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LABORATORY MANUAL
Electrical skills
Engineering Department
AY 2015-2016
Section No.
Level:
Semester: 2
Specialization:
Page
CONTENTS
Experiment
Name of the Experiment
No.
Page
No.
Table of contents
Course objectives, outcomes
Course assessment scheme
Laboratory rules
General safety precautions and guidelines
in the ELECTRICAL SKILLS lab
Introduction
Electrical Supply
Measurement of the Earth Resistance
Preparation of Galvanized Steel Conduit
Wiring Lighting Circuit
Testing Wiring Circuits
Connection of Fluorescent Tube Light
Sodium Vapor Lamps
Connection and Trouble Shooting of Fan
Circuit
Metal Halide Lamps
Page
1
2
3
4
5
6
7
COURSE OUTCOMES:
EEPW2241: ELECTRICAL SKILLS
Prerequisites: Engineering Workshop (EEPW 1240)
Goal: To provide the students with the concepts, techniques and applications of
electrical workshop
Objectives
Outcomes
This course should enable the Upon completion of the course, the student will be
student to:
able to:
1. Know the safety practices in
the workshop and production
areas.
2. Understand the
electrical
techniques.
aspects of
installation
4. Understand how to
lighting and circuits.
wire
methods
of
circuits
Page
Sources:
I. Text Books
1. Electrical Installation work, Brain McAdam, Elsevier 4Th Edition.
2. Electrical skills, Ministry Manual.
II. Reference Books
3.
4.
5.
6.
7.
8.
Page
: 67-69 (C grade)*
Grade
A
AB+
B
BC+
C
CD
F
GPA
4.0
3.7
3.3
3.0
2.7
2.3
2.0
1.7
1.0
0.0
Fail
Grade
A
AB+
B
BC+
C
CD
F
Page
Overall CGPA
4
3.7-3.99
3.3-3.3.69
923-92.3
.22-.33
.29-.2.3
.23-.2.3
922-9233
923-92.3
0.0-.99
Assessment Methods
(Total Practical Courses)
Theory (T)
Practical (P)
Lab report
Not Applicable
Viva-Voce
Written Questionnaire
marks
100 % Practical part marks= Total marks out of 100
45 marks
15 marks
40
Page
Attendance:
Issuing of Warning Letter
Percentage
Number of Hours
First
10%
Second
20%
Third
30%
If the absence reaches 30%, the student will be debarred from the final exam and will
get ZERO in the final exam.
A student will be considered as LATE when s/he arrives after 10minutes of the class
start time. Being LATE for THREE times in a class will be considered as ONE class
absence.
The full course delivery plan must be covered. If students are absent without a valid
reason, it will be considered as if the topic/s is already covered and will be included
in exams.
If a student is absent for two continuous weeks within the semester in all courses,
s/he will be DISMISSED from the College.
If a student failed to attend any class, s/he has to submit the original excuse
document within one week from the date of absence to registration department
only.
The coverage of topics in the midterm supplementary exam will include topics
covered up to the midterm exam + topics covered one week after the midterm
exam.
The final complementary exam will be conducted within four weeks from the
start of next semester.
Page
Absence Excuse:
Course Withdrawal
A student is allowed to withdraw one course during the semester. The withdrawal
period will end a week after the midterm exam resultannouncement.
Submission of Assignment
20% of assignment scored mark will be reduced for each day of late submission.
Cheating
In case of an accusation of cheating during an examination is proven, the following will
be imposed:
Page
Theory (T)
Not Applicable
Practical (P)
Lab report
45 Marks
Viva-Voce
15 Marks
Written Questionnaire
100 % Practical part marks= Total marks out of 100
40 Marks
Factors
Ability to follow procedure, data collection
Marks
10
Page
10
Total weightage for all the above procedures (Part I + Part II+ Part III) is 100%
1. Each Student has to write a Lab report on each Experiment / Exercise performed &
submit the report within one week.
2. But if the student fails to submit the report within one week, he/she will loose 1
mark each day till the report is submitted.
3. After the completion of each experiment student must take the signature of course
Lecturer on the cover page.
6. Neat report with all the required data, graph, units and conclusion will get better
Page
11
marks.
Before starting Laboratory work follow all written and verbal instructions
carefully. If you do not understand a direction or part of a procedure, ASK YOUR
CONCERN TEACHER BEFORE PROCEEDING WITH THE ACTIVITY
2.
Do your wiring, setup, and a careful circuit checkout before applying power.
3.
Conduct yourself in a responsible manner at all times in the laboratory. Dont talk
aloud or crack jokes in lab.
4.
5.
Do not eat food, drink beverages or chew gum in the laboratory and do not use
laboratory glassware as containers for food or beverages. Smoking is strictly
prohibited in lab area
2.
Do not make circuit changes or perform any wiring when power is on.
3.
Do not wear loose-fitting clothing or jewelry in the lab. Rings and necklaces are
usual excellent conductors in contact with your skin.
4.
Do not touch anything if your hands are wet. The "one-hand" approach is safest.
5.
Do not wander around the room, distract other students, startle other students or
interfere with the laboratory experiments of others
Page
1.
