UNIVERSITY OF MORATUWA

Faculty of Engineering

Registered Module No: EE3993

INDUSTRIAL TRAINING REPORT

Ceylon Electricity Board

Lanka Electricity Company (Pvt) Ltd
IPD Colombo (Pvt) Ltd

From 03/01/2023 To 23/06/2023

Date of Submission:
31/07/2023

Aponso J. H.
190045B
Department of Electrical Engineering
Preface

This is the final report of the industrial training program which I have undergone for 23 week
period at three training establishments. In this report I have mentioned the knowledge and the
experiences I obtained within my industrial training period, under three main chapters.

The first chapter is an introduction to the training establishments. It contains information about
those training establishments, their main functions, organizational structure and SWOT analysis
on the present performance of each training establishment. Further, I have discussed the usefulness
of those establishments to the country and the suggestions to improve their performance along
with the obstacles they have to be faced when achieving those objectives.

The second chapter includes the training experiences I gained within my training period. I have
explained the work carried out, duties and responsibilities assigned during the training, in this
chapter. Both technical and management experiences I acquired by completion of assigned tasks
are presents in detail here. The problems and difficulties encountered during the training period
along with the solutions found for solve them are also includes in this chapter. So this chapter is a
full reflection of my training experience in industry.

The third chapter is the conclusion on the entire training program. In this chapter, I have included
the information about each training establishment’s ability to provide useful training, the training
personnel of those establishments and their enthusiasm to provide proper guidance to the trainees,
according to my own experiences. Further, I have mentioned the weaknesses and deficiencies of
those establishments and my suggestions to improve their training programs to provide a better
training for the future trainees. Finally, I have included my comments on the overall industrial
training program and suggestions for further improvements .

1
Acknowledgement

Training period was a golden opportunity for me to experience how the industry operations
differ from what we have learnt in the university. There were so many people behind my success
of the training period. They should be properly acknowledged for the valuable contribution and
support.

My heartfelt gratitude goes towards the Industrial Training Division of the University of
Moratuwa as well as the NAITA (National Apprentice & Industrial Training Authority) for
attempting to make every one of the required assistance to guarantee the success of such a training
session as well as providing us with the opportunity to acquire in-plant apprentices at CEB (Ceylon
Electricity Board), LECO (Lanka Electricity Company (Pvt) Ltd), and IPD Colombo Sri Lanka.

Initially, I'd also want to thank the Director of Industrial Training Division for making the
required preparations well with training institutions for us to receive an outstanding learning
environment I'd want to thank our department training coordinator, Dr. Manuja Gunewardana, for
every one of his assistancesas well as collaboration. Eng. Chandani of CEB Training School from
Piliyandala should be thanked regarding her professional guidance throughout the training phase.

Secondly, I like to thank Lanka Electricity Company for giving this wonderful opportunity. Then, I like
to appreciate the chief engineers and all the engineers and staff for helping us to learn about the Lakvijaya
power plant. I would like to mention M.G.S.G. Karunarathna, chief engineer of Uma Oya Project for providing
us support to learn about Uma Oya power plant. I would like to thank Chief Technical Officer Eng. Arjuna
Jayadarshana and the training supervisor Eng. S. Epasinghe of IPD Colombo (Pvt) Ltd, along with Eng. J.
Indrajith the intern’s supervisor, Eng. S.Ranaweera, Eng. U.Gammanpila, and all other engineers in IPD for
providing guidance and sharing their knowledge to make my training successful.

2
Contents
Preface ........................................................................................................................................................................1
Acknowledgement ......................................................................................................................................................2
List of Figures .............................................................................................................................................................5
List of Tables ..............................................................................................................................................................6
Abbreviations ..............................................................................................................................................................7
Section 1 .........................................................................................................................................................................8
1 Introduction to Training Establishment .............................................................................................................8
1.1 Ceylon Electricity Board.............................................................................................................................8
1.1.1 Introduction ...............................................................................................................................................8
1.1.2 Vision and Mission ...................................................................................................................................8
1.1.3 Strengths of CEB ......................................................................................................................................9
1.1.4 Weaknesses of CEB ..................................................................................................................................9
1.1.5 Opportunities for CEB ..............................................................................................................................9
1.1.6 Threats for CEB ........................................................................................................................................9
1.2 Lanka Electricity Company (PVT) Limited ...........................................................................................10
1.2.1 Introduction ..................................................................................................................................................10
1.2.2 Vision and Mission ......................................................................................................................................10
1.2.3 Main Functions ............................................................................................................................................11
1.2.4 Strengths of LECO.......................................................................................................................................11
1.2.5. Weaknesses of LECO .................................................................................................................................11
1.2.6 Opportunities for LECO ..............................................................................................................................11
1.2.7 Treats for LECO ..........................................................................................................................................11
2 Training Experience.........................................................................................................................................12
2.1 Ceylon Electricity Board...........................................................................................................................12
2.1.1 Transmission Construction Project .........................................................................................................12
2.1.2 Victoria Power Plant ...............................................................................................................................15
2.1.3 Lakvijaya Power Plant ............................................................................................................................19
2.1.4 Protection Branch and System Control ...................................................................................................22
2.1.5 Kelanitissa and Sapugaskanda Power Plants ..........................................................................................23
2.2 Lanka Electricity Company (PVT) Limited ...........................................................................................25
2.2.1 LECO Training Center Ja-Ela .................................................................................................................26
2.2.2 LECO Branch Office (Nugegoda) ..........................................................................................................26
2.2.3 ANTE LECO Meter Factory ...................................................................................................................29
Section 2 ...................................................................................................................................................................30
3 Introduction to training establishment ..........................................................................................................30
3.1 IPD Colombo (PVT) Limited .......................................................................................................................30
3.1.1 Introduction ..................................................................................................................................................30
3
 3.1.2 Organization Structure of IPD .....................................................................................................................31
3.1.3 Vision and Mission ......................................................................................................................................31
3.1.4 Strengths ......................................................................................................................................................32
3.1.5 Weaknesses ..................................................................................................................................................32
3.1.6 Opportunities ...............................................................................................................................................32
3.1.7 Threats .........................................................................................................................................................32
3.1.8 Management.................................................................................................................................................32
4 Training Experience ........................................................................................................................................35
4.1 Familiarization ..............................................................................................................................................35
4.2 Designing........................................................................................................................................................36
4.2.1 Standard .......................................................................................................................................................36
4.2.2 Components of a Distribution Board. ..........................................................................................................36
4.2.3 Forms of Separation. ....................................................................................................................................36
4.2.4 Enclosure .....................................................................................................................................................38
4.2.5 Chassis .........................................................................................................................................................39
4.2.6 Protection Equipment...................................................................................................................................39
4.2.7 Lighting Control Equipment ........................................................................................................................41
4.2.8 Design Projects ............................................................................................................................................42
4.3 Quoting and Estimation ...............................................................................................................................45
Conclusion ................................................................................................................................................................49
Annex 1 - Map of Sri Lankan power Distribution divisions in 2015.......................................................................51
Annex 2 - Organizational Structure of CEB ...........................................................................................................52
Annex 3 - Organizational Structure of LECO .........................................................................................................53
Annex 4 - Organizational Structure of IPD.............................................................................................................54

