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Report on Industrial Training @ Venora Telecom (Pvt) Ltd.

Technical Report · March 2020

DOI: 10.13140/RG.2.2.29445.29920

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 Sri Lanka Institute of Information Technology

Report on Industrial Training

At
Venora Telecom (Pvt) Ltd.

Name: H. B. C. Jayasinghe
Registered No: EN17409056
Course: B. Sc. (Hons) in Engineering (UGC)
Field of Specialization: Electrical and Electronic Engineering
Period of Training: 4th November 2019 to 24th January 2020 (12 Weeks)
Abstract

I was interned at Venora Telecom (Pvt) Ltd. which was established under a subsidiary of the
Venora Group of Companies. Throughout the training period, I have gained understanding on the
earthing side of the telecommunication towers. And, I have obtained some practical experience
by assisting to the workshop works. Though I was a trainee from an engineering background, I
have performed some logistic tasks until a new officer was appointed attached with guidance of
the Accountant & the Marketing Executive except for the technical training.

i
Acknowledgement

I take this opportunity to express my profound gratitude and deep regard to the Sri Lanka
Institute of Information Technology for their exemplary guidance, monitoring and constant
encouragement throughout the training period. The blessing, assistance and guidance given by
them time to time, shall carry me a long way in the journey of life on which I am about to
embark.

I also take this opportunity to express a deep sense of gratitude to Venora Telecom (Pvt) Ltd. for
giving me the opportunity to carry out my industrial training. Specially to the CEO of the Venora
Telecom (Pvt) Ltd., Mr. Sanath Adhikari, who selected me for the training. And I am very
grateful to the Project Engineer of Earthing & Lightning Protection, Eng. Chinthana Wedamulla
who had given me the remarkable engineering project. And also, I like to thank to the Deputy
General Manager as well as to the Managers of Engineering Divisions, Engineers, Coordinators,
Quantity Surveyors etc. for their cordial support, valuable information and guidance, which were
very useful to me while completing the training successfully.

I am obliged to staff members of all the other departments in Venora; such as Site Engineers,
Technical Officers, Technicians and other minor staff for the information & assistance provided
by them in their respective fields.

I would also like to thank other trainees who were engaged with me during my industrial training
period for their kind cooperation specially to succeed the project.

At last, but not least, I would like to thank my parents for their tremendous contribution and
support, both morally and financially toward the completion of my training.

ii
List of Figures

Figure 1.1 Organizational Chart 3

Figure 2.1 Ingress Protection Ratings 5
Figure 2.2 Position of the DCDU in a Telecom Tower Site 6
Figure 2.3 DCDU-03 7
Figure 2.4 20 A Trip Switch 7
Figure 2.5 DCDU-12B 7
Figure 2.6 30 A Fuse 8
Figure 2.7 Front View of the Redesigned DCDU 8
Figure 2.8 Inside Appearance of the Redesigned DCDU 9
Figure 2.9 Diagram of Working Principle a Fuse 10
Figure 2.10 Classification of Fuses 12
Figure 2.11 Lightning Air Terminals 15
Figure 2.12 Principle of Protection System in Parallel 17
Figure 2.13 Digital Earth Tester 19
Figure 2.14 The Photo of Previously Prepared ACDB 22
Figure 2.15 HRC Fuse Box with Fuse Bases 23
Figure 2.16 HRC Fuse 23
Figure 2.17 ECBs 24
Figure 2.18 Plastic Dc Tape Clips 25
Figure 2.19 Prepared Meter Board 25

iii
List of Tables

Table 2.1 Comparison of Two Devices .......................................................................................... 8

Table 2.2 Timeline of the Training Project ..................................................................................... 9
Table 2.3 Task Description of the Timeline ................................................................................. 10
Table 2.4 Budget of the Re-designed DCDU ............................................................................... 11
Table 2.5 Used Workshop Tools .................................................................................................. 20
Table 2.6 Used Materials with Their Quantities ........................................................................... 21

iv
Contents

Abstract ........................................................................................................................................ i
Acknowledgement ....................................................................................................................... ii
List of Figures ............................................................................................................................ iii
List of Tables .............................................................................................................................. iv

1.0 INTRODUCTION .................................................................................................................... 1