12
Donts
Safety First
SAFETY CLOTHING MUST BE WORN
WORN
13
Girls
Page
Boys
Introduction
Electricity and related water sector in Sultanate of Oman
The Law for The Regulation and Privatization of the Electricity and
Related Water Sector (the Sector Law) was promulgated by Royal Decree
# 78/2004 and came into effect on 1 August 2004.
Page
14
Reference : http://www.ehcoman.com
Reference : http://www.ehcoman.com
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15
Reference : http://www.majanco.co.om
OES 1
OES 2
Underground Cables
OES 3
LT Overhead Lines
OES 4
OES 5, 5A & 6
Transformers
LT Equipment
OES 11
OES 24 3311KV
Indoor Substations
OES 27 Volume
OES 27 Volume 2
OES 30 33
OES 32
132KV OHL
16
Describe about
Page
Regulation
STANDARD OES 4
Ministry of Electricity and Water (now MHEW), Sultanate of Oman has
issued REGULATIONS FOR ELECTRICAL INSTALLATIONS known as
STANDARD OES 4 which is available at
http://www.aer-oman.org
BS 7671:2008
This British Standard specifies the Requirements for Electrical
Installations
It is also known as IEE Wiring Regulations
The regulations apply to the design, erection, and verification of
electrical installations.
Page
17
STANDARD OES 4
Scope and Coverage
(Where to use the standard?)
The regulations apply to electrical installations such as those of,
Residential Premises
Commercial Premises
Public Premises
Industrial Premises
Agricultural and Horticultural Premises
Prefabricated Buildings
Construction Sites, Exhibitions, Fairs and other temporary installations.
The regulations cover,
Circuits supplied at normal voltages up to and including 415/240 V AC 50
Hz.
Any wiring not specifically covered by the specifications of appliances.
Fixed wiring for telecommunications, signaling, control (excluding external
wiring of apparatus).
Page
18
ELECTRICAL STANDARD
Compliance with Regulations
(Why to use/meet the standard?)
Compliance with electrical regulations is essential to ensure safety of life,
plant, equipment and buildings especially from the hazards of fire, electrical
shocks and mishaps in the utilization of electricity in and around buildings.
PROTECTION AGAINST ELECTRIC SHOCK
In electrical installations, one of the major risks is electric shock. Persons and
livestock (animals) shall be protected against dangers that may arise,
a. from contact with live parts of the installation by:
appropriate measures to prevent contact; ISOLATION
Limiting the value and duration of current which can pass through a body to
a value lower than shock current. INSULATION
b. From contact with exposed metal parts by one of the following methods.
Preventing a fault current from passing through the body of any person or
any livestock. EARTHING
Limiting the value and duration of current which can pass through a body to
a value lower than shock current. INSULATION
Automatic disconnection of the supply on the occurrence of a fault likely to
cause a current to flow through a body in contact with the exposed metal
parts, where the value of the current is equal to or greater than the shock
current. ISOLATION
PROTECTION AGAINST THERMAL EFFECTS
Another major risk with the electrical installations is excessive temperature
likely to cause burns, fires and other injurious effects.
Protection shall be provided against
The harmful effects of heat or thermal radiation developed by electrical
equipment.
Ignition, combustion or degradation or material.
Reference: BS7671-2008
Page
19
flame and smoke where a fire hazard could be propagated from an electrical
installation to other nearby fire compartments and
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20
Reference: BS7671-2008
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21
22
Page
Page
23
Page
24
In the consumer premises, the consumer has another substation to step down this
voltage to 400V to meet lighting and low voltage applications.
25
Page
Page
26
Page
27
There are three commonly used arrangements of the earthing connection as described
in IEE Electricity Regulations which are discussed here.
Page
28
TN-S System
TN-C-S System
TT System
These have been designated in the IEE Regulations using the letters: T, N, C
and S. These letters stand for:
T - terre (French for earth) and meaning a direct connection to earth.
N - neutral
C - combined
S - separate.
When these letters are grouped, they form the classification of a type of system.
The first letter denotes how the supply source is earthed.
The second denotes how the metalwork of an installation is earthed.
The third and fourth indicate the functions of neutral and protective conductors.
Page
29
All exposed metalwork is connected to the protective conductor via the main
earthing terminal of the installation.
30
Page
This system has the neutral of power supply with connection of earth only at
one point to the source. The consumers earthing terminal is usually connected
to the metallic Armour of the distributors cable into the HV / LV transformer.
Page
31
Page
32
33
Page
The supply cable uses a combined protective earth & neutral (PEN) conductor.
At the supply intake point a consumers main earthing terminal is formed by
connecting the earthing terminal to the neutral conductor.
Page
34
All exposed conductive parts of the installation are then connected to the main
earthing terminals. Thus phase to earth faults are effectively converted into
phase to neutral faults
Page
35
For protection against indirect contact in domestic premises, every socket outlet
requires an RCCB with a maximum rated current of 30mA.
36
Page
37
Page
Page
38
By contrast, conventional circuit breakers or fuses only break the circuit when the total
current is excessive (which may be thousands of times the leakage current an RCD
responds to). A small leakage current, such as through a person, can be a very serious
fault, but would probably not increase the total current enough for a fuse or circuit
breaker to break the circuit, and certainly not to do so fast enough to save a life.
