SUMMER INTERNSHIP AT

JATSON POWER PRIVATE LIMITED

A SUMMER INTERNSHIP REPORT

Submitted by

AAYUSHI MAHESHBHAI PATEL

(210230109007)

BACHELOR OF ENGINEERING
In

ELECTRICAL ENGINEERING

Dr. S & S.S. GHANDHY GOVERNMENT

ENGINEERING COLLEGE, SURAT.

GUJARAT TECHNOLOGICAL UNIVERSITY

[ APRIL, 2025 ]

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DR. S & S.S GHANDHY GOVERNMENT ENGINEERING
COLLEGE, SURAT, GUJARAT-395008.

CERTIFICATE

This is to certify that the Internship report submitted along with Internship entitled JATSON
POWER PRIVATE LIMITED has been carried out by AAYUSHI MAHESHBHAI PATEL under my
guidance in partial fulfilment for the degree of Bachelor of Engineering in Electrical Department,
8 TH Semester of Gujarat Technological University, Ahmedabad during the academic year 2024-
2025.

Sign: - Sign:-

Prof U. N. PATEL Prof N.A. GAJJAR

Internal Guide H. O. D.

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3
GOVERNMENT ENGINEERING COLLEGE
BHARUCH

DECLARATION
I hereby declare that internship report submitted along with the internship entitled
Summer Internship at JATSON POWER PVT LTD has been carried out by ARYAN
PATEL under my guidance in partial fulfillment for the degree of bachelor of
engineering in electrical department, 7th semester of Gujarat Technological
University, Ahmedabad, is a Bonafide record of original internship work carried
out by me at Government Engineering College, Bharuch under the supervision of
PROF PANKAJ VASAVA and that no part of this internship report has been directly
copied from any students report or taken from any other source, without
providing the
reverences.

NAME:- ARYAN PATEL

ENROLLMENT NO:- 210140109062
SEM:-7TH
Sign of student

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ACKNOWLEDGEMENT
It is indeed a great pleasure and honor to have the opportunity to pursue an
industrial internship at Jatson power pvt ltd ,vapi GIDC where I gained a lot of
practical learning which in turn led to my professional development
I’m grateful to have had a chance to do an internship. I would like to thank
MR Sandip patel(HR jatson power) for allowing me to do an internship within the
organization.
I also would like to thank all the production engineers, operators, and workers for
helping me in a direct or indirect way. They keep me free to ask them questions
and any doubts without hesitating despite being busy with their own work. They
helped me a lot to understand the process and working of different processes &
plants.
I’m grateful to the company as well for providing me with different necessary
facilities like safety equipment, transportation, canteen, etc. I also hope to have
continued cooperation with the company in upcoming future.
I’m also thankful to my college principal Dr. Pradeep P. Lodha and HOD of the
electrical engineering department Prof. Vishal Doshi Sir for giving me such an
opportunity to pursue the summer internship in such an organization. Also, to my
internal guide Prof. Pankaj vasava for guiding me throughout the internship.

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ABSTRACT

Industrial training is conducted by the institutions to increase the practical

experience of the students. The students should achieve as more as they could
from this training. We have done our training at JATSON POWER PVT LTD. This
Industry manufactures different control panels using electrical components and
measuring instruments and are widely used in power grid or electricity distribution
systems. An oil and gas, and paper and pulp industries are main customers of Low-
voltage and medium-voltage panels, while high-voltage switchgear panels are
widely used by state electricity boards in various substations. The JPPL is a leading
manufacturer & supplier of different type of panel’s like-power control panels,
motor control panels, IMCC panels, APFC panels, VFD panels, etc. We learn about
industry automation with drive and control logic development using contactors. All
control panels are manufactured based on customer requirement. The whole staff
of the company, they share their experience with us during the training. This
training is conducted during the period from 29TH JUNE to 12TH JULY.

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List of Figure

Fig 2.1:- DOL stater wiring 10

Fig 2.2:- Three phase Star-Delta control circuit-------------------------------------------------------12
Fig 2.3:- Three phase Star-Delta control circuit 12
Fig 2.4- STAR-DELTA STARTER WIRING 13
Fig 2.5:- PCC panel 14
Fig 2.6:- MCC panel 15
Fig 2.7:- IMCC panel 16
Fig 2.8:- Variable Frequency drive (VFD) 18
Fig 2.9:- APFC 19
Fig 2.10:- Air circuit breaker 20
Fig 2.11:- Fabrication area 21
Fig 2.12 :- Assembly Area 21
Fig 2.13:- programmable logic controller 27
Fig 2.14 Testing of pannel 29
Fig 2.15:- Design of circuit 34
Fig 2.16 :- power circuit 35

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CHAPTER 1: COMPANY
PROFILE
CONTENTS
1.1 ABOUT THE ORGANIZATION

CHAPTER 2: INTERNSHIP DETAILS

2.1 Motor Control Starter(DOL)
2.2 Motor Control Starter(Star-Delta)
2.3 Power control centre (PCC) panel
2.4 Motor control centre (MCC) panel
2.5 Intelligent Motor control centre (IMCC) panel
2.6 Variable Frequency Drive (VFD) panel
2.7 Automatic power factor control (APFC) panel
2.8 Air circuit Breaker (ACB)
2.9 Panel Fabrication and Design
2.10 Assembly Area
2.11 Components used in making panel
2.12 Safety Standards in company
2.13 Selection of Busbar
2.14 Automation in panel
2.15 Testing and commissioning
2.16 Installation of panel
2.17 Costing and Estimation

CHAPTER 3: REFLECTION NOTE

3.1 Technical outcome
3.2 Personality development
3.3 Time Management
3.4 Skill Development

CHAPTER 4: CONCLUSION
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CHAPTER 1: COMPANY PROFILE
1.1 ABOUT THE ORGANIZATION:-

