltage distribution network and mainly used for
protection of transformers in compact substations. It is used for medium voltage distribution in
compact substations, small buildings, and residential housing complex, large Shopping malls,
airports, wind power, etc. comprising medium voltage networks.
The concept of RMU is offering a choice of other switch-fuse combination or circuit breaker
with relay for protection of the transformer
RMU Parts:-
 Protection Relay – operated by battery 1/2aa 3.6v
 Current Transformer
 Potential Transformer
 Vacuum Circuit Breaker
 Monometer
Constant - Green (gas not leaking)
Red - Slowly Down (Gas Leaking)
 Battery
 Command Input

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Features:
 SF6 gas insulation & current interruption – No fire hazard
 Maintenance free & sealed for life contact system
 Outdoor installation
 Robust construction
 Tee-off circuit breaker with integral protection system
 Low cost cable termination
 Fully extendable options
 Motorized mechanism
RMU is a compact ring main unit combining all MV functional units to enable to supply and
protect transformers on the secondary distribution network.
RMU can be supplied in various and different configurations suitable for most switching
applications in 12/17.5/24 kV distribution networks.
Technology
1. Metal enclosed unit for Indoor installation and type tested.
2. Insulated by SF6 Gas.
3. Maintenance free and easy installation.
4. Independent of climate.
5. ON-OFF-Earth, three position load break switch.

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6. Recyclable materials used.
Durability and usefulness
1. Metal enclosed tank is hermetically sealed; it means this is Independent of environmental
effects such as dirt, small insects, moisture and so on.
2. Load break switch operating is possible in the front of Ring Main Unit.
3. All switching operations can be made safely to personnel because of interlocking system that
operates automatically according to the switch position by the operator.
4. No requirement of recharging SF6 gas until its service life.
5. Remote operation available in case of using motor operating mechanism and FRTU.
6. HRC power fuse will trip the mechanism automatically by a fuse striker pin connected to
mechanism in the event of fault happening.
Safety
1. Approachable and operable safely in the presence of power in the cables.
2. Clear indication of operation status via mimic diagram on front panel.
3. Fully automatic interlocking system.
- Operation is only possible in case door is totally closed.
- Fuse compartment is only accessible when Load break
Switch is earthed.
- Voltage detector to check whether cables are lined or not.
4. Rupture disk is designed to protect devices in case of Emergency like gas expansion.
5. Internal arc withstand is tested for the operator safety in case of accident current occur.
(21kA/1s, without SF6 Gas)
Saving cost
1. No maintenance is required other than replacement of HRC Power Fuse after installation.
2. Compact design that requires minimum space to install and operate locally is main advantage
especially where the space is limited.
3. No additional costs for replacement because of long service life.

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4. Materials can be recycled after the end of its service life.
CB type RMU (LCL)
RMU offers a choice of solutions to make 2, 3 or 4 directional connections with line protection
by 630A CB, with network switching by switch-disconnectors with integrated power supply
telecontrol device.
1. L: LBS (Load Break Switch)
Three position Load Break Switch below 630A with disconnecting and earthing switch
2. C: VCB (Vacuum Circuit Breaker)
200A vacuum circuit-breaker for transformer protection 400/630A circuit-breaker for feeder
protection
3. Cable bushing horizontal in front
1. Ring S/W Earth operation
2. Circuit Breaker operation
3. Ring S/W operation
4. Pressure gauge
5. Earth S/W operation
6. Name plate
7. Voltage Indicator
8. Disconnector S/W operation
9. Cable compartment

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PRIMARY DISTRIBUTION PANEL – INDOOR
SECONDARY DISTRIBUTION PANEL – INDOOR
-OUTDOOR
INDOOR – GC
These units are suitable for indoor installation and can be made extensible on each side. Quick
break and air break is facilitated with the help of the manual i.e. fault making load breaking
switches, which are also known as RMUS. In order to control an incoming/outgoing 11 KV
feeder cable, these units come with allied bus bars and connections. These units are suitable for
11 KV systems.
Outdoor - GCT
These units are suitable for outdoor application and can be used as freestanding units. For
connections to industrial and commercial sites, these units are used in transformer substations,
distribution switchboards and ring distribution networks. Multiple panel switchboards are formed
by direct coupling of extensible ring switches; air insulated metering units and circuit breakers.
This process does not require accessing gas insulated chambers or additional cabling.

