Published by : International Journal of Engineering Research & Technology (IJERT)

http://www.ijert.org ISSN: 2278-0181

Vol. 9 Issue 04, April-2020

Design, Assembly and Quality Testing of Feeder

Panel
1
Palaash Pandit, 2Kaushal Patel
1
B.Tech Student, 2Assistant Professor,
Department of Electrical Engineering,
Indus University, Ahmedabad, Gujrat, India

Abstract— To design the feeder panel according to the load and done by the Q.C and the panel is dispatched for the
requirement of the consumer preparing the general installation at the site.
arrangement diagram and the wiring diagram. According to the III. DESIGNING
general arrangement assembling of Bus bars, Circuit breaker The designing is the first step of the production of the panel
and MCCB. Also drawing of wire for the control of the panel
and for the power to the control circuit. Quality testing for
for designing there are some components that are necessary
checking for the requirement to be achieved for the consumer. for it the following are as below:-
➢ The requirement sent by the receiver of the panel
Keywords— Designing, Assembling, Quality testing. ➢ The single line diagram including incoming line
outgoing line for the applications
I. INTRODUCTION ➢ The make list for the components to be used
The feeder panel is used for the distribution of the power for ➢ The rateing of the I/P lines and the applications
different uses and as per the requirement of consumer. It is
also used for the interconnection between the different supply After receiving the above information we should start the
and also synchronism with the diesel generator sets as the design process as per the requirement sent by the consumer.
backup supply. The feeder panel generally consists of We the designer decide the placement of the bus bar as per
MCCB’s for the distributions to the output ranging from the space available for the panel installation and the quantity
16Amp to 630Amps and the ACB’s for the incoming lines of the bus bar as per the cost of the production of the panel.
and the output ranging from 630Amp to 3200Amp. For The following are the different placements of the bus bar:-
controlling of the panel we use the Contactors, push buttons, ➢ Overhead Bus bar single tier Circuit breaker
selector switches as per the requirement. With all the ➢ Mid Bus bar single tier Circuit breaker
controlling and power components for the manipulation of ➢ Overhead Bus bar double tier Circuit breaker
the supply indication and metering are also installed in the
panel like light bulbs for different applications and with the The Mid bus bar single tier circuit breaker arrangement is
Voltmeters, Ampermeters, MFM, CT’s, etc. generally used were the space is less required for the
The following are the General sections of a feeder installation of the panel and also were there is an issue of the
panel:- cost because the quantity of the bus bar is used less
➢ Incomer section (TR)
➢ Bus-coupler section (BC) I. Outer shell of the panel
➢ Output section (O/P) ▪ After deciding the placement of the bus bar
according to the usage of the space the designer
In above general sections of the feeder panel the design the outer shell of the panel and the main part
Bus-coupler section is been the removed or of the outer shell is the box fabricated for the
added more as per the application or the number installation of the circuit breaker to be placed and
of incoming sections installed in the shell the dimension of the box is as
per the IEC standard the table show the standard
II. GENRAL OVER VIEW
used:-
The design of the feeder panel starts from the requriments ▪ Front cable alley (MCCB)
and Single line diagram sent from the consumer. The work
starts from the making list of the components, designing of Ampere rating Dimension of the box
the shell of the panel (fabrication) and electrical designing, to (mm*mm)
be used to meet the requirement of the consumer. After the 630Amp 400*400
Fabrication is completed as per the design, the assembling of 400Amp 400*400
320Amp 400*400
the components is been completed component like MCCB’s,
280Amp 300*300
Circuit breakers, Meters, Indications for Phases(R, Y, B), 100Amp 300*300
Current transformers. The wires are drawn for metering, 80Amp 300*250
Control Circuit, Power Circuit. After the completion of the 16Amp 300*250
assembling of the panel the Quality testing of the panel is

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http://www.ijert.org ISSN: 2278-0181
Vol. 9 Issue 04, April-2020

▪ Rear cable alley (MCCB)

Ampere rating Dimension of the box

(mm*mm)
630Amp 600*400
400Amp 600*400
320Amp 600*400
280Amp 450*300
100Amp 450*300
80Amp 450*250
16Amp 450*250