The JPPL is industry which manufactures various types of low voltage and medium voltage switch board and
different types of panels. In JPPL power electrical panel were designed as per IEC standard. These power
electrical panel were trusted and have better safety, reliability and quality in low and high voltage power
distribution and controlling segment. Power electrical panel made available in various specification in industrial
electrical workshop. In the JPPL electrical workshop we used safety method because of electrocution is mainly
due to serious injury. The operation of tool and machineries also cause to hazard. We considered about personal
safety, human health and equipment safety. We used personal protective equipment such as safety shoes, glow,
ear plugs, mask, safety goggles and etc. after the works was finished, clean the surface and electrical off the
machineries power supply. The company has a response for all electrical work systems and equipment under
their control.

Also provide service of energy audit. In this industry has also working on site projects of various forms.
Transformer installation and commissioning. Luminaries: Industry light fittings and installation. DG & DG sine
panel installation testing and commissioning. The power electrical panel consists of metering devices, protective
device switching device, conductors, bus bar chamber, indicator, circuit breaker, capacitor and many other types
of equipment.
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CHAPTER 2:- INTERNSHIP
DETAILS
2.1 Motor control starter (Direct on line)
The DOL starters are used for motor having low power ratings. Where the starting
current does not damage the windings of the motor. For applications where the starting
current does not cause huge dips in the line voltage. Direct online starters are used for
small water pumps, conveyor belts, fans and compressors.

In the DOL method of starting a squirrel cage induction motor, the motor is connected to
the full supply voltage through a starter. The direct-on line starter consists of a coil
operated contactor C which is controlled by start (normally open) push button and stop
(normally closed) push button.

The DOL starter has many important parts–the circuit breaker, the contactor, and the
thermal overload relay. The three parts provide overvoltage protection. Due to their use
as protective devices, the components should be selected and sized according to
function.

Fig 2.1:- DOL stater wiring

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2.2 Motor control starter(Star-Delta)

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A star delta starter is the most commonly used method for the starting of a 3 phase induction motor. In star
delta starting an induction motor is connected in through a star connection throughout the starting
period. Then once the motor reaches the required speed, the motor is connected in through a delta
connection. A star delta starter will start a motor with a star connected stator winding. When motor
reaches about 80% of its full load speed, it will begin to run in a delta connected stator winding.

The starting torque of an induction motor is proportional to the square of the voltage applied to the
winding per phase.
Staring Torque in Star Connected Stator Winding Motor
Staring Torque in Delta Connected Stator Winding Motor

= (VL/√3) 2 = 1
2
VL 3

The equation shows that star delta starter reduces the starting torque to one-third of that produced by DOL
starter. The star-delta starter is equivalent to an autotransformer with a 57.7% tapping.

2.2.1 Advantages of Star Delta Starter

1. Inexpensive
2. No heat is produced, or tap changing device needs to be used, hence efficiency increases.
3. Starting current reduced to 1/3 of direct online starting current.
4. Produce high torque per ampere of line current.

2.2.2 Disadvantages of Star Delta Starter

1. Starting torque is reduced to 1/3 of full load torque.
2. A particular set of motors required.

2.2.3 Application of Star Delta Starter

As discussed in the above advantages and disadvantages, a star delta starter is most suited to applications
where the required starting current is low and where the line current draw must be at a minimum
value. The star delta starter is not suitable for applications where high starting torque delivery is

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required. For these applications, a

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DOL starter should be used instead. If the motor is too heavily loaded, there will not be enough torque to
accelerate the motor up to speed before switching over to the delta position. Example application for a star
delta starter is a Centrifugal compressor.

Fig 2.2:- Three phase Star-Delta control circuit

Fig 2.3:- Three phase Star-Delta control circuit

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Fig 2.4- STAR-DELTA STARTER WIRING

2.3 POWER CONTROL CENTRE (PCC) PANEL

Power Control Centre Panels are used to supervise and control the voltage and power of the power system.
These panels are made of high-quality raw material and are extremely sturdy in fabrication. Main power
instrument panel which consists of feeder breakers and provide breakers, monitoring devices and control
devices. A reputed PCC panel manufacturer read all field data received for electrical power panels are
designing. Power control center Panels are the most essential part of electrical system. An industry from where
the power of the industry is controlled. Perfect Products (India) is widely known for premium quality power
distribution board designed and made consistent with the customer specifications. Best quality switchgear and
bus-bar are used for reliable and efficient performance. Main power control board which consists of feeder
breakers and provide breakers, monitoring devices and control devices. Our offered panel is very recommended
among our clients and widely utilized in various industries.

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2.3.1 Power Control Center panel Working
The Power Control Center Panel works by combine circuits from several places into a single central hub. This
enables access to the whole electrical connections of a grid, Industry from a single place. The electricity for all
circuits is controlled by a single main power switch in a PCC panel. When the main Circuit Breaker switch is
turned off, the entire electric supply might be temporarily shut down. There are situations, though, when you
may need to manage the power for individual components or places. As a result, each circuit will be divided
into its own switch by a PCC panel. If you need to turn off the electricity in just one part of your business, you
may do so without cutting off the power to other parts of the Industry that needs it. It would be quite risky to
power up your Plant or Commercial Place without a PCC panel. Basically to protect and control power
distribution for large manufacturing unit PCC Panels are used.