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List of Figures

Figure 1.1: CEB Logo……………………………………………………………………………………….8

Figure 1.2: LECO Logo…………………………………………………………………………………….10
Figure 2.1: Air Insulated Substation………………………………………………………………………..12
Figure 2.2: Gas Insulated Substation……………………………………………………………………….13
Figure 2.3: AIS Layout……………………………………………………………………………………..14
Figure 2.4: Victoria Power Plant…………………………………………………………………………...15
Figure 2.5: Victoria Power Plant switchyard arrangement…………………………………………………16
Figure 2.6: The Old Stator of the repaired turbine………………………………………………………....17
Figure 2.7: The Backup Generator of the power plant……………………………………………………..17
Figure 2.8: The Valve house of Victoria Power Plant……………………………………………………..18
Figure 2.9: Lakvijaya Power Plant………………………………………………………………………....19
Figure 2.10: A Generator unit of LVPP…………………………………………………………………....20
Figure 2.11: The 220kV GIS arrangement………………………………………………………………....21
Figure 2.12: A Diesel Engine at Sapugaskanda B PP……………………………………………………...23
Figure 2.13: A Diesel Engine at Sapugaskanda A PP……………………………………………………...23
Figure 2.14: Switchyard Arrangement of Sapugaskanda A Power Plant………………………………….25
Figure 2.15: Repairing of a Transformer at Ja-Ela…………………………………………………………26
Figure 2.16: Installation of a Bulk Transformer for a customer……………………………………………28
Figure 2.17: Installation of a new PS pole instead of an old RC pole to get 3-phase supply to a factory....28
Figure 2.18: Production Line of ANTE LECO meter factory……………………………………………...29
Figure 2.19: A Smart Energy meter and its interior………………………………………………………..29
Figure 3.1: The IPD Logo……………………………………………………………………………….....30
Figure 3.2: The evolution and the timeline of IPD…………………………………………………………31
Figure 3.3: The organization structure of IPD……………………………………………………………...31
Figure 4.1: The operation of IPD……………………………………………………………………...…...34
Figure 4.2.: Forms of separation………………………………………………………………………...…37
Figure 4.3: Enclosure Sizes………………………………………………………………………………...37
Figure 4.4: IT MCB Chassis…………………………………………………………………………….....38
Figure 4.5: Nysol8 Chassis………………………………………………………………………………...38
Figure 4.6: Nybus Chassis…………………………………………………………………………………38
Figure 4.7: Types of MCCBs at IPD………………………………………………………………………39
Figure 4.8: DS series 1P+N 6kA RCBO…………………………………………………….……………..39
Figure 4.9: External Lighting Control Kits………………………………………………….……………..40
Figure 4.10: ELTS 4 Emergency Lighting Control………………………………………….…………….41
Figure 4.11: Sample of a client E-Mail…………………………………………………….………………42
Figure 4.12: The Designing Template of Draftsight……………………………………….……………....43
Figure 4.13: The Interface of the Estimator Express……………………………………….…………..….44
Figure 4.14: The interface of the Technical Details of EE………………………………….………..……45
Figure 4.15: SLD and Specification for “Manly Hotel Project” ………………………….………..……..46
Figure 4.16: Final Design of the Distribution Board…………………………………….……….…….….47
Figure 4.17: A Final Quoting of a designed DB. ……………………………………….……….…….…..47

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List of Tables

Table 1: Types of transmission towers………………………………………………………………….….15

Table 2: Types of pre-stressed concrete poles and loads…………………………………………………...27
Table 3: LECO Pole Clearances……………………………………………………………………………27
Table 4: Forms of separation of LV Switchgear……………………………………………………………36

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Abbreviations
CEB - Ceylon Electricity Board
LECO - Lanka Electricity Company (Pvt) Ltd
DGM – Deputy General Manager
LVPP – Lakvijaya Power Plant
AIS – Air insulated switchgear
GIS – Gas insulated switchgear.
CT – Current transformer
IEEE – Institute of Electrical and Electronic Engineers
IEC – International Electrotechnical Commission
AS/NZS – Australian/New Zealand Standard
DB –Distribution Box
EE – Estimator Express.
MCCB – Molded Case Circuit Breaker
RCBO – Residual Current Circuit Breaker with Overcurrent Protection

7
 Section 1

1 Introduction to Training Establishment

1.1 Ceylon Electricity Board

Figure 1.1: CEB Logo

1.1.1 Introduction

The primary energy provider in Sri Lanka is Ceylon Electricity Board (CEB), which is owned and governed
by the government. In Sri Lanka, CEB is in charge of energy production, transmission, and distribution. It
is the only government agency with that power. According to Parliament Act No.17 of 1969, CEB was
created in 1969.

1.1.2 Vision and Mission

Vision:
“Enrich Life through Power”

Mission:

To establish and keep up more efficient, coordinated, and cost-effective energy deliverysystem
for all of Sri Lanka while adhering to our basic principles.
• Quality
• Service to the nation
• Efficiency and effective
• Safety, Professionalism
• Sustainability
• Commitment
8
1.1.3 Strengths of CEB
The key advantage of CEB is that it still controls the entire Sri Lankan electrical power market. And because
of the increasing population, industrialization, and economic expansion, electricity is one of the most
important elements that modern society needs. Government funds are used to run CEB. The upcoming power
plant projects such as Sobadhanawi will further strengthen the generation capacity of CEB. Another
advantage of CEB is the fact that it can survive economic downturns thanks to government backing. Another
strength of CEB is its employees, the top specialists with the highest knowledge of technology comprise the
CEB.

1.1.4 Weaknesses of CEB

A significant portion of CEB's power comes from a single thermal power plant (Lakwijaya), which makes
shutting it down for maintenance or other reasons problematic.
Due to its status as a government entity, CEB is subject to political intervention, which is detrimental to its
long-term goals for generation and transmission. such is the 2016 decision to shut down the Sampur power
station.

1.1.5 Opportunities for CEB

The possibility exists for CEB to produce electricity utilizing renewable resources like solar and wind energy.
In Sri Lanka, wind and solar energy are readily available, which presents a fantastic potential for CEB. Every
year, the need for electricity rises, providing a chance for CEB to grow their market.