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Tank welding:-
Indoor ring main unit
Outdoor ring main unit
With canopy structure
Canopy Structure
In outdoor ring
main unit an anti-
theft security
system is provided
to protect it from
thieves and a
hardcover is
provided and
corrosion free
.and a canopy
structure to
protect it from
rain, snow etc.

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Types of welding:-
 Mig(metal inert gas):-
MIG welding is an abbreviation for Metal Inert Gas Welding. It is a process developed in the
1940’s, and is considered semi-automated. This means that the welder still requires skill, but that
the MIG welding machine will continuously keep filling the joint being welded.
MIG welders consist of a handle with a trigger controlling a wire feed, feeding the wire from a
spool to the weld joint. The wire is similar to an endless bicycle brake cable. The wire runs
through the liner, which also has a gas feeding through the same cable to the point of arc, which
protects the weld from the air.
 Stud Welding :-
Stud welding is a technique similar to flash welding where a fastener or specially formed stud is
welded onto another metal part, typically a base metal or substrate. The fastener can take
different forms, but typically fall under threaded, unthreaded or tapped. The bolts may be
automatically fed into the spot welder. Weld nuts generally have a flange with small nubs that
melt to form the weld. Weld studs are used in stud welding systems.

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TIG welding (tungsten inert gas welding):-
Is a manual welding process that requires the welder to use two hands to weld. What separates
TIG welding from most other welding processes is the way the arc is created and how the filler
metal is added! When TIG Welding one hand is used for holding the TIG torch that produces the
arc and the other hand is to add the filler metal to the weld joint. Because two hands are required
to weld; TIG welding is the most difficult of the processes to learn, but at the same time is the
most versatile when it comes to different metals. This process is slow but when done right it
produces the highest quality weld! TIG welding is mostly used for critical weld joints, welding
metals other than common steel, and where precise, small welds are needed.

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Dye Penetrant Inspection:-
Dye penetrant inspection (DPI), also called liquid penetrant inspection (LPI) or penetrant
testing (PT), is a widely applied and low-cost inspection method used to locate surface-breaking
defects in all non-porous materials (metals, plastics, or ceramics). The penetrant may be applied
to all non-ferrous materials and ferrous materials; although for ferrous components magnetic-
particle inspection is often used instead for its subsurface detection capability. LPI is used to
detect casting, forging and welding surface defects such as hairline cracks, surface porosity,
leaks in new products, and fatigue cracks on in-service components.

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Tank Assembly:-
1ts1dc both side PTC bushing ac
Components of Tank assembly:-
1. 3 Pole Structure (Vacuum Circuit Breaker)
2. Switches (Customers)
3. Isolators (Bushes)
Isolate between phases and body
4. Bus bars
5. Tank
6. Chassis
7. Mechanism
3-POLE STRUCTURE ISFG
SWITCH
ISFG
SWITCH ISOLATOR OR BUSHING