2.3.2 Power Control Center panel Using Components:

PCC panels, the apparatus used for controlling switching, and protecting the electrical circuits and equipment is
known as switchgear. Circuit breakers, switch fuse units, switches, off-load isolators, contactors, HRC fuses,
miniature circuit breakers, GFCIs and ELCBs, and other switching devices are all included in the switchgear.
Protection, tripping times and selectivity

Fig 2.5:- PCC pannel

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2.4 Motor Control Centre Panel
The Motor Control Centre Panels, also called MCC Panels are used to control motors from a central point in big
industrial and commercial applications. In many industrial and commercial applications, many electric motors
are required, it is frequently advantageous to control part or all of them from a central place. The motor control
centre is the device designed for this function.
Multiple enclosed sections with common bus bars make up the motor control centres, with each section housing
power contactors, isolators, protection relays, and other control and indication devices.

2.4.1 Motor Control Centre panel Using Components:

A motor control center consists of one or more vertical metal cabinet sections with power bus and provision for
plug-in mounting of individual motor controllers. Very large controllers may be bolted in place but smaller
controllers can be unplugged from the cabinet for testing or maintenance. Each motor controller contains a
contactor or a solid-state motor controller, overload relays to protect the motor, fuses or a circuit breaker to
provide short-circuit protection, and a disconnecting switch to isolate the motor circuit. Three-phase power
enters each controller through separable connectors. The motor is wired to terminals in the controller. Motor
control centers provide wire ways for field control and power cables.

Fig 2.6:- MCC panel

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2.5 Intelligent Motor Control Centre Panel
Intelligent Motor Control Centre is a smart MCC panel for controlling multiple electric motors simultaneously
at a central location. I MCC consists of multiple feeders with common power as well as combination of
control bus-bars and starters in each section. An intelligent MCC panel is a type of MCC panel with enhanced
functionality using advanced features and a communication enabled motor management system (SIMOCODE)
that monitors other lead processes of the motor through the process control system. The SIMOCODE intelligent
motor control centre (IMCC) acts as the heart of the SIMOCODE motor. It is a pliable, modular motor
management system. In other words, easily and directly connected to the automation system via PROFIBUS or
PROFINET. What's New Now IMCC combines all the necessary security, monitoring, and safety and control
functions into just one compact system. In other words, our custom range of panels are manufactured without
compromising any safety and globe standards as compared to conventional compartmentalized and draw out
panels.

2.5.1 IMCC Panel Application

In Industries where multiple, remotely controlled loads linked to a central control in SCADA and Automation.
Also in industrial plant applications, like HVAC pump, fan loads, mining, and ball mill applications.

2.5.2 Advantages of IMCC Panel

Intelligent Motor Control Centres allow you to easily access data, make more informed decisions, and control the MCC
to optimize facility, process and power system performance

Fig 2.7:- IMCC pannel

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2.6 VARIABLE FREQUENCY DRIVE
The VFD Panel (Variable Frequency drive panel) also known as VFD Control Panel are designed to control the
speed of the electric motor and feed pump. They are widely used in drilling, pumping and other large machine
applications like Conveyor and Compressor.

AC motor speed is controlled in two ways – either by controlling the voltage or frequency. Frequency
controlling gives better control due to constant flux density than voltage control. This is where the working of
VFDs comes to play. It is a power conversion device which converts the fixed voltage, fixed frequency of the
input power to the variable voltage, the variable frequency output to control AC induction motors.

Most of the industrial applications require variable speeds at peak load conditions and constant speeds at
normal operating conditions. Closed loop working of VFDs maintains the speed of the motor at a constant
level, even in case of input and load disturbances.

2.6.1 Variable frequency drive Benefits

 Energy Savings
 Reduces Peak Energy Demand
 Reduces power when not required
 Fully Adjustable Speed
 Controlled starting, stopping, and acceleration
 Dynamic Torque Control
 Provides smooth motion for applications such as elevators and escalators
 Maintains speed of equipment, making drives ideal for manufacturing equipment and
industrial equipment such as mixers, grinders, and crushers
 Advanced overload protection
 Digital inputs/outputs
 Analog inputs/outputs
 Relay outputs
 Low motor starting currents
 Reduction of thermal and mechanical stresses on motors and belts during starts
 Simple installation
 High power factor
 Lower KVA

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Fig 2.8:- Variable Frequency drive (VFD)

2.7 Automatic power factor control panel (APFC)

An Automatic Power Factor Control (APFC) panel is a sophisticated electrical control system that
continuously monitors and regulates the power factor (PF) of an electrical network. Its primary function is
to optimize power factor by automatically switching capacitor banks in or out to match changing load
conditions.

2.7.1 How it works:

1. Sensors monitor the electrical network's voltage, current, and power factor.

2. The microcontroller processes the data and calculates the required capacitance to achieve the
desired power factor (usually 0.95-0.98).

3. The microcontroller sends signals to switch specific capacitor banks on or off to achieve the required
capacitance.

4. The display unit shows the real-time power factor, voltage, current, and other.

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2.7.2 Benefits of APFC panels:
- Improved power factor, reducing energy losses and penalties

- Optimized electrical efficiency

- Increased lifespan of electrical equipment

- Reduced heat generation and energy consumption

- Filtering of harmonics and improved power quality

APFC panels are widely used in industries with high inductive loads, such as cement, steel, and rolling mills,
to ensure efficient and reliable electrical power distribution.

Fig 2.9:- APFC

2.8 Air circuit breaker

An Air Circuit Breaker (ACB) is a type of electrical circuit breaker that uses air as the insulating medium to
extinguish the arc generated when the circuit is interrupted.

2.8.1 Principle of Air circuit breaker :

- ACBs work on the principle of air insulation, where the contacts are separated in air, creating an arc.

- The arc is then extinguished by the rapid expansion of air, which cools and dissipates the energy.