1.1.6 Threats for CEB

Changes in fuel prices such as coal, crude oil in global market and fluctuations happened in dollar rate due
to inflation cause severe impact on cost of generation. Since CEB’s large amount of power generation
depends on thermal based power plants. Influences from political situations, environmentalists and public
when implementing new policies become unbeneficial. Also connecting the Sri Lankan Grid with India
will also be a threat for CEB as it looses its control over Sri Lankan power market. Additional risk includes
electricity smuggling, particularly raising non-technical losses within the system. If indeed the proper
precautions aren't really followed, these damages may grow.Aside from power theft, the transmission power
losses have been increasing as a result of rural electrification. Such setbacks might well be financial as well
as energy-related. Throughout rural locations, most potential users typically home consumers who cannot

9
consume enough power to pay for the cost of power. Waste heat is also significant owing to lengthy transmission
lines but ismanageable in current network in Sri Lanka

1.2 Lanka Electricity Company (PVT) Limited

Figure 1.2: LECO Logo

1.2.1 Introduction
In 1983, Lanka Electricity Company (Pvt) Ltd was founded. LECO is authorized to perform power
distribution tasks in Sri Lanka. It is the sole private organization with that power. LECO employs 11 kV and
400 V for the distribution systems for the consumers and receives 33 kV from CEB supply. In order to supply
power, LECO has seven primary region offices: Kelaniya, Moratuwa, Kotte, Nugegoda, Kalutara, Negombo,
and Galle.

1.2.2 Vision and Mission

Vision:
“Enjoy being the light for lives of people through innovative eco-friendly
business.”
Mission:
To provide the best energy solutions to the society through continuous
innovations.

10
1.2.3 Main Functions
LECO distributes power using 11kV and 400v distribution networks and purchases electricity on a 33kV
supply from CEB. The primary duties of LECO are to:
• Provide Electricity to new consumers.
• Metering power distribution and collecting bill payments.
• Maintenance of the distribution network

1.2.4 Strengths of LECO

LECO is the only distributor in Sri Lanka after the CEB. LECO's greatest strength is its consumers. Because
LECO outlets being located in metropolitan locations, customer concentration is relatively heavy . LECO
buys energy from CEB at a competitive price and sells it to consumers.

1.2.5. Weaknesses of LECO

LECO is completely reliant upon power obtained through Ceylon Electricity Board.
As a result, throughout CEB disruptions, LECO has been unable to deliver uninterrupted
constant powersupply towards its customers. This is really a restriction that LECO encounters
with providing a great customer satisfaction. Additional constraint with LECO would be the
limited availability of energy in some places. Within those locations, it already accomplished
100% electricity plus excellent service. As little more than a result, future growth is indeed
not conceivable, resulting ina wastage of people resources and technological expertise.
.

1.2.6 Opportunities for LECO

Concentrate on growing your company in other closely related areas of the electricity sector outside
distribution. The smart metering industry presents a fantastic opportunity. They can quickly monitor their
network demand and other parameters because they can easily incorporate them with the LECO network.
Engage in the licensing process for the distribution of power in other parts of the nation to grow your
company. Due to urbanization and industrialization, there are more clients. Launching new, large-scale
development projects in metropolitan regions will aid in network expansion and provide clients with
dependable results.

1.2.7 Threats for LECO

The coastal region makes up a significant amount of the LECO's distribution area. Because of this, insulators,

11
overhead lines, and salt deposits on conductors act as barriers to raising their profit. The distribution
network's dependability will be immediately impacted by the power outages and system malfunctions of the
CEB system. The sole source of LECO's supply is CEB. LECO lacks a backup energy supplier.

2 Training Experience

2.1 Ceylon Electricity Board

2.1.1 Transmission Construction Project

Air Insulated Substations (AIS) and Gas Insulated Substations (GIS)

AIS

The insulation material is atmospheric air. Therefore, all the live components can be observed from outdoors.
AIS is suitable for remote areas which are not urbanized . Easy maintenance due to visible of components is
an advantage of the AIS. High space requirement and dielectric properties of the air is affected by the
environmental conditions are the major disadvantages. We observed the construction of Wagawatta Grid
Substation which is a AIS.

12
 Figure 2.1: Wagawaththa Air Insulated
Substation
GIS

Where there is expensive and hard-to-find land for the substation, like in Colombo, is where GIS is located.
A grounded metal box houses the complete live system.The system is a gas-filled chamber as a whole. SF6
gas serves as the main insulator in GIS. Due to its superior arc quenching and dielectric qualities, exceptional
cooling capabilities, and ability to keep its atomic and molecular properties even at high voltages, SF6 is
more suitable for use as an insulator. The primary benefits of GIS include minimal maintenance
requirements, minimal space requirements compared to AIS, and safe working conditions for substation
employees The drawbacks of GIS include the expensive cost of installation and the need for highly qualified
personnel for upkeep. We observed the construction at the Horana Grid Substation's GIS.

Figure 2.2: Gas Insulated Substation

Components of a Grid Substation

13
 • Surge Arrestor
• Capacitive Voltage Transformer
• Disconnector
• Current Transformer
• Circuit Breaker
• Post Insulator
• Bus Bars
• Transformer
• Earthing Transformer
• Auxiliary Transformer

Figure 2.3: AIS Layout

Transmission Lines and Towers

Transmission lines are used to transport large amounts of power to far-off loads. They can be found between
power plants and GSSs as well as between GSSs. The two current transmission voltages utilized in Sri Lanka
are 132kV and 220kV. When a new power plant is developed, transmission lines are built. Transmission
lines might be overhead lines or underground lines. Transmission lines of 400kV will soon be introduced
into Sri Lankan transmission network.

Classification of Transmission Lines

14
 Classification based on insulator configuration.
• Suspension Towers – To support the transmission lines. (Straight line)
• Tension/Strain Towers – When the transmission line bends.
Classification based on purpose.
• Line towers
• Angle towers
• Transposition towers
• Terminal or dead-end towers
Classification based on Number of conductors.
• Single conductor lines
• Double/ Twin conductor lines
• Four conductor lines

Transmission Tower Types

Description Tower Type Angle of Deviation (Degrees °)

Line Tower TDL 0-2°
Angle/Tension Tower TD1 0-10°
TD3 10° − 30°
TD6 30° − 60°
Terminal Towers TD9/TDT 90°

Table 1: Types of transmission towers

2.1.2 Victoria Power Plant

Figure 2.4: Victoria Power Plant

15
The Victoria Power Plant is the largest hydroelectric power plant in Sri Lanka with a capacity of 225MW. It
is also capable of operating at a higher capacity than that(about 240MW) during rainy seasons due to its high
water head of 190m. The Powerhouse consists of three Francis Turbines which is ideal for water heads about
100m-300m. The Turbine consists of 18 poles which gives us the RPM as,

120𝑓 120 ∗ 50
𝑁𝑠 = = = 333.3 𝑅𝑃𝑀
𝑃 18
The Governor Control - The governor is made up of numerous mechanical devices that regulate the output
torque at various frequencies. Using a hydraulic system, it manages the wicket gates' opening and closing.
Oil is pumped through this hydraulic system by an oil source. A comparable hydraulic system that uses oil
controls the turbine's brakes as well. The flyball mechanism is used by the speed measuring device since the
AVR is a mechanical-hydraulic governor. The frequency or speed needed to transition a prime mover from
fully closed to fully open is known as the speed droop. To counter a change in speed, the primary control
mechanism needs to travel far enough to send input through the droop element. If the droop is 5% the
movement will be 1/0.05=20. Speed Regulation means the amount of speed or frequency change necessary
to make the output of the generator from zero to maximum.