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Vacuum Circuit Breaker:-
A vacuum circuit breaker is such kind of circuit breaker where the arc quenching takes place in
vacuum. The technology is suitable for mainly medium voltage application. For higher voltage
vacuum technology has been developed but not commercially viable. The operation of opening
and closing of current carrying contacts and associated arc interruption take place in a vacuum
chamber in the breaker which is called vacuum interrupter. The vacuum interrupter consists of a
steel arc chamber in the Centre symmetrically arranged ceramic insulators. The vacuum pressure
inside a vacuum interrupter is normally maintained at 10 - 6
bar.
The material used for current carrying contacts plays an important role in the performance of the
vacuum circuit breaker. CuCr is the most ideal material to make VCB contacts.
Advantages of Vacuum Circuit Breaker or VCB
Service life of vacuum circuit breaker is much longer than other types of circuit breakers. There
is no chance of fire hazard as oil circuit breaker. It is much environment friendly than SF6 Circuit
breaker. Beside of that contraction of VCB is much user friendly. Replacement of vacuum
interrupter (VI) is much convenient.
Operation of Vacuum Circuit Breaker
The main aim of any circuit breaker is to quench arc during current zero crossing, by establishing
high dielectric strength in between the contacts so that reestablishment of arc after current zero
becomes impossible. The dielectric strength of vacuum is eight times greater than that of air and
four times greater than that of SF6 gas. This high dielectric strength makes it possible to quench
a vacuum arc within very small contact gap. For short contact gap, low contact mass and no
compression of medium the drive energy required in vacuum circuit breaker is minimum. When
two face to face contact areas are just being separated to each other, they do not be separated
instantly, contact area on the contact face is being reduced and ultimately comes to a point and
then they are finally de-touched. Although this happens in a fraction of micro second but it is the
fact. At this instant of de-touching of contacts in a vacuum, the current through the contacts
concentrated on that last contact point on the contact surface and makes a hot spot. As it is

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vacuum, the metal on the contact surface is easily vaporized due to that hot spot and create a
conducting media for arc path. Then the arc will be initiated and continued until the next current
zero.
Operational sequence for CB

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Chassis:-
 45 Hardware
Shaft
 Axle
 Bearing
 Small shaft
Mechanism (CD1):-
Closing shaft:-
 Changing spring
 Closing spring
 Push button
 Striker
21

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Adapter
Spangle
Counter
I bolt
After this motor is fitted in the chassis and the work of chassis is complete and the machine goes
to tank assembly.

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ISFG SWITCH:-
There are two switches:-
Input switch
Output switch
Two Types of Contacts are there:-
 Copper
 Silver Plated on Copper
There are 3 turns:-
 Line Flow – To Flow
 Earth - In Maintenance and Fault
 Disconnect
Silver Plated for ON Condition
Copper Contact for Grounding
And in middle condition there is off position
 Silver Plated copper s used for resistance control.
Operation of 3-Position Load Break Switch
Main Close Open earth

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TESTING OF VACUUM CIRCUIT BREAKER:-
Parameters r y b
Close time (MS) 42.3 42.5 42.6
Closing synchronism 0.30
(MS) Pass
Contact stroke (mm) 8.55 8.66 9.28
Velocity 1(m/s) 1.22 1.29 1.22
Velocity 2(m/s) 1.11 1.13 1.08
Max. Coil current 4.23 0.2

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Parameters r y b
Open time (MS) 35.70 35.70 35.60
Open syn. (MS) 0.10
Contact stroke (mm) 8.55 8.66 9.08
Over travel open (mm) 1.18 1.05 0.63
Over travel time open (MS) 8.40 6.80 5.30
Over rebound (mm) 0.69 0.52 0.55
Velocity 1(m/s) 0.32 0.50 0.36
Velocity 2(m/s) 0.79 0.91 0.76
Max. Coil current c1 c2 c3
0.26 2.31

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LEAK DETECTION TEST:-
Leak Detection & Gas Filling Machine
This is the best & largest machine in the South Asia in terms of size of the test chamber &
accuracy of Mass Spectrometer used to detect leakages in Ring Main Unit Tanks. The machine
will detect a leak of 6X10-6 mbar l/s at 300mbar, 100% Helium. The process is fully automated
with predefined cycle of evacuation, leak testing with Helium, purging with Nitrogen and then
filling of SF6 & leak testing with SF6 with no manual intervention.
The machine has a capacity of testing 15-20 tanks per day
18% Helium is used currently in the bag for leakage detection in the helium bag. Helium Gas is
the lightest gas

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Leakage Area in tank Assembly:-
 Back cover Welding
 Bearing
 Bellow
 Ext. PTC Welding
 PTC Bushing
 Tee-off Bushing
 Extension Bushing
 Protection Sheet
 Dilo Valve
 Leak not found
 Air pressure low
 Pressure Switch
 Run Welding
 Test Welding