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2.8.2 Features of ACB:
- High interrupting capacity

- Fast arc extinction

- Low maintenance

- Compact design

- Suitable for high-voltage applications

2.8.3 Applications of ACB:

- Medium-voltage and high-voltage electrical distribution systems

- Industrial power systems

- Commercial buildings

- Data centers

- Power generation and transmission systems

Fig 2.10:- Air circuit breaker

2.9 Panel Fabrication and Design

Fabrication is the construction of items from different parts using at least one of a range of processes and
materials such as metal, laminates, wood and other solid surface materials. Frequently used in relation to
metal fabrication, the steps involved can include stamping, welding, cutting, bending, and assembling

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processes. As With Other

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Manufacturing Processes, Fabrication Can Be Done Manually, But The Processes Are Often Automated These
Days With The Use Of Computer Aided Designs (CAD) That Can Be Programmed Into Computer Numerical
Control (CNC) Technologies That Can Communicate Directly With Machines On The Shop Floor, Reducing
Lead Times, Costs And Material Usage While Improving Accuracy And Quality.

Fig 2.11:- Fabrication area

2.10 Assembly Area

All connections to individual circuits from the bus bar shall preferably be solid connections; however flexible
connections shall also be permitted as per recommendations of the Panel Manufacturer. Assembly Solutions is
an established and experienced manufacturer of quality custom-designed control panels, electric panels,
and panel wiring. At Assembly Solutions, our engineers are dedicated to working with customers from
supporting the initial design, right through to prototype and volume production.
Panel Manufacturer shall furnish warranty for all materials and workmanship for a period of one calendar year
from the date the panels are received against all defects due to faulty workmanship or materials and agrees to
replace same at no expense to GRDA. Manufacturer means the person or body who is responsible to the
approval authority for all aspects of the type approval process and for ensuring conformity of production.

Fig 2.12 :-Assembly Area

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2.11 Components used in Making Panel
=> The following components are commonly used in making electrical panels:

2.11.1 Switchgear
1. MCB(Miniature circuit breaker) :- A small, thermally operated circuit breaker used for low-voltage
electrical distribution in residential and commercial applications.

2. MCCB(Molded Case Circuit Breaker):- A type of circuit breaker that uses a molded plastic case and is
used for higher current ratings than MCBs. MCCBs are commonly used in commercial and industrial
applications.

3. ACB(Air Circuit Breaker):- A type of circuit breaker that uses air as the insulating medium and is
commonly used in high-voltage electrical distribution systems.

4. VCB(Vacuum Circuit Breaker):- A type of circuit breaker that uses a vacuum as the insulating medium
and is commonly used in high-voltage electrical distribution systems, particularly in outdoor applications.

2.11.2 Fuses
A fuse is a sacrificial device that melts or vaporizes when an excessive current flows through it, interrupting
the power supply to protect the electrical circuit from damage. Fuses are designed to fail (melt or blow) when
a predetermined current limit is exceeded, disconnecting power to prevent damage to equipment,
conductors, or other components.

1. Cartridge Fuses:

Cartridge fuses are a type of fuse that consists of a cylindrical body (cartridge) containing the fusible element
(usually a thin metal strip). They are commonly used in industrial, commercial, and residential applications.
Cartridge fuses are available in various sizes, shapes, and current ratings.

2. HRC (High Rupturing Capacity) Fuses:

HRC fuses are a type of cartridge fuse designed to handle high fault currents (short circuits) without causing
damage to the fuse holder or surrounding equipment. They are constructed with a special fusible element and
arc-quenching material, allowing them to safely interrupt high fault currents (up to 100 kA or more). HRC
fuses are commonly used in high-voltage applications, such as industrial power distribution, substations, and
transmission systems.

2.11.3 Switches
A switch is an electrical component that controls the flow of electrical current by opening or closing a circuit. It
allows a user to turn a device on or off, or redirect the flow of current. Switches are essential components in
electrical circuits, enabling control over the flow of electricity.

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1. Toggle Switches:

A toggle switch is a type of switch that has a lever or handle that can be flipped between two positions, often
marked as "on" and "off". When the lever is flipped, it connects or disconnects the circuit, allowing the user to
control the flow of electricity. Toggle switches are commonly used in applications such as lighting, power
tools, and electronic devices.

2. Push Buttons:

A push button is a type of switch that requires a user to press a button to activate the circuit. Push buttons are
often used in applications where a momentary action is required, such as starting a machine, sounding an
alarm, or triggering a relay. There are two main types of push buttons:

- Momentary push buttons: The circuit is only activated while the button is pressed.

- Latching push buttons: The circuit remains activated even after the button is released.

2.11.4 Indicating Instruments

An indicating instrument is a device that displays the value of a physical quantity, such as voltage, current,
temperature, or pressure, in a visual format, like a meter or gauge. Indicating instruments provide a way to
monitor and measure various parameters in electrical circuits, machines, and processes.

1. Ammeter:

An ammeter is a type of indicating instrument that measures the current (in amperes) flowing through an
electrical circuit. It is typically connected in series with the circuit to be measured.

2. Voltmeter:

A voltmeter is a type of indicating instrument that measures the voltage (in volts) across an electrical circuit.
It is typically connected in parallel with the circuit to be measured.

3. Motor Protection Device (MPD):

A Motor Protection Device (MPD) is a specialized electrical device designed to protect motors from various
types of faults, such as overloads, overcurrents, overheating, and phase imbalance. MPDs can detect these
faults and interrupt the power supply to prevent damage to the motor. They often include features like
thermal overload protection, short-circuit protection, and phase-loss protection.