The AVR - The basic objective of the AVR control is to keep the output voltage steady even while the load
is changing. When the loads are raised, an unregulated generator may experience voltage loss; a regulated
generator will not experience this. This regulates how powerful the magnetic field the rotor produces is. Due
to Faraday's rule, the magnetic field strength will also rise when more loads are connected to the transformer.
A signal is sent to the Excitation system by the AVR. The Thyristor bank in the excitation system transforms

Figure 2.5: Victoria Power Plant

switchyard arrangement

16
 the AC feed from the excitation transformer into a DC. The AVR's signal does this. The phase position of
the input signal can be used to adjust the Thyristor's DC output.
Switchyard Arrangement - The switchyard is designed with a one-and-a-half bus bar arrangement,
maintaining a frequency of 50Hz at both bus bars. Generators are connected to the lower half of each zone,
while the upper part is linked to the main grid. To integrate a new generator into the system, it must first be
turned on and synchronized with the main system. Once synchronized, the generator is added to the system
by closing the circuit breaker located in the center of the switchyard.

On each side of the circuit breaker, there are two Current Transformers, Capacitive Voltage Transformers,
and Disconnectors. The circuit breakers are insulated with SF6 gas, which quickly absorbs arcs when they
are formed, ensuring safe operation. This busbar arrangement allows for easy isolation of the generators
during maintenance, and it enables the Kotmale and Randenigala lines to operate independently.

For protection against surges, there are three surge arrestors for each transmission line, strategically
positioned at the transmission end, as surges can travel through the transmission lines to the switchyard.

The generators' output is transformed by the main transformer bank and connected to the switchyard through
an underground tunnel. All of the wires in the system are oil-insulated, and the oil pressure is maintained

Figure 2.6: The Old Stator of the repaired turbine Figure 2.7: The Backup Generator of the
power plant

17
using a pressure pump.. All the equipment in the switchyard can be operated manually but circuit breakers
are normally operated by the control room. The transmission lines end has a disconnector with an earth which
consists of an interlock mechanism. Because of this bus can only earthed when it is disconnected, which
prevents line faults. (Such as earthing a live line which has happened previously)

Transformer Bay - The transformer configuration comprises three sets for each zone or line bay, with each
set consisting of three single-phase transformers. In total, there are nine transformers, all of which are cooled
using a combination of oil and air. The cooling process involves both Air Forced and Oil Forced mechanisms,
employing one oil pump and two fans. The primary cooling method is oil-based, while the two fans activate
when the temperature surpasses 40℃ and 65℃, respectively. The cooling system is centralized and located
behind the transformer bank within the MK (martial kiosk), which also controls the related relays for
transformer cooling. This setup ensures the transformers are automatically cooled down, maintaining their
safe operation. The transformer oil is supplied from a pressure tank located next to the transformer bank.
Additionally, there is an extra transformer kept as a backup in case of any transformer failures. For ease of
mobility, the transformers are installed on rails.. The transformer conservator tank is a little different from
the transformer at Wagawatta. This transformer had no breather to filter out moisture in the air. Instead, it
had a coal breather system installed. Each transformer consists of a surge arrester too, which protects the
transformer from lighting. After transforming 12.5kV into 220kV the power transmission lines are connected
to the switchyard through the underground tunnel.

Figure 2.8: The Valve house of Victoria

Power Plant

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2.1.3 Lakvijaya Power Plant

Figure 2.9: Lakvijaya Power Plant

Lakvijaya is the largest power plant in Sri Lanka, which has three units of 300MW and total capacity of
900MW. Unit 1 of the LVPP was started and connected to the grid in 2011 and unit 2 and unit 3 was started
the operation in 2014. It produces about 810MW to the National Grid and supplies more than 40% of daily
electricity demand of Sri Lanka.

The Operation of the LVPP

We were given a basic introduction of the operation of the Power plant on the first day. The bituminous coal
used in the plant has 12% ash and around 84% carbon. The coal is transported to a crusher building where it
is crushed into pieces measuring 30 to 40 mm after being put onto the belts by the barges. Then, coal is
moved into the mills through a belt system, where it is further crushed by pulverizers into particles measuring
around 50 micrometers. Only four of the five mills are being used regularly; the fifth is a standby mill.
Following the pressurised air injection of the crushed coal into the boiler, heat is produced. Water absorbs
this heat, changing its phase to steam as a result. Then this steam is used to turn the steam turbine and
generate electricity. The Generating voltage of the power plant is 20kV and it is stepped up to 220kV for
distribution purpose.

Coal Handling System

Due to its low cost and recognition as a cheap energy source, coal is now utilized in many countries. Diesel

19
is used in LVPP as the first fuel source. The primary fuel utilized in the power plant is coal fuel. Following
the purchase of coal for LVPP, it transports to a jetty.
Barges, cranes, a coal yard, bunkers, a grab, conveyor belts and coal mills make up the coal handling system.
The facility uses over 2 million tons of coal annually. High levels of coal dust from the coal handling
operation are detrimental to the 16 nearby residents as well as the workers. For the purpose of preventing
this coal dust, wind barriers, mist generating systems, and mist blowers were installed.

Boiler
As for the fuel pulverized coal is used. Coal is burned in the furnace and release heat energy to the water
pipes inside the boiler. The stating of the plant is done burning Auto Diesel in the furnace. The hot gases go
through the Super heater, Re-heater, Economizer, ESP, FGD and Stack before the atmosphere. Generated
steam in water pipes directed to steam turbines.
Manufacturer – Harbin Boiler Company of China
Superheated steam temperature: 541C
Boiler capacity: 1025 Tons/hr
Boiler efficiency: 88.58%

Turbine
After condensing into water, the steam passes through turbines as they rotate. High pressure turbine,
intermediate pressure turbine, and low-pressure turbine are the three stages of a turbine. The 3000-rpm
turbine was created by the Chinese company Harbin Turbine. It is 300MW in size.

Generator

Figure 2.10: A Generator unit of LVPP

20
The generation voltage is 20 kV. Three generators with 353 MVA capacity make up the plant. The three
generators were made in China by Harbin Electric Machinery. The generator's efficiency is 99.02%.