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Final Assembly of Ring Main Unit:-
1- Lifting points
2- Cable test bushings compartment
3- Earth switch operating mechanism
4- Switch disconnector operating mechanism
5- Live cables indication neon lamps
6- LBS cable compartment access panel
7- CB spring charger operation shaft
8- Circuit breaker pushbuttons
9- Circuit breaker spring status
10- Pressure indicator
11- Self-powered protection relay
12- VCB cable compartment access panel

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The Enclosure is used for outdoor applications. Manufacturing of this enclosure with GI sheet
and Powder coated. The access is available for Installation of RMU and connection of earthing
from outside of enclosure for customer.Anti-theft door hinge and pad locking facility is available
in this enclosure.
Enclosure for Outdoor application
Electrical Data:-

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Load Break Switch:-
Standard features
1. Three position load break switch with disconnector and earthing switch
2. Operating mechanism with two separate shaft for load and earthing function
3. Switch position indication for LBS and ES
4. Cable bushing horizontal in front with integrated capacitor for voltage indication

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Optional features
1. Motor operation for load break switch
2. Auxiliary switches
- Load breaks switch position
- Earthing switch position
3. Voltage indicating system
4. Short circuit and earth fault indicator

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Supplied Configuration:-
Operating mechanisms:-
MECHCI1 (M) and MECHCD1 (M) operating mechanism elements Identification
1 -Function label holder
2 -Switch and earth switch status indicator
3 - Lock for "open" earth switch interlocking (optional)
4 - Pressure indicator
5 - Earth switch operation shaft
6 - Earth switch interlocking pin (prevents handle insertion)
7 - Live cables signaling lamps
8 - Lock for "open" switch interlocking (optional)
9 - Switch interlocking pin (prevents lever insertion)
10 - Switch operation shaft
11 – Circuit breaker closing operation pushbutton interlock (optional)
12 – Circuit breaker operation pushbuttons
13 – Circuit breaker status indicator
14 – Circuit breaker spring status indicator
15 – Circuit breaker spring charger operation shaft
16 – Circuit breaker operation counters

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17 – Self-powered protection relay
18 – Protection relay low voltage access panel
19 - Switch or Earth switch manual operation lever
Operating mechanism functional principle

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Circuit Breaker:-
Standard features
1.200 A vacuum circuit-breaker for transformer protection or 630 A vacuum circuit-breakers for
feeder protection
2. Three position disconnecting and earthing switch
3. Switch position indication for CB and DS/ES
4. Cable bushing horizontal in front
5. Interlocking between CB and DS/ES
Optional features
1. Motor operation for circuit breaker
2. Auxiliary switches
- CB position
- Disconnector position
- Earthing switch position
3. Voltage indicating system
Operating mechanism functional principle

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4. Trip coil and close coil
Vacuum interrupter:-
In the closed position, normal current flows through the interrupter. When a fault occurs and
interruption is required, the contacts are quickly separated. The arc drawn between the surfaces
of contact is rapidly moved around the slotted contact surface by self-induced magnetic effects,
preventing gross contact erosion and the formation of hot spot on the surface. The arc burns in an
ionized metal vapor, which condenses on the surrounding metal shield. At current zero they are
extinguishes and vapor production ceases. The metal vapor plasma is very rapidly dispersed,
cooled, recombined, and deionized, and the metal vapor
Products are quickly condensed so that the contacts withstand the transient Recovery voltage.
OCR (Current Relay): CT powered protection relay:-
This relay is self-powered relay by the CT in RMU and can be set with definite time and inverse
time characteristics for short circuit, overload and earth Fault current. Parameter setting can be
done in different user-friendly ways, computer controlled or with HEX switches on the front.
The relay is also provided with a digital memory for the storage of the most recent tripping
values. This relay has proven to be a reliable and widely accepted method of protection in
worldwide distribution networks.
CT (Current Transformer):-
A current transformer (CT) is used for measurement of alternating electric currents. Current
transformers, together with voltage (or potential) transformers (VT or PT), are known
as instrument transformers. When current in a circuit is too high to apply directly to measuring
instruments, a current transformer produces a reduced current accurately proportional to the
current in the circuit, which can be conveniently connected to measuring and recording
instruments. A current transformer isolates the measuring instruments from what may be very
high voltage in the monitored circuit. Current transformers are commonly used in metering
and protective relays in the electrical power industry.