▪ Air break circuit

Ampere rating Dimension of the box

(mm*mm)
630Amp 700*700
800Amp 700*700
▪ MCB
3200Amp 1000*700
4000Amp 1000*700 The MCB box is to be selected as the number of the
5000Amp 1200*700 MCB’s the following is the common size to be used
6300Amp 1200*700 the height of the box is fixed to the 250mm but the
The above tables are of the standard used for the width will increase as the quantity. If there are 2
design of the outer shell and the width of the panel. MCB’s the width selected is 300mm and the width
The above dimensions are without any metering and will increase as the quantity like 3 MCB’s the width
with basic indications like on off status indication. will be increased to 400mm.
The dimensions will change and will be increased Now if the line of the MCB is increased the height
with addition of the meters, selector switches and for 2 line will be 400mm, 3line will be 550mm and 4
extra indication of status. line will be 700mm. The line of the MCB should not
be more then 4 line it is the general rule for the
switch board using MCB’s.
II. Selection of the Bus Bars
As we have decided the location of the bus bar in the panel
we have to select the bus bar as per the requirement and the
current capacity of the panel.
The Bus Bars could be of 2 types:-
I. Copper
II. Aluminum
▪ Thumb rule
For Aluminum:-0.8Amp/1Sq mm of bar
For Copper:-1.6Amp/1Sq mm of bar
▪ Points to be consider while doing sizing
calculation
➢ Adequate minimum required clearance
between 2 phases and phase to earth.
➢ Selection of adequate bus bar insulator
standoff.
➢ Bolting arrangement for continuous bus bar
connections.
➢ Thermal effects on bus bar and insulator
standoffs under normal and fault condition.
➢ Electrodynamic forces applied to bus bar
and insulator standoff under fault
conditions.
➢ Avoidance of mechanical resonance under
normal operating and fault conditions.
▪ Temperature rise
Maximum permissible temperature rise for
bolt connected devices including bus bars.

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Vol. 9 Issue 04, April-2020

MATERIAL AND MAXIMUM III. Wiring of the panel

DIELECTRIC PERMISSIBLE The feeder panel consists of 2 type of wiring as
MEDIUM TEMPERATURE (OC)
Bolted connection follows:-
Bare copper, Bare ▪ Control wiring.
copper alloy, Bare ▪ Power wiring.
aluminum alloy
In air 90oC The wiring is been design as per the requirement of the
In Sf6 115oC
In oil 100oC
consumer. The control wiring includes the indication and
▪ Consider ambient temperature of 40oC. metering of the panel, the bus coupler wiring is also
▪ Source reference:-IEC 62271-1 important and the auto manual operation selector wiring is a
▪ The general equations that is used for the sizing part of the control wiring. The power wiring includes the
Co-efficient factors ‘K’ wiring of the control feeder for the power the wires are
generally taken from the bus bar.
The Total ‘K’ factor derived from six ‘K’ factors,
Which is listed below

▪ K = K1*K2*K3*K4*K5*K6
▪ K1=Function of the No. of Bars Per phase
and their space
▪ K2=Corresponds to the surface finish of the
bus bars
▪ K3=Function of the mounting arrangement
▪ K4=Function of the installed location
▪ K5=Function of any artificial ventilation
▪ K6=Function of the type of current

Rated current I = Total ‘K’ factor * Main

Formula

▪ Bus Bar clearances Figure:- Bus coupler wiring diagram

Voltage (V) Phase to Phase Phase to Earth
Clearance (mm) Clearance (mm)
415V 19 16
600V 25 19
11000V 127 77

▪ Requirement of the consumer

Breaker size needed- 1250Amp ACB
Transformer secondary full load current
=1066.72Amp

▪ According to thumb rule

➢ For copper:-1.6Amp/1Sqmm of Bar
For area 800Sq.mm [80*10mm] the current
carrying capacity will be 1280Amp

So, according to formula as per IEC-62271- Figure:- Bus bar arrangement for bus coupler
1
▪ K = K1*K2*K3*K4*K5*K6 ▪ The above figure shows the wiring diagram
K = 1*1*1*0.8*1*1 of the bus coupler it is used to satisfy the
=0.8 conditions of interlocking.
Rated current I = Total ‘K’ factor * Main ▪ The below table shows the interlocking conditions
Formula (Auto/Manual) for the above shown bus coupler.
1250Amp=0.8*Main Formula TR-1 DG-1 BC TR-2 DG-2
Main formula derived value will be = ON OFF ON OFF OFF
OFF ON ON OFF OFF
1562.5Amp OFF OFF ON ON OFF
Rated Current=0.8*1562.5 OFF OFF ON OFF ON
=1250Amp ON OFF OFF OFF ON
OFF ON OFF OFF ON
▪ To carry the current of 1066.72Amp one ON OFF OFF OFF ON
OFF ON OFF ON OFF
runner of 80*10 mm of copper is enough.