Transformer
There are 3 types of transformers used in LVPP. Which is Generator transformer, Unit Auxiliary transformer
(UAT), Startup standby transformer. (SST)

Figure 2.11: The 220kV GIS arrangement

Generator transformer
Generator transformer steps up the 20kV generated voltage up to 220 KV which is transmission voltage.
Each generator has a dedicated power transformer.
• Rated Capacity – 360MVA
• Vector group – YNd1
• Rated frequency – 50Hz

Unit auxiliary transformer

Power plant has three types of unit auxiliary Transformers. The main purpose of installing them is to supply
the power needs inside the power plant. Unit auxiliary 18 transformer stepped down the generated 20KV
voltage from the generator to 6 KV to power the equipment in the plant.
• Rated Capacity – 31.5MVA
• Vector group – Dyn1
• Rated frequency – 50Hz

21
Startup standby transformer
When the generators are not operating startup standby transformer are used to power auxiliary system. It
steps down the voltage from 220kV to 6kV.
• Rated Capacity – 31.5MVA
• Vector group – YNyn0
• Rated frequency – 50Hz

2.1.4 Protection Branch and System Control

Types of protection schemes in Transmission network of Sri Lanka

1. Line bay
➢ Differential
➢ Distance
➢ Directional EF
➢ Over current
➢ Earth fault
2. Transformers
➢ Differential
➢ Restricted earth fault
➢ Overcurrent
Earth fault
➢ Overvoltage
➢ Undervoltage
3. Bus bar
➢ Overcurrent
➢ Earth fault
4. Feeders
➢ Overcurrent
➢ Earth fault

The System Control Center - The Ceylon Electricity Board (CEB) has relocated its System Control Center
from Dematagoda to Pelawatta. It is generally acknowledged that maintaining a balance between the nation's
electrical generation and consumption is essential to guaranteeing a consistent supply of power. The system
control center's main duty is to plan the nation's electricity production in order to meet demand and maintain

22
the frequency stability of the power system. The center also comprises distinct divisions for system
modeling, auditing, and operation planning.

From the synchronizing breaker all the way to the feeder's 33kV grid end breaker, the System Control
Center is in charge of and has jurisdiction over how the power network operates.

Victoria, Kotmale, New Laxapana, Samanlawewa (controlled manually), and Upper Kotmale (operated
temporarily) are the key power plants engaged in controlling the system frequency. Effective frequency
control is accomplished by using the Automatic Generation Control (AGC) mode. Because they are unable
to continuously vary their active power generation as needed, other power plants cannot be employed for
frequency-regulated power generation.

2.1.5 Kelanitissa and Sapugaskanda Power Plants

Figure 2.12: A Diesel Engine at Sapugaskanda Figure 2.13: A Diesel Engine at

B PP Sapugaskanda A PP

Sapugaskanda Power Plant, situated within the Thermal Complex, is a diesel power plant connected to the
grid. Its generators are driven by marine engines, which typically operate on heavy fuel oil during normal
running conditions but require auto diesel for starting and stopping. Various auxiliary systems, such as hot
water systems, injector water systems, jacket water systems, and lubricating oil systems, support the plant's
operations. These auxiliary systems rely on station service 11/0.4 kV transformers for power supply.

23
The power plant consists of two separate power houses, named Sapugaskanda A (80MW) and Sapugaskanda
B (80MW). Powerhouse A comprises four 20MW diesel engines, while Powerhouse B includes eight 10MW
diesel engines. Although these engines can run on diesel, they predominantly use heavy fuel oil (HFO) as
fuel due to lower generation costs. However, during engine start-up and shutdown, diesel is employed
because it helps clean out any residual heavy fuel that might otherwise accumulate and solidify into tar within
the diesel engine.

Diesel Engine Operation

The engine consists of four strokes,

1. Suction Stroke – The piston pulls an air fuel mixture into the cylinder by producing a partial vacuum
inside the cylinder.
2. Compression Stroke – Stroke starts at BDC and ends at TDC, both inlet and exhaust valves are closed
during this stroke.
3. Power Stroke – The start of the second revolution of the four-stroke cycle. The air fuel mixture is
ignited by the heat generated while the compression.
4. Exhaust Stroke – The stroke once again starts from BDC to TDC but now the exhaust valve is open and spend
fuel is taken out by the exhaust.

Excitation System

In Station A, a 14-pole Permanent Magnet Generator (PMG) is utilized to generate a 3-phase system. This
3-phase system is then half-rectified using the Automatic Voltage Regulator (AVR). The half-rectified wave
is directed to the stator of the main exciter, resulting in the creation of another 3-phase system as the
generator's engine rotates. This second 3-phase system is further rectified by a rotating rectifier unit on the
generator field, producing the final DC power required to operate the generator.

On the other hand, Station B employs a 5-phase winding instead of a PMG. The required Electromotive
Force (EMF) is generated within this 5-phase winding due to the residual flux in the generator. This winding
serves two purposes: it provides energy for the excitation system and also powers other control equipment
within the station.

Switchyard Arrangement

The switchyard has a double bus bar setup operating at 132kV, with a bus coupler. Sapugaskanda A
powerhouse has two step-up transformers, each connected to a separate bus bar through an 11kV bus bar.
Sapugaskanda B powerhouse has three step-up transformers, with one on standby and the other two
24
connected to the bus bars via the 11kV bus bar. The transformers in Sapugaskanda B can be switched
between the bus bars based on requirements. The 11kV bus bar in powerhouse B is also divided, allowing
the standby transformer to connect to either side. The switchyard used to have a neutral bus bar, but it is
currently inactive and not connected to the generators' grounding. Only transformer earthing is now
performed using the neutral earthing resistors.

Figure 2.14: Switchyard Arrangement

of Sapugaskanda A Power Plant

2.2 Lanka Electricity Company (PVT) Limited

Day one we visited to LECO Training Center in Ja-Ela. An introduction session about LECO was conducted by
the training coordinator. Then we observed the meter testing lab and a basic explanation was conducted on energy
meters. After that observed transformer repair and testing workshop at the Training Center.

25
2.2.1 LECO Training Center Ja-Ela

Figure 2.15: Repairing of a Transformer at Ja-Ela

LECO does minor repairs by itself in this workshop. Those repairs are Oil replacement or purification of the
transformers, insulation failure checking, and transformer bushing replacement and cleaning. These were
repaired by this unit with the highly skilled employees. This workshop does not conduct major repairs such
as replace windings, core, or insulation in the transformers. Testing for the transformers are also conducted
in this workshop those main tests are,
• Insulation test
• Oil breakdown voltage test
• Ratio test

2.2.2 LECO Branch Office (Nugegoda)

Types of Conductors used for Distribution.

There are mainly two types of conductors,

1. All Aluminum conductors (ACC)
2. Aerial bundle conductors (ABC)

Types of Poles used for Distribution.

1. Reinforced Concrete Poles (RC poles) – Reinforced concrete poles are used only for LV distribution.
They are only available in 7.6m and 9m poles. The 7.6m pole is mainly used as a service pole and
9m pole is used for LV distribution.
2. Prestressed Concrete Poles (PS poles) – Prestressed concrete poles are used for both HV and LV
distribution. There are 9m, 11m, 13m, and rarely 13.7m prestressed poles. 9m prestressed poles are

26
 sometimes used for distribution of LV and other heights are rarely used for LV distribution where
clearance is necessary.

Pre-stressed concrete pole types and loads.