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Voltage indicator lamps (Voltage Detector):-
It is a device to check the presence or absence of voltage in the cables. It is conforming to IEC
standard 61958. Push button type LED voltage indicator is provided and lamp power is supplied
by bushing type capacitive dividers.
Switch-fuse combination:-
Standard features
1. Three position switch-fuse combination with earthing switch
2. Switch position indication for switch fuse combination and earth switch
3. Cable bushing horizontal in front
4. Fuse holder for DIN type fuse-links
5. Fuse-link rating
- 12/17.5kV: max. 100 A, LSIS DIN type fuse-link
- 24kV: max. 75 A, LSIS DIN type fuse-link
6. Automatically tripped to protect from fault current when a fuse is blown
Optional features
1. Motor operation for switch-fuse combination
2. Auxiliary switches
- LBS position
- Earthing switch position
- Fuse blown status
3. Voltage indicating system
4. Trip coil

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Cables connection:-
RMU ID was designed to use separable pre-moulded (screened and unscreened) or thermo
retractile Connectors. The cables and connectors selection is a customer’s responsibility and
must be compatible with RMU ID equipment.
- Screwed Tee connectors or thermo-retractile connectors for 400/630A bushings, which
accommodate Copper or aluminum thermop lastic insulated cables, for Incoming/Outgoing
function.
MRB (Manual Reset Button):-
1. It is a function which resets a circuit breaker manually when a circuit breaker is tripped by
OCR.
2. When a circuit breaker tripped by fault current, a mechanical trip indicator (MRB, Manual
Reset Button) pops out from the main cover and the switch (SDE) which sends control signal
electrically is conducted to output the information occurred from fault circuit breaker.
3. MRB can be operated only by OCR but not by OFF operation of circuit breaker, To re-close a
circuit breaker after a trip, press MRB to reset it for closing.

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EFI (Earth fault indicator):-
EFI can be installed at RMU frame or anywhere customer wants.
1. Single Phase AC supply split core type sensor
2. Automatic resetting function on AC 220~230V3Ph
3. 3Phase
Routine quality check:-
While producing RMU, various routine tests are taken for product capacity.
Tested items are as shown follows.
1. Filling pressure check
2. Tightness check
3. Manual and motor operation check
4. Dielectric check
5. Contact resistance check

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Final Ring Main Unit

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Conclusion
As an undergraduate of Gautam Buddha University. I would like to say that this training
program is an excellent opportunity for us to get to the ground level and experience the things
that we would have never gained through going straight into a job. I am grateful to C&S Electric
Ltd (Greater Noida) for giving us this wonderful opportunity. The main objective of the
industrial training is to provide an opportunity to undergraduates to identify, observe and practice
how engineering is applicable in the real industry. It is not only to get experience on technical
practices but also to observe management practices and to interact with fellow workers. It is easy
to work with sophisticated machines, but not with people. The only chance that an undergraduate
has to have this experience is the industrial training period. I feel I got the maximum out of that
experience. Also I learnt the way of work in an organization, the importance of being punctual,
the importance of maximum commitment, and the importance of team spirit. In my opinion, I
have gained lots of knowledge and experience needed to be successful in a great engineering
challenge, as in my opinion, Engineering is after all a Challenge, and not a Job

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References
 Web
 C&S Electric Ltd.
 Wikipedia
 Google images
 Switchgear and Power System Protection by Ravindra P Singh
 Switchgear Protection and Power Systems by Sunil S Rao