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Vol. 9 Issue 04, April-2020

▪ The auto manual indicates the breaker interlocking the panel in auto or manual mode. The
would be operated by the push buttons in contacts of the ACB are being also connected as per
case of manual operations and in case of the wiring diagram. The connection of the CT’s is
auto operation the breaker operates by the been done to the meter for the metering of the panel.
supply to the breaker directly and if the ▪ There are some extra accessories to the ACB and
selector switch is on the auto and the MCCB from its already included parts some of the
breaker should not operate by the push parts are mentioned below.
buttons. I. Secondary isolating contact and electrical
▪ This is the last step for the designing after position indicator and cradle secondary
this step the fabricators start the fabrication isolating contact block.
work as per the approved drawing of the II. Volt-meteric releases for U-power ACB
outbox (Shell). III. Closing coil for U-power ACB
IV. Assembly IV. Mechanical type door inter lock
▪ Installation of the equipment in the shell V. Operation counter for U-power ACB
finished with powder coating and ready to ▪ There are also some Supplementary modules used to
be assembled. The breakers are been provide addition protection to basic protection and
installed in 2 parts the cradle case and the control circuit are listed below
contacts box. When the installation of the ▪ ZSI module
ACB and MCCB is been completed the bus ▪ PS module
bar are been sent for the making as per the ▪ AO module
design. The fabrication of the bus bar is ▪ DIO module
been done in some steps. ▪ Relay module
▪ The following steps shows the steps of the ▪ TCS module
bus bar fabrication:- ▪ EL module
I. Selecting the size of bus bar as per ▪ REF module
the specifications of the design. ▪ The earthing strip is been installed at the bottom of
II. Measuring the length of the bus the panel made of copper generally the green wire is
bar and marking the bends. been connected between the door and the frame of
III. Making any one bus bar for the panel as earthing.
checking the accessibility in the • Quality Testing
bus duct and to the ACB or ▪ The last process of the panel fabrication is to check
MCCB. the panel meets the requirement of the consumer.
IV. Approving the bus bar by the There are some test listed below for checking the
designer as a sample if not change quality of the panel after the process of assembly is
in bend and change in length if been completed.
any changes needed from the • Verification of Bill of material as per
designed bus bar. approved GA drawing
V. Approved from the designer • Overall dimensions as per approved GA
making of the same sets for all 3 drawing
phases as per the approved • Tightness of bus bar joints and pull test of
sample. crimping of lugs (on random basis)
VI. Fitting the bus bar in the panel • Provision of partitions and shrouds &
with the help of supporters and effectiveness of safety shutters
spacers as the specified area. • Electrical clearances and creepage distance
VII. Tighten the face plate and connect
• Earth continuity / earthing system
the bus bar sections with each
• Operational test as per scheme drawing
other connecting the bus couplers
• Wiring check as per scheme drawing
with the other 2 sides of the bus
coupler. • Phase sequence / Polarity check
Checking the tightness of the all the parts of the bus bar • Overall appearance and surface finish
connected with the bolt and nut. • Verticality of panels
• Wiring:- • Waviness of doors etc.
The wiring is the most important part of the panel • Neatness of wiring
because the controlling of the panel and some low • Accessibility & adequacy of space for
power transmission is also done through wire. The external cabling / wiring termination
control wiring is usual done with 2.5 Sq mm copper • Insulation resistance
wire or the 1.5 Sq mm copper wire. We have to • High voltage test
draw the wire as per the designed diagram in the • Dry film thickness test
panel and select the wire as specified by the • CT polarity test
designer. The contactors are used for the • Bus bar joint resistance test