Advantages
Page
39
Disadvantages
1. They do not detect faults that dont pass current through the CPC to the earth rod.
2. They do not allow a single building system to be easily split into multiple sections
with independent fault protection, because earthing systems are usually use
common earth Rod.
3. They may be tripped by external voltages from something connected to the
earthing system such as metal pipes, a TN-S earth or a TN-C-S combined neutral
and earth.
4. As electrically leaky appliances such as some water heaters, washing machines
and cookers may cause the ELCB to trip.
5. ELCBs introduce additional resistance and an additional point of failure into the
earthing system.
4) What is the supply voltage obtained from the electricity board to Shinas college of
Technology?
5) What is the kVA rating of the distribution substation in the college premises?
Page
40
7) How much voltage is required at the consumers premises for Lighting and low
voltage applications?
Page
41
42
Page
Aim: To measure the value of earth resistance and earth voltage by using Earth
Resistance Tester (Kyoritsu 4102A).
Apparatus Required:
1) Earth resistance tester
- 1 No.
2) Connecting leads
- 3 Nos.
3) Earth Electrodes
- 2 Nos.
4) Hammer
- 1 No.
Theory:
The importance of earthing lies in the fact that it deals with safety. The word
earthing comes from the fact that the technique itself involves making a lowresistance connection to the earth or to the ground. The earth is considered to be a
large conductor which is at zero potential.
Reason for Earthing:
Page
43
The basic reason for earthing is to prevent or minimize the risk of shock to human
beings and livestock by providing a low resistance discharge path for earth leakage
currents which would otherwise provide injuries or even death to a person or animal
touching the metal part.
The following diagram describes the degree of danger of the leakage current; if, it
flows in the human body.
The following example through the figures describes how the earthing system works:
In the following diagram the metallic part is not earthed and the human being is
touching it.
Let,
The supply voltage is 240V, AC circuit. The apparatus is having 40 and the defective
insulation is making the metallic body live and it is not earthed. Let the body
resistance is 1000:
As shown above the leakage current may cause death to the person that is in contact
with the metallic part. The fuse in the path will not be able to identify the small rise in
current.
In the following diagram the metallic part is earthed and the human being is touching
it.
With the same supply system let, the sum of the resistance of cable and the metallic
part be 10
Page
44
Now the current is 4.8 times the fuse rating current. So, the fuse will operate and
protect the human by:
i. Blowing out and separating the supply from the body in touch with the
equipment
ii. By making the potential across the body Zero (i.e. a shorted electric part
through the earth wires).
Page
45
Plate electrodes:
Page
46
The following drawing describes how such electrodes are used in a distribution
wiring system:
47
Page
Page
48
Connection Diagram:
Procedure:
1) Strike the auxiliary earth spikes P and C into the ground deeply. They should be
aligned at and interval of 5 -10 meters from the earthed equipment under test.
2) Connect the Green Wire to the earthed equipment under test, Yellow to the
auxiliary earth spike P and the Red to the auxiliary earth spike C from terminals E,
P and C of the instrument respectively.
3) Set the range switch to EARTH VOLTAGE position to check earth voltage. Record
the reading in table below.
4) Set the range switch to 100 positions, and press the test button. The LED
remains illuminated during testing. Turn the range switch to 10 and 1
when the earth resistance is low. This indicated value is the EARTH RESISTANCE of
the earthed equipment under test.
5) Change the spike P position to 2m, 4m, 6m, 8m, 10m from the earth pin E and
note down the earth resistance and tabulate the readings.
Observations:
Distance From the Earth
Pin E to the Spike P
2m
4m
6m
8m
Page
49
10 m
Graph
The variation of earth resistance with distance
Conclusions:
Answer Following Questions,
Page
50
Page
51
Section 6.4
Radius of Bend
The radius of every conduit bend shall not be less than 2.5 times the outside
diameter of the conduit.
Section 6.5
Galvanized Steel Conduits
Galvanized Steel conduit system shall be earthed and connected to the earthcontinuity conductor. All joints shall be made mechanically and electrically
continuous by screwing. The conduit shall not however be used as an earth
continuity conductor and a separate earth continuity cable shall be drawn
into the conduit for every final sub-circuit.
Only Galvanized Steel conduits shall be used in the space between a roof and
suspended false ceiling, in situations subject to fire risk and in surface
mounted industrial installation. PVC conduits shall not be used for such
applications. (Derogation issued in2009 to use PVC conduits)
Galvanized Steel conduits shall not be used under floor tiles of buildings or in
concealed wiring systems embedded in walls or floors. PVC conduits shall be
used for all such applications.
Section 6.6
PVC Conduits and Fittings
PVC conduits and fittings shall be of the unthreaded type. All joints shall be
made with vinyl cement and entries of all conduit fittings shall be designed
such that reliable water tight joints can be obtained.
Surface mounted PVC conduit systems shall be so supported as to allow for
longitudinal expansion and contraction. A cement that shall remain in
adhesive plasticized state shall be used for expansion couplers.