2.11.5 Contactors
A contactor is an electrical device that uses a low-power signal to control a higher-power circuit. It's essentially
a relay, but designed for heavier loads and higher currents. Contactors are commonly used in industrial and
commercial applications to control motors, lighting, and other loads

1. A low-power signal (typically from a control circuit or PLC) is applied to the contactor's coil.
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2. The coil energizes, causing the contactor's contacts to close.

3. When the contacts close, they connect the higher-power circuit, allowing current to flow to the load (e.g., a
motor).

4. When the low-power signal is removed, the coil de-energizes, and the contacts open, disconnecting the
load from the power source.

2.11.6 Relay
A relay is an electrical device that uses a low-power signal to control a higher-power circuit. It's essentially
an electrically operated switch that allows a low-power signal to switch a higher-power circuit on or off.

Control Relay:

A control relay is a type of relay used to control various electrical circuits, such as lighting, heating, or
motor control. It receives a low-power signal from a control device, like a PLC or timer, and uses it to
switch the higher-power circuit on or off.

Overload Relay:

An overload relay is a protective device that detects excessive current in a circuit and interrupts the power
supply to prevent damage from overloading. It monitors the current flow and trips (opens) the circuit
when the current exceeds a predetermined value, protecting the circuit and connected equipment from
damage.

Earth Leakage Relay (ELR):

An Earth Leakage Relay (ELR) is a safety device that detects earth leakage current (current leaking to
ground) in a circuit and interrupts the power supply to prevent electrical shock or damage. It monitors the
leakage current and trips (opens) the circuit when the current exceeds a predetermined value, ensuring
personnel safety and equipment protection.

2.11.7 Timers
Timers in a panel are devices that control the duration of electrical circuits or events. They are used
to automate various processes, sequences, and safety features in industrial, commercial, and
residential applications. Here are some common types of timers used in panels:

1. On-Delay Timer (TON): Turns on a circuit after a set delay period.

2. Off-Delay Timer (TOF): Turns off a circuit after a set delay period.

3. Interval Timer (INT): Turns on and off a circuit at set intervals.

4. Repeat Cycle Timer (RCT): Repeats a set sequence of on and off periods.

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5. Retarder Timer (RET): Delays the turn-off of a circuit after the input signal has been removed.

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2.11.8 Busbar
A busbar is a metallic bar or strip within an electrical panel that conducts electricity and provides a common
connection point for multiple circuits. It's a vital component in electrical distribution systems, allowing for
efficient and safe power distribution.

In a panel, busbars are typically made of copper or aluminum and are mounted on insulators to prevent
electrical shock. They can be arranged horizontally, vertically, or in a combination of both, depending on
the panel's design and application.

1. Top Entry Busbar:

In a top entry busbar, the electrical conductors (wires or cables) are connected to the busbar from the top
side of the panel. This means that the wires or cables enter the panel through the top and are then
connected to the busbar.

2. Bottom Entry Busbar:

In a bottom entry busbar, the electrical conductors are connected to the busbar from the bottom side of the
panel. This means that the wires or cables enter the panel through the bottom and are then connected to
the busbar.

2.12 Safety Standard in company

A safety standard is a set of guidelines, rules, or specifications that outline the minimum requirements for
ensuring safety in a particular context, such as an electrical workshop. Safety standards aim to protect
individuals from harm, injury, or illness by providing a framework for safe practices, procedures, and
equipment use.

- Insulated gloves: These are designed to protect against electrical shock.

- Arc flash gloves: These are designed to protect against electrical shock and arc flashes.

- Insulated matting: These are used in high-voltage areas and can be found in switchboards and transformers.

- Safety glasses: These are designed to protect the eyes from debris and other hazards.

- Earplugs: These are designed to protect the ears from excessive noise levels.

- Insulated tools: These are designed to protect against electrical shock.

- Arc flash face shields: These are designed to protect the face from arc flashes.

- Arc flash coveralls: These are designed to protect the body from arc flashes.

- Flame-resistant clothing: These are designed to reduce the risk of burns from arc flashes or fires.

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2.13 Selection of Busbar
The selection of a busbar in a panel depends on several factors, including:

1. Current rating: The busbar must be able to handle the maximum current required by the panel.

2. Voltage rating: The busbar must be suitable for the voltage rating of the panel.

3. Material: Busbars are typically made from copper, aluminum, or silver-plated copper. Copper is the most
common choice due to its high conductivity and durability.

4. Size and shape: The busbar size and shape must fit the panel's dimensions and layout.

5. Insulation: The busbar must be properly insulated to prevent electrical shock and short circuits.

6. Flexibility: The busbar may need to be flexible to accommodate panel movements or vibrations.

7. Corrosion resistance: The busbar material must be resistant to corrosion, especially in harsh environments.

8. Cost: The busbar selection must balance cost with performance and safety requirements.

The width of a busbar can be calculated using the following formula:

Width (W) = (Current (I) x 0.8) / (Conductor Material Constant (K) x Voltage (V))

Where:

- Current (I) is the maximum current expected to flow through the busbar

- Conductor Material Constant (K) is a value specific to the busbar material (e.g., copper, aluminum)

- Voltage (V) is the voltage rating of the busbar

For example, for a copper busbar with a current rating of 100A and a voltage rating of 240V:

Width (W) = (100A x 0.8) / (55 x 240V) ≈ 12.7mm

This calculation provides a minimum recommended width for the busbar. However, other factors like
thermal considerations, mechanical strength, and manufacturing limitations may require a wider busbar.

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2.14 Automation in Panel
Automation control panels are one of the most important pieces of equipment for any industrial facility. We
all know that machines and equipment across the industrial, manufacturing, and commercial sectors are
getting automated. At the same time, such automation must be monitored. That is where automation control
panels come into the picture.