Given below is a table of heights (m)/ daN (x10N) values of the types of prestressed concrete poles used for
distribution. The force value indicates the maximum horizontal force the pole can withstand along its angled
side. The other side(B) can only withstand 25% of its displayed daN value.

9m 11 m 13 m
9/200 11/200 13/350
9/350 11/350 13/500
9/500 11/500 13/850
11/850 13/1200
11/1200

Table 2: Types of pre-stressed concrete poles and loads.

Type of Pole Recommended Span (m) Maximum Span (m)

HV only 80-100 120
LV only (ABC) 40-50 60
HV and LV(ABC) 40-50 60

Table 3: LECO Pole Clearances

Clearance for ground and the structure

For HV lines,
• Along any road or street – 5.2 m
• Across any road or street – 6.1 m
• Places inaccessible to vehicles – 4.9 m
• Vertical clearance from trees, buildings and structures – 2.7 m
• Horizontal clearance from trees, buildings and structures – 1.5 m
• Telephone lines – 1.5 m

For LV lines (ABC),

27
 • Along any road or street – 5 m
• Across any road or street – 5.5 m
• Places inaccessible to vehicles – 4.6 m
• Vertical clearance from trees, buildings, and structures – 0.15 m
• Horizontal clearance from trees, buildings, and structures – 0.15 m
• Telephone lines – 0.6 m

Transformer Types

• Bulk Transformers
• Distribution Transformers.
Both available in capacities, 100kVA, 160kVA, 250kVA, 400kVA, 1000kVA.

Figure 2.16: Installation of a Bulk Transformer

Figure 2.17: Installation of a new PS pole instead of
for a customer.
an old RC pole to get 3-phase supply to a factory.

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2.2.3 ANTE LECO Meter Factory

Figure 2.19: A Smart Energy meter and its interior

Figure 2.18: Production Line of ANTE LECO meter factory

This factory opened in 2008. This company produces energy meters for CEB and LECO. The factory is
primarily owned by LECO (70%) with a 30% stake held by the Chinese company ANTE, which provided
technical support during its establishment in 2008. It began producing Smart meters in 2018, but its
operations have been affected by COVID-19 and related restrictions, causing the current output to be limited
to 600 meters daily, despite its capacity to produce 2000 meters daily.

Initially, the factory had three production lines, but only two are currently operational. Previously, all
component assembly, including soldering, was done in-house. However, the process has changed, and now
pre-manufactured Logic boards along with all components are imported and installed into the meters.

The factory produces three types of meters:

1. Digital Type C meters: These meters can only measure power consumed and do not register power
given to the grid. If power is fed into the grid, it is still recorded as consumed power.
2. Smart Meters: These meters can measure both power consumed and power given to the grid. They
offer various options, such as calculating electricity bills based on time of use or units consumed.
3. Three-phase meters: These meters measure power consumed in kVA (kilo-volt-amperes) value.

29
 Section 2

3 Introduction to training establishment

3.1 IPD Colombo (PVT) Limited

Figure 3.1: The IPD Logo

3.1.1 Introduction
IPD Colombo commenced operations in 2005, as a fully owned subsidiary of IPD, a publicly listed
Australian Company. It began as an offshore operation with two people to support the day-to-day operations
in Australia, that has now grown to what it is today, specializing in
• power distribution
• power monitoring
• industrial control
• photovoltaic
• industrial automation
• communication
• HVAC.

There are currently over 170 people employed in Sri Lanka and over 290 people acrossAustralia within
different business units.
The Production of the components is done in Australia and Drafting, Designing and Estimation is done in
Sri Lanka by IPD Engineering Team. Other than the Design and Estimation Engineering team there is
Applications Engineering Team, IT Team and Administrative Team at IPD Colombo.

30
 IPD is a leading Australian company that has been supplying electrical products to the
Australian market forover 70 years. The evolution of the company is reflected by the following
figure,

Figure 3.2: The evolution and the timeline of IPD.

3.1.2 Organization Structure of IPD

Figure 3.3: The organization structure of IPD

3.1.3 Vision and Mission

Vision:
To build the best team, provide an outstanding end-to-end customer experience and implement
solutions to the challenges faced by the industries we serve.

Mission:

Through early adoption of technology, provide products, solutions and services of superior
quality and value that exceeds expectation.

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3.1.4 Strengths
IPD conducts their services in accordance with international standards including IEEE, BS, VDE, and IEC.
IPD Colombo uses cutting-edge technologies to improve the effectiveness of business processes and offers
both internal and external clients creative IT solutions and software tools. Their Development and Support
teams deliver projects in a variety of disciplines like App Development, Cloud Refactoring, Cyber
Security, IIOT, IT Operations, ERP Management, Data Management, and Machine Learning solutions
across on-premises, hybrid, and cloud environments. Numerous industries are served by these services. To
effectively handle these activities, the IPD has a strong engineering team of roughly fifty highly qualified
engineers.

3.1.5 Weaknesses
Workplace needed more space. If then more people/ engineers can engage in a project at the same time. Then
higher number of projects could be carried out. Marketing section and Machine Learning section of the
company needed to be improved.

3.1.6 Opportunities
Currently, IPD Australia's marketplace is confined to Australia only. However, there is significant potential
for the company to expand and tap into the international market in the near future. By exploring opportunities
beyond its national borders, IPD Australia can reach a broader customer base and experience substantial
growth on a global scale.

To achieve this expansion, IPD Australia should focus on developing and manufacturing innovative
electrical switchgear that can rival its competitors. By investing in research, development, and cutting-edge
technologies, the company can create high-quality switchgear solutions that meet international standards and
cater to the specific needs of customers worldwide. This approach will position IPD Australia as a
competitive player in the global market and open doors to new business opportunities and partnerships..

3.1.7 Threats
Has a competition with other switchgear manufacturing companies such as, ABB, Schnieder, etc.

3.1.8 Management

There are 10 departments at IPD Colombo (Pvt) Ltd.

1. Application support team

2. Engineering
3. Finance
4. Human Resources
32
 5. IT
6. Marketing
7. Order processing
8. Procurement
9. Special projects
10. Techno department

At IPD, there are two sections under the Engineering team.

• Design and estimating

• Design and drafting

Design and Estimating team prepare the design and quotations according to the customer requests
and when the order is confirmed, the design and drafting team finalizes the detailed drawing with
details such as the design with doors opened, doors closed, cover plate removed , etc.

3.1.8.1 Recruitment
The team leader will notify the HR department of any openings in the team. The HR marketing team then
posts the job openings on Top Jobs. Candidates' resumes are gathered using the Bamboo HR connection.
The candidates are contacted for interviews after the CVs have been reviewed. In the interviewing procedure,
there are two interviews. The interview will be successfully completed, and then there will be an English
language test. The list of the chosen applicants is delivered to the team leader once references have been
checked. In Australia, you must get the Director of Strategic Development's consent before hiring an
employee.
3.1.8.2 Administrative Practices
An employee is entitled to 14 yearly leaves, 7 unscheduled leaves, and 7 sick days. Six months is the standard
probationary period. After the probationary term, all employees are entitled to medical insurance. After the
probationary term, all employees are eligible for EPF and ETF.
3.1.8.3 Welfare
Christmas and Awurudu are observed by the entire staff at the business. To recognize top performers among
the workforce, there is an award ceremony. When an employee's baby is born, there is a special payment
made. An employee who marries receives a LKR 25000 stipend. Day trips are planned by the appropriate
departments.