Section 6.7
Flexible Conduits
Flexible conduits shall only be used for the final connection of motors and
other equipment subject to vibration or adjustment of position.
PVC flexible conduits and fittings shall comply with BS 4607 part 3. Metallic
flexible conduits and fittings shall comply with BS 731 Part 1 and shall
preferable be provided with an outer sheath of PVC.
Page
52
Flexible metal conduit shall not be used as the sole means of providing earth
continuity and a separate earth continuity cable shall be provided.
Page
53
Conduit Sizes
Conduits shall be limited to the following sizes
16 mm, 20 mm, 25 mm, 32 mm and 50 mm
Aim: To make the Galvanized Steel conduit to do the wiring for the following
measurement.
1) Making 900 bend from a fixed point.
2) Making two 900 set.
3) Making thread for 1.5 cm at one end.
Tools Required:
1) Steel Pipe Bending Vice
2) Steel Pipe
3) Threading Die
4) Hand File
5) Wire Brush
6) Measuring Tape
7) Marker Pen
- 1 No.
- 1 No.
- 1 No.
- 1 No.
- 1 No.
- 1 No.
- 1 No.
Cutting:
Conduit pipes can be cut by using a hacksaw or a pipe cutter as shown in the following
figures:
Procedure:
1. Fix the conduit in the vice so that the vice grips the conduit 50 or 75mm from the
point where the cut has to be made
2. The blade is to be installed so that the cut is made on the forward stroke.
Precautions:
a. After cutting by any method the inside edge
of the conduit must be smoothed with half
round file as shown in the figure.
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54
Threading:
When short lengths of conduits are to be used for switch or lamp drops, the end of
the pipe needs to be threaded to enable fixing of the conduit to the accessories. The
threads on the conduit in all cases shall be between 11mm to 27mm long.
This threading of conduit is done by using dies and a die-stock.
Note:
1. Apply cutting oil to the end before starting to cut threads.
2. Cutting threads longer than necessary will leave exposed threads that are not
protected from corrosion.
Precaution:
a. Use only a brush to remove the metal burrs from the die. Do not use your hand.
Page
55
Metal conduit boxes and the symbols used in metal conduit wiring:
The following figure shows different popular outlet boxes used in metal conduit
wiring:
Following figure shows the various symbols used for different boxes in a single line
diagram for such a wiring:
Page
56
The following figure shows the wall and ceiling boxes for conduit wiring, a switching
box is also displayed:
57
After removing the knockouts the boxes are prepared as shown in the following
Page
figure:
58
Page
b.
d 160
8
8
63 mm
d = outer diameter of
the bending pulley
60 mm
80 mm
Page
59
Pulley
Procedure:
1. Measure diameter of the Galvanized Steel Pipe given for the exercise.
2. Select suitable pulley for bending the pipe.
3. Making 900 bend from a fixed point.
1) Take a steel pipe of length 900 mm and mark 300 mm from the edge or a fixed
point consider that mark as an initial mark.
900
mm
300
mm
2) Add 1 th of the outer circumference of the bending pulley from the initial mark
8
Example: 300mm + (
160
) =363 mm and consider this as a new mark.
8
63 mm
300
mm
3) Place the tube in the former with the fixed point at the rear and place the pipe
exactly at the new mark which should be aligned with the perpendicular scale.
4) This will give a 900 bend at the required distance from the fixed point to the back
of the bend.
300
mm
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60
1) From initial mark of 300 mm, measure another 300 mm and mark.
2) Take this new mark as reference, subtract 1 th of the outer circumference of the
8
bending pulley. Consider this as reference mark for the second bend.
300 mm
63 mm
300
mm
3) Now measure the gap between two bends. If you get 300mm from center to
center of the bends means your work is carried out successfully.
300 mm
300
mm
300
mm
Page
61
for one full circle and rotate in opposite direction for one full circle.
3) Repeat the same thing until the full thread is made at one end as per the
measurement.
S.No
Quantity
Measurement
Results:
1. Mention the various types of conduits.
2. What are the available sizes of conduits used in industry?
3. Mention the applications of various types of conduits.
Page
62
Page
63
Switches for lighting and fans inside a room shall be mounted inside the room
on the side of the door nearest to the door catch, handle knob or lock
approximately 150mm from the door frame.
Section 5.2
Current Ratings
Current Ratings for single core and multicore cables to be adopted for use in
consumers installation are set out in tables 2, 3, 4 and 5 (Appendix IV) of OES4.
The current carried by the cables at any time shall not exceed the specified
ratings.
Section 5.4
Protection against damage
All conductors and cables shall be adequately protected against any risk of
mechanical damage to which they may be liable in normal condition of service.
Where cables pass through hole in metal works, rubbers or plastic grummets or
bushes shall be provided of the edge lined with soft material to prevent
abrasion of the cables.
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64
Section 5.18
Flexible cord and cables
Current ratings for flexible cords and cables are set out in Table 1 (Appendix IV)
of OES4.
Where the apparatus requires to be earthed, flexible with earth core shall be
used.
Where the flexible cables and cords are exposed to the risk of mechanical
damage, they shall as a minimum be sheathed with PVC or rubber and where
necessary shall be armored, the armour not being used as sole means of
providing earth continuity.