2.14.1 What are the features and purpose of automation control panels?

They are used to monitor and control heavy-duty and large-scale machinery in industrial and commercial
applications. Automation control panels can perform both simple and complex processes by employing relays,
timers, sensors, starters, and controllers. The main advantage of automation control panels is that they
provide more control over the industrial equipment in a facility. One can enjoy the comfort of a hands-free
approach and experience high efficiency, functionality, and flexibility with automation control panels.

Convenient systems are everyone’s favorite. That is exactly what automation control panels offer. They offer
flexibility in modification of logic, have a reduced frame, and provide an edge over control of the various
automated equipment in the facility. They will also help in accomplishing tasks efficiently and with
impressive speed.

2.14.2 Types Of Automation Control Panels

Sectors that rely on consistent productivity and production greatly benefit from using automation control
panels. Industries belonging to manufacturing, mining, agriculture are only a few such sectors that rely heavily
on automation control panels. There are many varieties of automation control panels. PLC automation control
panels are of reduced size, flexible to use, are user-friendly, and are most reliable and efficient than other
convention automation control panels.

2.14.3 PLC Control Panels (Programmable Logic Controller)

Fig 2.13:- programmable logic controller

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These types of control panels have high efficiency and reliability. They are used to accomplish both simple and
complex processes. Though used for heavy-duty equipment, PLC control panels have a wide range of
applications. PLC control panels offer different options for a protocol which thereby increases their range of
applications in the industrial sector.

PLC control panels are designed in such a way that they deliver messages about the monitoring and
functionality of various equipment in the facility to the operator. PLC control panels can be integrated and
hence be enabled to provide data even remotely through different means. They can be customized as per your
needs and designed in a way to fit your specifications.

2.15 Testing and Commissioning

2.15.1 Testing

1). Physical Check

To confirm that the parts are connected properly and that a complete visual inspection was done, the included
checklist was used to record the findings.

2). Polarity Check

Verify the polarity of the switch & the threaded connections, and write the results on the provided format.

3). Continuity Check

All circuits’ continuity is verified with a multimeter, and it is made sure that the value of resistance is within
acceptable bounds.

4). Insulation Check

Check the insulation between wires using an insulation tester; if any is found, replace it right away.
Additionally, note the insulation resistance (IR) value for each circuit in the format that is attached.

5). ELCB and Polarity Test

Check the ELCB – Earth Leakage Circuit Breaker’s performance with an ELCB tester while using the
recommended current.

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Fig 2.14:- Testing of pannel

2.15.2 Commissioning
1. Installation Verification: Confirm correct installation and wiring.

2. System Integration: Connect the panel to the electrical system and verify proper operation.

3. Functional Testing: Perform comprehensive testing of the panel and connected equipment.

4. Performance Verification: Verify the panel's performance meets specifications and industry standards.

5. Documentation: Record test results, commissioning data, and maintenance instructions.

6. Handover: Transfer responsibility to the end-user or facility management team.

2.16 Installation of panel

The installation of an electric panel involves several steps, which are outlined below:

1. Prepare the site:

- Ensure a safe working environment

- Clear the area of debris and obstructions

2. Mount the panel:

- Install the panel on a suitable surface (e.g., wall, floor)

- Use appropriate mounting hardware (e.g., screws, brackets)

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3. Connect the incoming supply:

- Connect the main electrical supply to the panel

- Ensure proper wiring and termination

4. Install circuit breakers and fuses:

- Add circuit breakers or fuses to the panel

- Connect them to the appropriate busbars

5. Connect outgoing circuits:

- Run wiring from the panel to individual circuits

- Connect to devices (e.g., lights, outlets, motors)

6. Ground the panel:

- Connect the grounding system to the panel

- Ensure all equipment is properly grounded

7. Wire the panel:

- Connect all wires to the appropriate terminals

- Use wire nuts or connectors as needed

8. Test the panel:

- Verify proper voltage and current flow

- Test circuit breakers and fuses

9. Add labeling and documentation:

- Label circuits and components

- Document the panel's configuration and testing

10. Final inspection and commissioning:

- Verify the installation meets safety standards

- Commission the panel for operation

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Remember to follow local electrical codes, regulations, and industry standards (e.g., NEC, IEC) during
installation. It's also crucial to involve qualified personnel and ensure proper documentation and record-
keeping.

2.16.1 Problems in Installation of panel

Some common problems that may arise during the installation of an electric panel include:

1. Improper sizing: Incorrectly sized panels for the electrical load.

2. Inadequate wiring: Insufficient or poorly connected wiring.

3. Grounding issues: Improper grounding or missing grounding connections.

4. Overheating: Insufficient ventilation or overcrowding leading to excessive heat.

5. Moisture exposure: Panels installed in damp or wet locations without proper protection.

6. Incorrect connections: Miswired or loosely connected circuits.

7. Inadequate insulation: Insufficient insulation between conductors and phases.

8. Missing or damaged components: Lost or damaged parts, such as circuit breakers or fuses.

9. Poor mounting: Panels not securely fastened or mounted incorrectly.

10. Non-compliance: Installations that don't meet local electrical codes or regulations.

11. Arc flash hazards: Panels not designed or installed to mitigate arc flash risks.

12. Electrical shock hazards: Exposed live parts or inadequate safety features.

To avoid these problems, it's crucial to:

- Follow local electrical codes and regulations

- Use proper materials and components

- Ensure correct sizing and wiring

- Provide adequate ventilation and grounding

- Perform thorough testing and inspection

- Involve qualified and experienced personnel

- Document the installation and testing process

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Remember, a poorly installed electric panel can lead to safety hazards, equipment damage, and downtime.
Prioritize safety and proper installation practices to ensure a reliable and efficient electrical system.