33
3.1.8.4 Training
03 months and 06 months paid internships are offered. Interested people can apply throughthe
IPD Colombo webpage.

34
4 Training Experience
4.1 Familiarization

On the first day we were given an introduction about the history and operations in the IPDColombo
company by the Technical Services Manager. Since there are 10 departments as mentioned before, were
given a brief overview of some of these departments by their respective leaders.
At the introduction to the Marketing Department, few digital marketing trends were explained.One
of them was the “five finger story.”

• Promotion
• Personal selling
• Direct marketing
• PR and publicity
• Advertising

At the introduction to the Procurement department, it was explained that IPD only works as a
solution provider and a distributor.

Supplier Manufacturer Distributor Customer

IPD

Figure 4.1: The operation of IPD

At the introduction to the Finance department, we learnt that IPD Colombo is a Tax exempted
company in Sri Lanka because it is a overseas service provider. The financial year of IPD Colombo
is from 1st of July – 30th June. At the IT department introduction, we were introduced to few
software under operation,
• Pronto Xi – order processing
• SharePoint – storing and sharing information and files.
• Power BI – visualize financial data.
• BI-Cube – Extract and organize past sales records.
• CRM – Record orders with designs

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4.2 Designing
4.2.1 Standard

The standard AS/NZS 61439 is followed by all low-voltage switchgear and control gear assemblies
in Australia which is an adaptation of IEC 61439 that has been changed to add in country notes
Australia and New Zealand.
4.2.2 Components of a Distribution Board.

• Enclosure

• Escutcheon

• Mounting Pan

• Main Switch

• DIN Rail

• Chassis

• Neutral and Earth Bars

Optional components

• Meters
• MCB’s, RCBOs, MCCBs, RCCBs
• Control equipment.
• Surge protective device
• Lighting control equipment
• Emergency lighting equipment

4.2.3 Forms of Separation.

Electrical systems utilize various forms of separation within switchboards to safeguard individuals
and equipment from electrical hazards. These forms, such as Form 1, Form 2, and Form 3, are
standard, but there are also variations marked with "a" and "b." These variations signify different
enclosure types and component arrangements within the switchboard.

36
 ▪ Form 1 – No internal segregation
▪ Form 2 – Separation of busbars from functional units.

Form 2a Form 2b
Separation of busbars from functional units Separation of busbars from functional units
but terminals not separated from bus bars but terminals separated from bus bars

▪ Form 3 – Separation of bus bars from functional units and separation of functional units
from each other

Form 3a Form 3b
Separation of bus bars from functional units Separation of bus bars from functional units
and separation of functional units from each and separation of functional units from each
other but terminals not separated from the other but terminals separated from the
busbars busbars

▪ Form 4 – Separation of the bus bars from the functional units, separation of the
functional units from each other and separation of the terminals from each other.

Form 4a Form 4b
Separation of the bus bars from the Separation of the bus bars from the
functional units, separation of the functional units, separation of the
functional units from each other and functional units from each other and
separation of the terminals from each other separation of the terminals from each other
terminals in the same compartment as the terminals in the same compartment as the
related functional units related functional unit

Table 4: Forms of separation

37
 Figure 4.2.: Forms of separation

4.2.4 Enclosure

The Evolution Range is available in the following colors:

• RAL7035 Grey
• RAL2000 Orange
Enclosures with IP43 rating have a maximum height of 1400mm, made with 1.0 & 1.2mm mild steel, and
can accommodate up to 96 poles. They are available in RAL2000 Orange and RAL7035 Grey colors. For
IP65 rated enclosures, the maximum height is 1200mm, made with 1.6mm mild steel, and can hold up to 84
poles, also available in RAL2000 Orange and RAL7035 Grey colors. Enclosures with IP66 rating have a
maximum height of 1200mm, made with 1.6mm 316 stainless steel, and are typically offered unpainted.

Figure 4.3: Enclosure Sizes

38
4.2.5 Chassis

MCB Chassis – The IT MCB chassis is offered in two current ratings: 250A and 400A, with respective fault
withstand ratings of 25kA/0.1s and 30kA/0.1s. These chassis are available in 3P and 3P+N configurations.
Additionally, the MCB chassis comes in various pole sizes, with options for 250A (18mm) chassis
accommodating up to 120 poles and 400A (18mm) chassis also supporting up to 120 poles.

Figure 4.4: IT MCB Chassis

Nybus Chassis – The NYBUS chassis is compatible with XT1, XT2, and XT4 MCCBs and comes in two
current ratings: 630A and 800A. This encapsulated chassis range offers various configurations, including
single-sided, double-sided with top, bottom, or universal feed options. The double-sided chassis can
accommodate a maximum of 72 poles, while the single-sided chassis supports up to 36 poles.

Figure 4.5: Nysol8 Chassis Figure 4.6: Nybus Chassis

Nysol8 Chassis – The Nysol8 Chassis is a disconnect-style chassis specifically designed for chassis mount
MCBs and RCBOs. It offers a safer way to connect, power, and disconnect circuit breakers. With a fault
withstand rating of 10kA/1s and 36kA/0.1s, it is fully type tested to accommodate a wide range of MCBs.
The chassis has a current rating of 250A and is available in various pole sizes, supporting up to 96 poles.
4.2.6 Protection Equipment

MCBs - MCB’s provide overcurrent protection to equipment and personnel, MCB is equipped
with two trigger mechanisms to ensure the reliability and safety of people and assets. Delayed
thermal trip device for overloadprotection and magnetic trip device for short circuit protection.

39
Single, double, triple with neutral, and four-pole configurations are available at IPD.

MCCBs - A Molded Case Circuit Breaker (MCCB) is an electrical protection device utilized to
safeguard electrical installations from higher load currents, usually exceeding 100 A. It offers
protection against overload and short circuit faults, and it can also serve as a manual disconnection
switch.

Figure 4.7: Types of MCCBs at IPD

RCBOs - RCBOs offer protection against short circuits, thermal overload, and earth leakage. They come in
6kA and 10kA fault withstand ratings and are available in two categories: type A and type AC, depending on
customer requirements. RCBOs are offered in various configurations, including 1P+N, double pole, and
3P+N. Most ranges have a maximum rating of 40A

Figure 4.8: DS series 1P+N 6kA RCBO

40
4.2.7 Lighting Control Equipment

External Lighting Control

IPD offers a range of external lighting control kits, including ELCK-L, ELCK-D, ELCK-P, ELCK-DP, ELCK-DB,
and ELCK-DPB. These kits incorporate components like mechanical time clocks, digital time clocks, PE cells, and
override push buttons. The choice between quoting a complete kit or individual components depends on the specific
control diagram of the project.