Flexible cords and cables shall be connected to plugs, ceiling roses and movable
apparatus with the BROWN core to phase, BLUE core to neutral and
GREEN/YELLOW core to earth terminal of accessory or frame of the apparatus.
In situations where high temperatures are encountered, flexible cables and
cords shall be insulated with silicon rubber type E12 of BS6899/IEC540
Where a flexible cord supports or partially supports a luminaire, the maximum
mass supported by the cord shall not exceed the values given in Table 1
(Appendix IV)
Section 5.19
Colour identification of cable cores
a. Colour identification of insulated cable cores for fixed installation and of
sleeve, band or disc for bare conductors shall be as follows:
- earthing conductor
green and yellow
- phase of a.c. single phase circuit
red
- neutral of a.c.single phase or three phase circuit black
- phase R of three phase a.c. circuit
red
- phase Y of three phase a.c. circuit
yellow
- phase B of three phase a.c. circuit
blue
- positive of d.c. 2 wire
red
- negative of d.c. 2 wire
black
b. Colour identification of flexible cables and flexible cords shall be as follows:
- live
brown
- neutral
blue
- earthing
green and yellow
Mounting Heights of Accessories
Height from finished floor level
Lighting Switch
1250 mm
1250 mm
1250 mm
1250 mm
450 mm
250 mm
1000 mm
65
outlet in kitchen
Page
Item
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66
67
Page
68
Page
Pliers
Accessories Required:
1) PVC Conduit
2) Conduit Saddles and Screws
3) Elbow or Bend
4) Junction box
5) Lamp Holders with Lamps
6) Single pole switch
7) Miniature Circuit Breaker (MCB)
8) Earth Leakage Circuit Breaker (ELCB)
9) 15 Amps , 1 Way Terminal Box
Measuring Instruments:
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69
Circuit Diagram:
Single Phase
240 V, 50 Hz
L1
L2
N
E
Line Diagram:
Lamp 1
Distribution
Board
ELCB
MCB
Switch
Page
70
Lamp 2
Page
71
Layout Diagram:
List of Material:
Sr. No.
Item
Conduit
Saddles
Specification
Quantity
Required
Cable Red
3
Cable Black
Switch
Junction box
Elbows or Bends
Lamp holder
MCB
ELCB
10
Lamp1
11
Lamp2
12
Clamp meter
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72
Procedure:
1) Connect the items collected per the layout diagram on the work board.
2) Check the tightness of the connections.
3) Never forget to verify the tracing of the wires as per the layout diagram.
4) CHARGE THE CIRCUIT UNDER THE SUPERVISION OF TECHNICIAN.
5) Verify the live terminal at input of the ELCB using line tester.
6) Switch ON the ELCB and using line tester observe that the circuit is live and the
wiring is perfect.
7) Switch on the MCB and observe that the wiring is working perfect.
8) Similarly check that the live terminal at the Lamp Holders turns Live, only on
making the switch ON.
9) Note the Operation of the circuit by visual inspection and record the data in
your report.
10) Note down the reading of Voltage and current in the observation table and
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73
Condition
Only Lamp1
(______W,______V)
Only Lamp2
(______W,______V)
Lamp 1 and 2
Voltage (V)
Current (I)
Calculations:
Sl
No
Result:
Specification
Voltage
V
Current
I
Power
Consumed (P)
Page
74
Page
75
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76
COMPLETION CERTIFICATE
(Completion certificate to be given by the Electrical Contractor and signed by
Contractors Competent Engineer/ Supervisor):
has been completed, inspected and tested in accordance with the regulations
for electrical installations issued by the Ministry of Electricity and Water,
Sultanate of Oman and is now ready for connection to mains supply.
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77
FORM A
Particulars of the installation covered by this Certificate:
New Installation.
Installation Drawing:
It is anticipated that the installation would comprise the following:
S. No.
Description
Light Points
Air conditioners
Fans
Water Heaters
Refrigerators
Freezers
Cookers
10
13 A Socket Outlets
11
Other Loads
12
13
No.
kW
Unit
Total
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78
Signed:____________________________________ Date:_________________
FORM B
INSPECTION AND TEST REPORT
1. Compliance with drawings:
2. Standard of Installation:
Material:
Workmanship:
3. Colour identification of wiring:
4. Polarity Checks:
Switches:
Breakers:
Links:
Linked Switches:
5. Resistance of Earth Continuity
Conductor from remote end to
main earthing point:
6. Insulation Resistance:
- With all poles and phases
connected
together
and
switches, fuses and breakers
all in place
- With all conductor on one
phase connected together
and in turn all conductors
connected to each other.
Red:
Yellow:
Blue:
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79
Neutral:
Red:
Yellow:
Blue:
Neutral:
Earth:
Operating Current
(A)
(mA)
Main Subsidiary 1)
2)
11. Load Balance
Red
-
Lights
Refrigerators
Air conditioners
Freezers
Cooker
Motors
Water Heaters
Other Loads
Yellow
Blue
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80
Signed:_____________________________________ Date:_________________
Objectives: At the end of the exercise the student should be able to understand the
following:
1) Understanding the need for Testing and Inspection of wiring in electrical
installations
2) Understanding the different types of Testing and Inspection procedures as per
OES 4
3) Preparing Completion Certificate pertaining to Testing and Inspection of
electrical wiring as per OES 4
4) Inspection & Testing procedure required to follow as per OES 4, for a given
electrical circuit.