2.17 Costing and Estimation

Costing and Estimation are very crucial for the growth and development of an industry as it determines the
overall cost of an project. JATSON has an dedicated team for the Estimation of the panel.

Estimation teams conduct various meeting with the client and also pay visit to the site where the installation
of the panel is to be made and also understands the special requirement of the client . After that they
conduct meeting with different departments within the organization like(production, design ,purchase etc )
then comeup with the final decision about the estimation of the panel.

The art of cost estimation lies at the heart of every successful venture, shaping competitiveness and
ensuring profitability. As control panel manufacturers grapple with an array of factors from material costs
to labor and overhead, breaking down the numbers becomes a meticulous process that demands both
expertise and a systematic approach.

2.17.1 Understanding the Foundations: Key Components of Cost Estimation

 Material Costs:
 The foundation of any control panel is laid with its materials. Breaking down
material costs involves a keen understanding of the pricing dynamics of
components such as wiring, connectors, and circuit breakers. Manufacturers must
track market fluctuations, explore cost-effective alternatives, and establish a robust
system for inventory management

 Labor Intensity:
 Control panel assembly is a labor-intensive process encompassing tasks like wiring,
mounting, and testing. Estimating labor hours requires an in-depth analysis of the
project’s complexity, the skill set of the workforce, and the potential for automation.
Recognizing the nuances of labor intensity is pivotal for an accurate breakdown of
costs.

 Overhead Allocation:
 Beyond direct costs, allocating overhead expenses is a critical aspect of cost
estimation. Facility costs, utilities, and administrative expenses must be distributed
fairly across projects. A systematic approach to overhead allocation ensures that
each project bears its proportionate share of indirect costs.

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2.17.2 Best Practices for a Precise Estimation Process
 Detailed Project Scoping:
 Thorough project scoping is fundamental for precise cost estimation.
Manufacturers need to understand client requirements, delve into the intricacies of
control panel designs, and anticipate any unique challenges that could impact costs.
A comprehensive project scope lays the groundwork for accurate estimations.
 Utilizing Historical Data:
 Historical data serves as a compass for cost estimations. Analyzing data from past
projects helps manufacturers identify patterns, learn from experiences, and
establish benchmarks. This iterative process enables continuous improvement
and enhances the accuracy of future estimates.
 Collaborative Cross-Functional Approach:
 Cost estimation is a collective effort that extends beyond the finance department.
Collaboration between engineering, production, and procurement teams is
essential. By gathering insights from different functional areas, manufacturers
ensure a holistic approach that considers all aspects of a project.

2.18 Panel Designing

Panel designing plays a vital role in reducing the overall cost of an project . thus an specific team makes
design of the panel using varios software such as.

-E3.panel: A software that allows users to layout components inside electrical panel enclosures in both 2D
and 3D. It also allows users to navigate between the panel and schematic and changes to either are
immediately reflected.

- Control Panel Design by Siemens Xcelerator : A software that allows users to design the main and control
current components and the power supplies with just a few clicks. It also provides a correct short-circuit
calculation and cable dimensioning.

Cost is always important, but so is an attractive appearance, simple operator controls and reliable
operation. Simple panel designs are less expensive to produce and easier to operate and maintain.It helps
when you understand design is a process. Often you think you know exactly what you want when you get
started and find you want something different when you’re done. When you first put your design
requirements on paper they seem unorganized. That’s normal. No one gets everything right in one pass.
Design is a process and it takes time to get it right. Rewrite your requirements until they’re properly
organized and clear. Understand what you want, write it down using clear language, then proceed with the
actual hardware design.

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2.18.1 Start physical
Good control panel design includes physical and electrical requirements. Don’t shortcut the design process
and produce schematic drawings without producing physical layout drawings. Alternate between the physical
and electrical until all potential problems have been solved.

Good control panel design includes accurate physical layout drawings and schematic drawings. This minimizes
problems and delivery delays due to unresolved physical layout problems discovered during production or
testing.
Include National Electric Code (NEC) required clearance for power wiring and Underwriters Laboratories (UL)
required clearance around heat producing devices.

 NEC requires bending radius clearance for incoming and outgoing power connections to insure
the installing electrician has adequate room to make their power connections,
 UL requires manufacturer recommended clearance for heat producing devices
(Programmable Logic Controllers, Variable Frequency Drives, etc.) to insure for adequate
room for ventilation.

Fig 2.15:- Design of circuit

2.18.2 Analysing the power circuit

Identify each power circuit and determine the required wire size and circuit protection. The right wire size
insures the circuit can deliver the required load current. The right circuit protection insures the wiring doesn’t
overheat and start a fire.

 Select power wire size based on load current

 Select power circuit protection based on wire size.
Then determine the best power component type to use based on function and select the right size based
on voltage and load current. The right type insures it’ll function as desired and the right size insures it’ll
reliably handle the load.

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Fig 2.16 :- power circuit

2.18.3 Use the best control type

Always start with simple control components (Relays, Timers, etc.) When simple does’t get the job done, use
something with more functionality like a programmable Smart Relay or a Programmable Logic Controller (PLC).
These provide significantly more functionality, but they also require a computer and programming software
and someone who knows how to program the desired functionality.

2.18.4 Use the best operator device type

Always start with simple operator devices (Pushbuttons, Pilot Lights, Digital Panel Meters, etc.). For a stylish
appearance add a Color Graphic door laminate. When simple does’t get the job done, use a color touch screen
display as the Human Machine Interface (HMI). This provides significantly more functionality, but it also
requires a computer and programming software and someone who knows how to program the desired
functionality.
Some control panel designers start with a Human Machine Interface (HMI). Sometimes an HMI is the way to
go, but you should always use the simplest operator device type appropriate to the application.