Figure 4.9: External Lighting Control Kits

41
 Emergency Lighting Control

IPD utilizes the ELTS4 emergency lighting test switch, which enables testing of a single-point emergency
lighting system by simulating a mains supply failure. The kit allows control of four emergency lighting
circuits. To initiate the test, the selector switch is set to the TEST position, activating the contactor and
starting the delay off-timer. After the test cycle, power is automatically restored.

Figure 4.10: ELTS 4 Emergency Lighting Control

4.2.8 Design Projects

4.2.8.1 Software

For the design work, we utilized the "DraftSight" software, which closely resembles my previous
experience with AutoCAD. The commands in both software were identical, making the transition smooth.
Additionally, I was provided with a DraftSight sheet containing essential blocks for designing, such as
Enclosures, MCCBs, Isolators, Escutcheons, RCBOs, RCCBs, Meters, etc.
4.2.8.2 Details of the design

Before starting the design of the DB, we should note some crucial factors in order to deliver the
most suitable solution such as,
• IP rating

• Enclosure material and thickness

• Form of separation

• Cable entry (Top/Bottom)

• Cable size

• Fault withstand rating of the DB

• Application type (Indoor/Outdoor)

• Dimensions

42
 • Colour and finish

• Current rating and Main switch type

• Current rating and fault level of outgoing devices

• Bus bar rating and short time withstand rating

• Lighting control and emergency lighting control requirement

• Spare pole capacity

• Surge protective device

• Door locks and handles

• Mounting method (Wall / Floor)

• Plinth/rainhood requirement

• Special requests

4.2.8.3 Designing Procedure

Step-1 – Refer to the Client Email sent by the CRM system. The Request for Quote (RFQ) is a document
that includes essential details about a project, such as project name, state, customer information (name,
number, email), quote phase (live job or tender), winning probability, project size, profit margin, and
compliance with specifications. Additionally, the RFQ may be accompanied by the single line diagram
(SLD) and, optionally, the specifications document for further reference and evaluation.

Figure 4.11: Sample of a client E-Mail

43
Step 2- Referring to the SLD and Specifications. The Single Line Diagram (SLD) holds significant
importance as it provides a comprehensive overview of the Distribution Board (DB) design,
encompassing vital information. However, certain critical details may be found in the
Specifications document, such as upstream breaker rating, cable size, and cable entry, which are
essential for the overall understanding and proper execution of the DB project.

Step 3 – Selecting recommended components, the selection of components for the main switch
and outgoing breakers in the Distribution Board (DB) depends on factors like current rating,
upstream breaker rating, cable size, and fault level. A common offering for the main switch is the
ABB OT250 isolator. Meters, Surge Protective Devices, and other components have specific
selection procedures provided by IPD. Chassis selection considers pole size, including spare poles.
Lighting controls and emergency lighting systems are chosen based on specific requirements
outlined in the control diagram. Enclosure selection depends on the required IP rating and
dimensions.

Step 4 – Designing the DB using draftsight software, the design layout should utilize pre-designed
CAD blocks. Tier height must not exceed 2000mm; if it does, enclosures should be arranged side
by side. The selected enclosures should accommodate various components, including the Main
Switch, Chassis, Earth and Neutral bars, MCCBs, RCBOs, RCCBs, Meters, Surge Protective
Devices, DIN rails, and Control equipment, among others.

Figure 4.12: The Designing Template of

Draftsight.

44
4.3 Quoting and Estimation

The quotation is prepared with all the prices of quoted components and relevant
conditions. The design and estimation team prepares two different types of
quotations.
1. IPD assembled DBs.

2. Loose component quoting

3. Load center quoting

“Estimate Express” is the software used to prepare quotations. It is a software with

all the details of components and prices which was invented by the IPD.

Figure 4.13: The Interface of the Estimator Express

45
 Figure 4.14: The interface of the Technical Details of EE.

We only change the following details under quote terms section when quoting for a new DB,

• Technical details

• Drawing details

• Additional comments

46
Project-Manly Hotel DBs

The "Manly Hotel DBs" project involved designing three distribution boards (DBs). For DB-N1,
cable entry details were assumed to be top entry as they were not provided. The SLD included a
cable sizes table. ABB OT250 isolators were used despite the isolator rating being 160A in DB
N1 and DB N3 because they were commonly offered by IPD. Pole sizes were easily determined
based on given lighting, power, and air conditioning chassis sizes. The EM4M-3P-C-100A meter
was selected for the project. Outgoing breakers/devices were chosen with a 10kA fault withstand
rating, as specified. To accommodate the customer's request for a DALI lighting system, an empty
DIN header box was provided for DALI controls in each DB.

Figure 4.15: SLD and Specification for “Manly Hotel Project”

47
Figure 4.16: Final Design of the Distribution Board

Figure 4.17: A Final Quoting of a designed DB.

48
Conclusion

During the initial phase of the industrial training program, we had the valuable opportunity to be
assigned to both the Ceylon Electricity Board (CEB) and Lanka Electricity Company (LECO).
This experience provided invaluable hands-on exposure to the power and energy sector. The
training encompassed working at well-known power plants like Victoria, Lakvijaya, and
Sapugaskanda, offering valuable insights into power generation. Additionally, the we acquired
knowledge about transmission towers, actively participated in line maintenance, and gained a
comprehensive understanding of grid substations within the Transmission Construction Projects
division at Pannipitiya.
Moreover, during the training period, the we spent three weeks at LECO's Nugegoda branch
office, providing a deeper understanding of distribution network operation and maintenance.

As an Electrical Engineering Undergraduate, it is crucial to acquire robust technical knowledge

in the field. IPD Colombo (Pvt) Ltd offered an exceptional opportunity to develop expertise in
Switchboard design and electrical installation. Throughout the three-month training, the student
gained extensive knowledge and practical experience across various domains in the electrical
engineering field. Being an off-shore service provider for IPD group Australia, IPD Colombo
exposed the trainee to world-renowned products like ABB, General Electric, Socomec,
Schneider, and DEHN, offering valuable hands-on experience. Working with dynamic
Engineering professionals at IPD Colombo was rewarding, as they were supportive and eager to
share their knowledge. The theoretical knowledge acquired during the Installation and CAD
modules has proven to be highly beneficial in comprehending practical aspects and applying
what was learned at the university. Being assigned a live job with a deadline enabled me to gain
valuable experience in effective time management and staying focused on daily tasks. This
experience offered valuable insights into the differing routines of being an employee and a
student..

49
50
Annex 1 - Map of Sri Lankan power Distribution divisions in 2015

51
Annex 2 - Organizational Structure of CEB

52
Annex 3 - Organizational Structure of LECO

53
Annex 4 - Organizational Structure of IPD

54