Aim : To Connect a 3 Pin Plug connection and perform following tests
1) Visual inspection
2) Color Identification
3) Earth Continuity Test
4) Continuity Test and
5) Protection Test
Tools Required:
1) Electrical / Manual Driller
2) Screw Drivers
3) Hacksaw frame with Blade
4) Wire Stripper
5) Pliers
6) Line Tester
Accessories Required:
1) Conduits
2) Conduit Saddles and Screws
3) Elbow or Bend
4) Red, Black and Yellow/ Green Cable
5) Junction box
6) 3 Pin Plugs with Switches
7) Miniature Circuit Breaker (MCB)
8) Earth Leakage Circuit Breaker (ELCB)
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81
Measuring Instruments:
Page
82
Circuit Diagram:
Single Phase
240 V, 50 Hz
AC Supply
Line Diagram:
Distribution
Board
MCB 1
ELCB
Switch Socket
Outlet 1
MCB 2
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83
Switch Socket
Outlet 2
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84
Layout Diagram:
List of Material:
Sr. No.
Item
Conduit
Saddles
Elbows or Bends
Specification
Quantity
Required
Cable Red
4
Cable Black
Junction box
Terminal Box
MCB
ELCB
10
Clamp meter
Page
85
Procedure:
Visual Inspection Test:
Observe the following points in this test and write observations.
1. The installation is as per the layout diagram.
2. The installation comprises of the protection devices as shown in the line
diagram.
3. Accessories used are of standard quality and note down the standards printed
(if any)
4. Connections and joints of the cable are firm/ tight and appropriately insulated.
5. Cables are protected against mechanical damage.
6. Switches are mounted at a minimum height of 1250 mm from finished ground
surface.
Colour Identification:
Observe that appropriate colour code is used in the electrical installation. Write the
observations below,
1. Colour of the cable used for Live/ phase wire:__________________
2. Colour of the cable used for Neutral wire: _____________________
3. Colour of the cable used for Earth wire: _______________________
Earth Continuity Test:
Write observation in the table below.
Observation
Sound
Resistance
Comment
86
Page
Sr.
No.
Continuity Test:
Sr.
No.
Connection of meter
Observation
Sound
Resistance
Comment
Protection Test:
Page
87
Press the test button of the ELCB and note your observation:
Page
88
Page
89
Types of lamps:
Construction:
The fluorescent tube light consists, a sealed glass tube. The tube contains very
small amount of Mercury mixed with an inert gas, typically Argon, kept under very
low pressure.
Page
90
The tube also contains a Phosphor powder, coated along the inside of the glass.
The tube has two electrodes, one at each end, which are connected to the electrical
supply through bi-pin plugs at both ends of the tube.
Ballast/ Choke:
Starter:
Circuit diagram:
Starter
Capacitor
Cathode
Bi-Pin
Plug
Cathode
Bi-Pin
Plug
Switch
91
240V, AC
Supply
Page
Ballast/
Choke
Page
92
When the switch is turned ON, the path of least resistance is through the bypass
circuit, and across the starter switch. In this circuit, the current passes through the
electrodes on both ends of the tube. These electrodes are simple filaments, like you
would find in an incandescent light bulb. When the current runs through the bypass
circuit, electricity heats up the filaments. This boils off electrons from the metal
surface, sending them into the gas tube, ionizing the gas.
At the same time, the electrical current sets off an interesting sequence of events in
the starter switch. The conventional starter switch is a small discharge bulb,
containing neon or some other gas. The bulb has two electrodes positioned right
next to each other. When electricity is initially passed through the bypass circuit, an
electrical arc (essentially, a flow of charged particles) jumps between these
electrodes to make a connection. This arc lights the bulb in the same way a larger
arc lights a fluorescent bulb
One of the electrodes is a bimetallic strip that bends when it is heated. The small
amount of heat from the lit bulb bends the bimetallic strip so it makes contact with
the other electrode. With the two electrodes touching each other, the current
doesn't need to jump as an arc anymore. Consequently, there are no charged
particles flowing through the gas, and the light goes out. Without the heat from the
light, the bimetallic strip cools, bending away from the other electrode. This opens
the circuit.
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93
By the time this happens, the filaments have already ionized the gas in the
fluorescent tube, creating an electrically conductive medium. The tube just needs a
voltage kick across the electrodes to establish an electrical arc. This kick is provided
by the lamp's ballast, a special sort of transformer wired into the circuit.
When the current flows through the bypass circuit, it establishes a magnetic field in
part of the ballast. This magnetic field is maintained by the flowing current. When
the starter switch is opened, the current is briefly cut off from the ballast. The
magnetic field collapses, which creates a sudden jump in current and the ballast
releases its stored energy. Now the tube light becomes switched ON.
Procedure:
1) Connect circuit as per the diagram.