2.18.5 use the best in class products by category

Experienced control panel designers use the best in class products by product category. This is subjective
based on product awareness. Experienced control panel designers are aware of the array of products available
in a product category. This allows them to compare and use products that provide the best balance of price,
form and function.
Some control panel designers try to use one manufacturer for all components in a panel. European companies
tend to do this and some US companies do too. Sometimes there’s a reason why this makes sense, but
generally it limits your ability to use best in class products by product category.

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CHAPTER 3:- REFLECTION
NOTE
3.1 TECHNICAL OUTCOMES
An internship in JATSON POWER PVT LTD has provide valuable technical outcomes, including:
1. Hands-on experience with industry-standard equipment: Familiarity with tools
and machinery used in panel manufacturing, such as CNC machines, laser cutters, and
printing equipment.
2. Understanding of manufacturing processes: Knowledge of the entire production
process, from design to assembly, including quality control and testing procedures.
3. Material science and engineering principles: Insights into the properties and
applications of various materials used in panel manufacturing, such as metals, plastics, and
composites.
4. Electrical and electronics fundamentals: Understanding of circuit design, wiring,
and electrical systems, depending on the type of panels manufactured (e.g., control
panels, electrical panels).
5. Quality control and assurance procedures: Familiarity with quality management
systems, testing protocols, and certification standards (e.g., ISO 9001).
6. Design for manufacturability (DFM) principles: Insights into designing products for
efficient manufacturing, including design optimization and prototyping.
7. Collaboration with cross-functional teams: Experience working with engineers,
technicians, and production staff to develop and improve manufacturing processes.
8. Problem-solving and troubleshooting skills: Development of analytical skills to identify
and resolve technical issues in the manufacturing process.
9. Familiarity with industry-specific software and technologies: Exposure to
specialized software, such as CAD/CAM systems, and technologies like automation
and robotics.
10. Enhanced technical communication skills: Ability to effectively communicate
technical information to both technical and non-technical stakeholders.

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3.2 PERSONALITY DEVELOPMENT

My personality development outcomes include:

- Improved communication skills through interactions with colleagues
and supervisors
- Enhanced teamwork and collaboration skills through group projects and tasks
- Developed adaptability and flexibility in a fast-paced industrial environment
- Increased confidence and self-belief through achievement of tasks and goals
- Improved problem-solving and critical thinking skills
- Developed a growth mindset and a willingness to learn from failures
- Enhanced time management and organizational skills
- Improved leadership skills through mentorship and guidance of junior interns
- Developed a stronger work ethic and sense of responsibility
- Improved ability to receive and act on feedback and constructive criticism
These personality development outcomes have helped me become a more
wellrounded and capable individual, prepared

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3.3 TIME MANAGEMENT

My time management outcomes include:

- Prioritizing tasks and managing workload effectively
- Meeting deadlines and delivering results on time
- Minimizing procrastination and staying focused on tasks
- Optimizing my daily routine for maximum productivity
- Using tools like calendars, to-do lists, and timers to stay organized
- Learning to say "no" to non-essential tasks and commitments
- Batching similar tasks together to reduce switching costs
- Taking regular breaks to recharge and avoid burnout
- Adapting to changing priorities and adjusting my schedule accordingly
- Reducing time-wasting activities and staying on track with goals
These time management outcomes have helped me become more efficient,
productive, and effective in my work and personal life.

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3.4 SKILLS DEVELOPED
During the duration of my internship in JATSON POWER I develop following skills:-
1. Technical skills:
- Proficiency in panel macufacturing(MCC,IMCC,PCC,ABFC),designing,estimation,purchase.
- Understanding of electrical and electronics fundamentals.
- Familiarity with materials science and engineering principles.
2. Problem-solving skills:
- Analytical thinking to identify and resolve technical issues.
- Troubleshooting and debugging techniques.
3. Communication skills:
- Effective communication with cross-functional teams (engineering, production,
quality control).
- Clear and concise reporting of technical information.
4. Project management skills:
- Assisting in project planning, execution, and delivery.
- Coordinating with teams to meet project timelines and goals.
5. Collaboration and teamwork:
- Working with diverse teams, including engineers, technicians, and production staff.
- Building strong relationships with colleagues and mentors.
6. Time management and organization:
- Prioritizing tasks and managing time effectively.
- Meeting deadlines and delivering results in a fast-paced environment.
7. Adaptability and flexibility:
- Adjusting to new situations, challenges, and technologies.
- Willingness to learn and take on new responsibilities.

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8. Attention to detail:
- Ensuring accuracy and quality in work outputs.
- Identifying and correcting errors.
9. Leadership and initiative:
- Taking ownership of projects and tasks.
- Demonstrating leadership skills and mentoring junior team members.
10. Professionalism and work ethic:
- Developing a strong work ethic and professional demeanor.
- Demonstrating a commitment to safety, quality, and continuous improvement.

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CHAPTER 4:- CONCLUSION
My internship at JATSON POWER PVT LTD has been a transformative
experience that has provided me with invaluable industry experience, technical
knowledge, and personal growth. I have gained a deeper understanding of
electrical and instrumentation systems, developed practical skills in problem-
solving, communication, and teamwork, and built a network of professionals in
the field.

I am grateful for the opportunities provided by JPPL and the guidance and
support received from my supervisors and colleagues. I am confident that the
skills and knowledge gained during this internship will enable me to make a
meaningful contribution to the industry and achieve my career goals.

I recommend this internship to any student or young professional seeking to gain

practical experience and build a strong foundation in the industry. Thank you to
JPPL for this opportunity, and I look forward to staying connected and
contributing to the company's success in the future.

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