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Vol. 9 Issue 04, April-2020

• Temperature rise test

▪ Testing of metering and indication ▪ High voltage test
▪ The supply is given to the control indication and This test also requires a HV testing kit the supply of
metering circuit through MCB board the glowing of 1.5kv to 2.5kv AC 50Hz is given for 10 seconds
lamp, volt meter, ampere meter and setting of MFM between any terminal and mounting plate
meters by installing the CT ratio in the meter.
Testing of breaker operation
The supply is given to the breaker and the operation
of opening and closing was performed multiple
times. The breaker should perform the tripping and
connecting operation successfully without any
problem. At the time of trip condition the current
should be zero and in the connected condition rated
current must be noted.
▪ Testing of interlocking condition
The panel is given supply and by selecting the
manual mode the ON-OFF condition of the breaker
would be checked as the table. The condition should Fig:-High voltage tester
be satisfy in any mode the breaker in a interlock ▪ Temperature rise test / Short circuit test
condition should not be operated like if TR-1 is in This test requires Auto transformer, low voltage
off condition and the interlock condition is satisfy high current transformer, bus bar assembly, bus bar
then the TR-1 should not be turned on in any mode. short link. The mentioned apparatus are been
connected to the panel. The main bus bar is been
▪ Contact resistance test short from one end by the BB short link and another
This test is performed by the contact resistance kit. is been connected to the LVHI transformer and
The kit has an auto transformer and a resistance given supply for 4 hours. During this test it is
meter like meggar to get the resistance between the essential to keep the breaker at the SC end to be
contacts of a bus bar with another contact of the bus connected and other breaker to be disconnected the
bar with the face plate in the connection between 2 temperature of bus bar should not exceed 90oC at
contact. The resistance should not be more then any point of time as specified in the IEC standards.
0.2micro-ohm. The below table shows the reading of temperature
rise test:-

Fig:-Contact resistance meter

Time First connection ACB TOP ACB BUTTOM HBB END
o o o o
C C C C
14:00 36 38 35 36 37.6 36.7 32.3 34.7 35.5 29.4 33 29.4
14:30 51.7 52.3 44 43.6 47.5 48.5 36.3 42.2 45.3 29.9 33.5 30.1
15:00 57.6 59.8 50 50.5 55 53.9 39.4 46.3 48.9 30.9 41.7 30.8
15:30 65.4 65.7 54.8 56.5 60.9 61.6 40.7 48 56 37.8 46 31.7
16:00 66.9 70.4 58.6 60.8 64.1 64.5 41.7 48.9 52.2 33.5 49.8 33.2
16:30 67.9 71.8 59.9 61.8 65.5 68.2 43.8 51.9 54.3 35.6 51.8 35.5
17:00 69.2 73.5 61.5 64.3 67.5 69.5 45.9 53.7 56.4 37.9 53.5 37.2
17:30 70.1 74.5 62.5 65.9 68.5 71.5 46.5 54.9 57.3 38.5 54.3 37.7
18:00 70.2 74.6 62.6 70 68.6 71.6 46.6 55 57.4 39 54.7 37.9

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Vol. 9 Issue 04, April-2020

The maximum temperature reach after 4 hours is 74.6oC and

is are under 90oC. The ambient temperature was 30oC.

Fig:-(C)
Fig:-(A) Figure: - (A) Bus bar short circuit link
Figure: - (B) Arrangement of the equipment for the
test
Figure: - (C) Display for the kit

• CONCLUSION
This paper has described the process of building
Feeder panel from designing of the panel to the
testing of panel. This paper also includes the
designing parameters to be considered will
designing of any rating of feeder panel. We can
build any rateing of feeder panel with help of above
given data.
• REFERENCES
[1] International Electrotechnical Commission 62271-1:2017. High
voltage switch gear and control gear – part 1: common specifications
for alternating current switchgear and control gear.
[2] International Electrotechnical Commission 62271-102:2018. High
Fig;-(B) voltage switch gear and control gear – part 100: Alternating current
disconnectors and earthing switches.
[3] International Electrotechnical Commission 62271-103:2011. High
voltage switch gear and control gear – part 103 switches for rated
voltages above 1Kv upto and including 52Kv.
[4] Shiv Shakti Engineers – Technical support for designing, installation
and testing of all parameters
[5] Switch gear manual, L&T switch gears, U-POWER ACB- UW-
MTX3.5

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