2) Energize the circuit with 240V, 50 Hz single phase power supply.
3) Check Whether Light is glowing properly.
Page
94
Observations:
Page
95
Specifications printed on ballast: --------------------------Specifications printed on the Fluorescent Tube: -------------------Specifications printed on the Starter: ----------------------------------Voltage of the electrical supply: _________________
Current taken by the circuit from supply: ____________
Power (P) measured: __________________
Power factor of the Fluorescent Tube circuit (calculate): _________________
Layout Diagram:
Result: The tube light connections were made and checked as per the circuit diagram.
Answer the following questions.
1. What do you understand by power factor?
2. Which kind of circuit is your fluorescent lamp circuit?
3. What is the power factor of the circuit?
4. How can you improve the power factor of such a circuit?
5. If the power factor will improve. What will happen to the total power consumed?
Page
96
Page
97
Low-pressure sodium (LPS) vapor lamps, also known as sodium oxide (SOX) lamps,
consist of an outer vacuum envelope of glass coated with an infrared reflecting layer
of indium tin oxide, a semiconductor material which allows visible light wavelengths
to pass and reflects infrared back, keeping it from escaping. It has an inner
borosilicate glass U-pipe (arc tube) containing solid sodium and a small amount of
neon and argon gas mixture to start the gas discharge, so when the lamp is turned
on it emits a dim red/pink light to warm the sodium metal and within few minutes it
turns into the common bright yellow as the sodium metal vaporizes.
LPS lamps are the most efficient electrically-powered light source when measured
for photopic lighting conditions up to 200 lm/W, primarily because the output is
light at a wavelength near the peak sensitivity of the human eye. As a result they are
widely used for outdoor lighting such as street lights and security lighting where
faithful color rendition is considered unimportant.
Page
98
Page
99
Because of the extremely high chemical activity of the high pressure sodium arc, the
arc tube is typically made of translucent Aluminum Oxide. Xenon at a low pressure
is used as a "starter gas" in the HPS lamp. It has the lowest thermal conductivity and
lowest ionization potential of all the non-radioactive noble gases. As a noble gas, it
does not interfere with the chemical reactions occurring in the operating lamp.
The low thermal conductivity minimizes thermal losses in the lamp while in the
operating state, and the low ionization potential causes the breakdown voltage of
the gas to be relatively low in the cold state, which allows the lamp to be easily
started.
High Pressure Sodium vapor lamps have no starting electrodes. In addition to an
open circuit voltage of approximately two times the lamp voltage, these lamps are
started by a high voltage starting pulse, provided by an ignitor, applied across the
arc tube.
Advantages of High-pressure sodium (HPS) lamps:
Good efficiency (lumens per watt)
Smaller size than LPS or fluorescent, the HPS fits into many fixture types
Can be retrofitted into older Mercury Vapor fixtures
Better bulb life than LPS lamps
Disadvantages of High-pressure sodium (HPS) lamps:
Still has a bad color rendering compared to metal halide and halogen lamps
Requires a lossy ballast (inefficient) that operates a low arc voltage of 52100V. This reduces the actual efficiency of the lamp when you count the
whole system together.
High pressure
sodium vapor
lamp
35 W to 1000 W
70000 Lumens
150000 lumens
50000 lumens
80-180 lm/W
50-140 lm/W
14000 h -18000 h
16000 h -24000 h
Yellow
White
25-60 lm/W
16000 h 24000
h
White
25
15-55
7 -10 minutes
3 -12 seconds
3- 4 minutes
0.5 - 1 minute
5 -7 minutes
3 6 minutes
Mercury Vapor
lamp
50 W to 1000 W
100
Ratings
Maximum light
output Range
Efficacy Range
Approximate
lamp life
Color of Light
CRI Color
Rendering Index
Warm up time
Re-strike time
Low pressure
sodium vapor
lamp
18 W to 180 W
Page
Properties of
discharge lamps
Circuit diagram:
Connection of Low Pressure Sodium Lamp:
Page
101
Procedure:
1) Connect circuit as per the diagram.
2) After giving connection energize the circuit with 240V, 50 Hz single phase power
supply.
3) Check Whether Light is glowing properly.
4) Switch off the supply and disconnect the circuit.
Observation: Write your observation
Quantity
Voltage
Current
Power Consumed
Warm-up time
Restrike Time
Page
102
Discussion questions:
1. What are the differences between Low pressure and High pressure
Sodium Vapor Lamps?
2. What is the need for Ballast in Sodium Vapor Lamp?
3. What is the need for Ignitor in High pressure Sodium Vapor Lamp?
4. Give the applications of Sodium Vapor Lamps.
Accessories Required:
1) Motor body Stator and Rotor
2) Cap and cover
3) Housing.
4) Capacitor
5) Terminal Connecter
6) Hanging bolt rod, pin, bobbin.
7) Fan blades
8) Wire guards
9) Speed regulator
Page
103
Theory:
Fan is an electrical load which contains single phase induction motor, speed
variation resisters, and capacitor etc. We know, that if a single phase induction
motor is energized with single phase supply then the resultant torque produced by
it will be equal to zero. So the motor does not have self starting torque.
