كل ما تحتاج معرفته عن مجال الـ Panel Builder | التدريب الصيفي لـ EPE 2023

Introduction to Engineering Activities and Training

Overview of the Session

• The session is led by Engineer Mohamed Sharaf El-Din from API Group, focusing on a workshop about panel building.

• Topics include an introduction to panel building, market insights in Egypt, and detailed discussions on manufacturing panels.

Panel Building Fundamentals

• Discussion on the classification of roles within electrical engineering related to panel building: sales engineer, tender engineer, design, quality control, material control, and production.

• Emphasis on understanding standards governing panels and their classifications.

Understanding Panels

What is a Panel?

• A panel is described as an enclosure that houses various components like circuit breakers for protection against current surges.

Functions of Panels

• Panels provide protection against overload currents and allow for isolation during maintenance operations.

• They also facilitate control over devices such as motors by integrating specific controls within the panel.

Components Inside Panels

Materials Used

• Copper is primarily used in panels due to its excellent conductivity properties compared to aluminum.

Accessories Included

• Common accessories found in panels include ammeters for measuring current and voltmeters for voltage measurement. Digital power meters may also be included for comprehensive monitoring.

Classification of Panels

Types Based on Voltage

• Medium voltage switchgear operates at voltages like 11kV or 22kV while low voltage switchgear handles up to 1000V.

Distribution Hierarchy

• Explanation of distribution boards (MDB), sub-distribution boards (SMD), and final branch boards (FB). Each serves a specific role in distributing electricity throughout a facility.

Emergency Power Systems

Importance of Emergency Distribution Boards (EMDB)

• EMDB ensures critical loads remain powered during outages by connecting directly to generators when main power fails.

Automatic Transfer Switches (ATS)

• ATS manages the transition between normal power sources and emergency generators automatically during outages.

Power Factor Correction

Understanding Power Factor

• Active power is the useful work done; reactive power does not perform work but is necessary for maintaining electric fields in inductive loads like motors.

Role of Power Factor Correction Equipment

• Capacitors are used in correction equipment to improve efficiency by reducing reactive power drawn from utilities. This helps avoid penalties from utility companies due to poor power factor performance.

Distribution System Insights

Relationship Between Load Types

• The discussion emphasizes how different load types affect overall system performance and efficiency.

Conclusion

This structured overview captures key concepts discussed throughout the session regarding electrical engineering practices related to panel building, emphasizing practical applications within industry standards.

Overview of Electrical Panels and Their Construction

Types of Electrical Panels

• The discussion begins with the distinction between two main types of electrical panels: Panel Boards (small boards) and Switch Boards (larger boards).

• Panel Boards are described as smaller units, while Switch Boards are larger and can accommodate more circuit breakers.

Features of Fish Bone Panel

• A specific type of panel called Fish Bone Panel is introduced, characterized by its copper layout resembling fish bones, allowing for branching circuits to the left and right.

• The design allows for increased height as more circuit breakers are added, emphasizing the vertical distribution of power.

Modular Design in Switch Boards

• The modular aspect is highlighted where circuit breakers can be arranged horizontally on a rail system known as DIN Rail Module, contrasting with the vertical arrangement in Fish Bone Panels.

Single Line Diagram Explanation

• A single line diagram is presented for a switch board that includes multiple large circuit breakers, illustrating how power flows through these components.

Circuit Breakers and Power Distribution

Functionality of Circuit Breakers

• Circuit breakers serve to protect circuits by controlling power flow; they act as switches that can turn on or off based on load requirements.

Power Feeding Mechanism

• The mechanism involves feeding power from a main busbar to various loads via cables connected to each circuit breaker.

Vertical Busbars Explained

• Vertical busbars distribute power vertically within the switchboard, ensuring efficient energy transfer to different sections.

Differences Between Main and Vertical Busbars

Understanding Busbar Functions

• Main busbars connect different cells within a switchboard while vertical busbars distribute energy downwards to outgoing circuit breakers.

Common Practices in Street Panels

• It’s common practice in street panels to include fuses or regular circuit breakers depending on local standards; this varies across regions like Egypt.

Practical Demonstration: Converting Diagrams into Real Panels

Transitioning from Diagrams to Physical Panels

• A practical demonstration shows how a single line diagram is transformed into an actual physical panel setup, focusing on utilizing vertical space effectively.

Assembly Process Overview

• The assembly process involves arranging frames, installing circuit breakers, and connecting copper bars according to design specifications.

Role of Panel Builders in Electrical Engineering

Definition of Panel Builders

• Panel builders are companies licensed by original manufacturers (OEM), such as ABB or Schneider Electric, allowing them to assemble and sell electrical panels using OEM components.

Importance of Original Equipment Manufacturers

• OEM companies provide essential designs and components necessary for building compliant electrical panels.

Integration with Automation Systems

Connection Between Electrical Panels and Automation

• There’s a significant relationship between electrical panels (like control gear panels), which manage automation systems effectively through integrated controls.

Roles Within Electrical Engineering Projects

Sales Engineer Responsibilities:

• Sales engineers play crucial roles in acquiring new projects by negotiating prices with clients based on project specifications.

Tendering Process:

• Engineers involved in tendering assess project costs based on detailed requests for quotations (RFQs), including material quantities needed for construction.

Design Phase:

• Once an order is confirmed, design engineers create detailed drawings that specify dimensions and component placements required for manufacturing.

Quality Control Measures

Testing Procedures:

• Quality control engineers ensure compliance with standards during production through routine tests followed by acceptance tests conducted by external committees before final delivery.

Understanding the Evolution of IC Design and Testing

The Transition from 60 439 to 61 439

• The original IC for circuit boards was known as 60 439, a number familiar to professionals in the field. The updated version is now referred to as 61 439, indicating significant modifications.

• Previously, the IC distinguished between boards produced by original manufacturers and those from assemblers using different naming conventions: "Type Test Assembly" for original and "Partial Type Test Assembly" for assembler outputs.

Testing Methodologies Explained

• Original manufacturers conduct extensive design tests called "Type Tests," which are destructive tests assessing maximum tolerances such as current capacity and thermal limits.

• Routine testing is performed on all assembled boards under operational conditions, ensuring functionality without destruction. This contrasts with type testing, which is only done once per board type unless significant changes occur.

Changes in Testing Terminology

• The new standard has eliminated the term "Type Test," replacing it with "Design Verification." This reflects a shift towards more flexible verification methods beyond just destructive testing.

• Verification can now include calculations or comparisons with existing designs rather than solely relying on physical tests.

Importance of IP Ratings

• IP (Ingress Protection) ratings indicate how well a board can withstand dust and water exposure. The first digit represents dust protection (0-6), while the second digit indicates water resistance (0-8).

• An IP rating of IP68 signifies total protection against dust and immersion in water, making it one of the highest standards available.

Mechanical Impact Resistance (IK Rating)

• IK ratings measure a board's ability to withstand mechanical impacts. For example, an IK10 rating means it can endure impacts from weights up to 5 kg dropped from heights of up to 40 cm.

Circuit Breaker Functionality

• Low voltage circuit breakers protect devices against overload currents or short circuits. Overload refers to minor increases in current that require time to disconnect safely.

• Short circuits create immediate high currents that necessitate instant disconnection; thus, circuit breakers must respond quickly during these events.

Understanding Renard Series in Circuit Breakers

• Circuit breaker ratings follow the Renard series—a systematic method for selecting values that minimizes error margins when choosing appropriate breaker sizes based on load requirements.

This structured approach provides clarity on key concepts discussed throughout the transcript while maintaining chronological order and relevance.