To overcome this drawback and make the motor self starting, the motor is
temporarily converted into a two phase motor during starting period. For this
purpose the stator of a single phase motor is provided with an extra winding which
is called as starting or auxiliary winding in addition to the main or running winding.
The two windings are spaced 900 electrically apart from each other and connected
in parallel across single phase ac supply.
The phase difference between currents flowing through the two windings is kept
large (ideally 900) just as two phase currents to produce rotating magnetic field and
make the motor self-starting.
Page
104
A Yoke
B Motor Cover
C Bearing
D Rotor
E Stator
1
OFF
4
O
N
240 V, 50 Hz,
AC Supply
VRegulator
VFan
Page
105
VSupply
Page
106
A test for grounds can be made with a test lamp or continuity tester. One test
lead should be placed on the frame and the other on a lead to the winding. If there is
no ground, the lamp will not light, nor will any deflection be present when a meter is
used. If the lamp does light or the meter shows continuity, it indicates a ground is
present due to a defect somewhere in the motors insulation.
Short circuits: Short circuits between any two windings can be detected by the use of
a test lamp or continuity tester. Place one of the test leads on one wire of the
starting winding and the other test lead on the wire of the running winding. If these
windings are properly insulated from each other, the lamp should not light.
If it does, it is a certain indication that a short or ground fault exists between the
windings. Such a condition will usually cause part of the starting winding to burn
out. The starting winding is always wound on top of the running winding, so a
defective starting winding can be conveniently removed and replaced without
disturbing the running winding.
Procedure:
1. Collect the necessary items like fan, regulator, PVC conduit, saddles, screws,
screw drivers, drilling machine and wires required for doing fan experiment.
2. Measure the conduit and wires as per the requirement and cut it. Fix the conduit
over the work board with the help of saddles and screws.
3. Take the red wire and connect to the one end if the regulator and take the other
end and connect it to the fans line terminal.
4. Take the black wire and connect it from the fans neutral point to the supply
neutral point.
5. Now energize the fan circuit with the help of single phase 240 V, 50 Hz supply.
6. Now vary the speed of the fan by using conventional regulator.
Page
107
Observations:
1. If regulator is kept in maximum resistance position then part of the input supply
will be dropped across the regulator and remaining will be applied across the
fan so the fan will run slowly.
2. If regulator is kept in medium resistance position then part of the input supply
less than the previous one will be dropped across the regulator and remaining
will be applied across the fan so the fan will run at moderate speed.
3. If regulator is kept in minimum resistance position then very less input supply
will be dropped across the regulator and remaining will be applied across the
fan so the fan will run at maximum speed.
Sr.
No.
1
2
3
Connection of
Multimeter
Red and Black
Wire of fan
motor
White and Black
Wire of fan
motor
Red and White
Wire of fan
motor
Resistance Value
Sr. No.
Voltage
0V
25 V
50 V
75 V
100 V
125 V
150 V
175 V
200 V
10
225 V
11
250 V
Speed
Page
108
109
Page
1.
2.
3.
4.
5.
Apparatus Required:
1)
2)
3)
4)
Page
110
Metal halide (MH) lamps consist of an arc tube (also called a discharge tube or
"burner") within an outer envelope, or bulb. The arc tube may be made of either
quartz or ceramic and contains a starting gas (usually argon), mercury, and MH salts
(Bromides or Iodides of Sodium/ Scandium/ Thallium/ Indium/ Holmium/
Thulium). Traditional quartz MH arc tubes are similar in shape to mercury vapor
(MV) arc tubes, but they operate at higher temperatures and pressures .Inside
the fused quartz arc tube two tungsten electrodes doped with thorium, are sealed
into each end and current is passed to them by molybdenum foil seals in the fused
silica. The ends of the arc tube are often externally coated with
white infrared reflective zirconium silicate or zirconium oxide to reflect heat back
onto the electrodes to keep them hot and thermionicaly emitting
MH lamps start when their ballast supplies a high starting voltage higher than
those normally supplied to the lamp electrodes through a gas mixture in the arc
tube. The gas in the MH arc tube must be ionized before current can flow and start
the lamp. In addition to supplying the correct starting voltage, the ballast also
regulates the lamp starting current and lamp operating current.
As pressure and temperature increase, the materials within the arc tube vaporize
and emit light and ultraviolet (UV) radiation. A bulb (also called "outer jacket" or
"outer envelope"), usually made of borosilicate glass, provides a stable thermal
environment for the arc tube, contains an inert atmosphere that keeps the
components of the arc tube from oxidizing at high temperatures, and reduces the
amount of UV radiation that the lamp emits. Some MH lamps have a coated finish on
the inside of the bulb that diffuses the light. Often a phosphor coat is used to both
diffuse the light and change the lamp's colour properties.
Page
111
Connection Diagram
Observation Table
Power rating of
MH Lamp ( P )
Result
Voltage (V)
Current ( I )
Power Factor
= P/(V*I)
Experiment on given Metal Halide lamp is conducted and the Power factor of this
lighting load is found as above.
What are the differences between sodium vapor lamp and Metal Halide lamp.
2.
3.
4.
Page
1.
112