1.1 Vision and Mission................................................................................................................ 1
1.1.1 Vision.............................................................................................................................. 1
1.1.2 Mission ........................................................................................................................... 1
1.2 Company Background/History.............................................................................................. 2
1.2.1 Venora Group ................................................................................................................. 2
1.2.2 Venora Telecom ............................................................................................................. 2
1.3 Management .......................................................................................................................... 3
2.0 TRAINING EXPERIENCE ...................................................................................................... 4
2.1 Safety Procedures .................................................................................................................. 4
2.2 Ingress Protection .................................................................................................................. 4
2.3 Training Project ..................................................................................................................... 6
2.3.1 Introduction to the Designed DCDU .............................................................................. 6
2.3.2 Redesigned DCDU ......................................................................................................... 8
2.3.3 Timeline of the Training Project .................................................................................... 9
2.3.4 Protection Methods ....................................................................................................... 10
2.3.5 Problems Encountered .................................................................................................. 11
2.3.6 Estimated Budget .......................................................................................................... 11
2.3.7 Conclusion .................................................................................................................... 12
2.4 Different Types of Fuses ..................................................................................................... 12
2.4.1 DC Fuses....................................................................................................................... 13
2.4.2 AC Fuses....................................................................................................................... 13
2.5 Lightning Risks ................................................................................................................... 13
2.5.1 Step Potential ................................................................................................................ 13
 2.5.2 Touch Potential ............................................................................................................. 13
2.5.3 Side Flashing ................................................................................................................ 13
2.6 Lightning Protection Systems (LPS) ................................................................................... 14
2.6.1 Functions of an External Lightning Protection System ................................................ 14
2.6.2 Internal Lightning Protection System ........................................................................... 14
2.6.3 Lightning Equipotential Bonding ................................................................................. 14
2.6.4 Elements of a Lightning Protection System ................................................................. 14
2.6.5 Classes of Lightning Protection System (LPS) ............................................................ 15
2.7 Lightning Protection Methods ............................................................................................. 15
2.7.1 Lightning Air Terminals ............................................................................................... 15
2.7.2 Residual Current Circuit Breaker (RCCB) ................................................................... 16
2.7.3 The Surge Protection Device (SPD) ............................................................................. 17
2.8 Site Visits ............................................................................................................................ 18
2.8 Summary of Duties.............................................................................................................. 20
2.8.1 Assisted to Manufacture an ACDB .............................................................................. 21
2.8.2 Assisted to Manufacture a HRC Fuse Box ................................................................... 23
2.8.3 Assisted to Prepare an ECBs ........................................................................................ 24
2.8.4 Performed Logistic Tasks ............................................................................................. 25
3.0 Conclusion........................................................................................................................... 26
References…………………..……………………….....................................…………….27
 1.0 INTRODUCTION

I have attached to the Venora Telecom (Pvt) Ltd. which was established under a subsidiary of
the Venora Group of Companies. Throughout the training period, a sample DCDU (Direct
Current Distribution Unit) was designed by me & other trainees of SLIIT as a reverse
engineering project. And, I have gained fair understanding on the earthing side of the
telecommunication towers. After attaching to the Telecom division, I was in the workshop in
my free time to learn the manufacturing processes. Though I was a trainee from an
engineering background, I have performed some logistic tasks until a new officer was
appointed attached with guidance of the Accountant & the Marketing Executive except for
the technical training.

1.1 Vision and Mission

1.1.1 Vision
Actively contribute to sustainable development of project rollout in telecommunication
engineering in Sri Lanka by utilizing capable & experienced personals with high standard
project management.

1.1.2 Mission
To lead Venora Telecom towards in strategic position telecommunication sector through our
enhanced service offerings.

1
1.2 Company Background/History

1.2.1 Venora Group

Venora is one of the leading companies in the field of Electrical Engineering &
Telecommunication in Sri Lanka, operating with mission to be “Solution Providers for an
Energized World”. Procedures are managed under ISO 9001 quality certifications. It covers a
wide range of services including design & supply of Electrical Systems Low/High & Extra
Low Voltage, Switch Boards & Power Factor Correction Systems, Installation of
Telecommunication Equipment, Lightning & Surge Protection with the world-renowned
brands.

Venora Group of companies has four subsidiaries. They are namely

i. Venora International Projects (Pvt) Ltd.
ii. Venora Telecom (Pvt) Ltd.
iii. Venora Lanka Power Panels (Pvt) Ltd.
iv. Venora Industrial Solutions (Pvt) Ltd.

1.2.2 Venora Telecom

Venora Telecom (Pvt) Ltd. is an Engineering Company which provides Telecommunication
services & supply. It was set to offer Technical support to Telecommunication services &
supply and management service to the valued customers. Venora Telecom consists of the
following divisions.
1. Telecommunication Implementation
2. Telecommunication Operation & Maintenance
3. Earthing & Lightning Protection

Venora Telecom stepping up to the international Telecommunication market from the year
2016 and formed a company in Myanmar as ‘Venora (Myanmar) International (Pvt) Ltd’ and
Venora Telecom expands the business with foreign exposure.

2
1.3 Management

Figure 1.1 Organizational Chart

3
 2.0 TRAINING EXPERIENCE

At first, I have worked in the workshop of the Venora for one day. In there, my task was
assisting to the technicians, who were making power panels. After attaching to the Telecom
division, I was in the workshop in my free time to learn the manufacturing processes. While
working in it, everybody should aware on the below Safety Procedures.

2.1 Safety Procedures

1. When replacing a new fuse for a damaged fuse, be careful on the reasons which were
caused to damage.
2. When closing an opened switch, be careful on the reason which was caused to open.
3. Don’t work with live circuits without the permission of the relevant officers. Check
the first aids are enough. Before working with live circuits, be careful that they can be
properly switch off & earthed.
4. Switch on/off a fuse/ switch without a delay.
5. Don’t use low insulated cables.
6. Don’t touch circuits with wet fingers.
7. Don’t touch live circuits without proper safety equipments.
8. Don’t use water for the electrical fires. Use sand or blanket.
9. Be careful you are properly insulated, before saving an electrocuted person. Use
rubber boots or rubber covering.
10. Don’t check circuits with uncovered fingers.
11. Don’t let outsiders for entering to the workshop.

2.2 Ingress Protection

Electrical enclosures & their contents are protected from solids & water by understanding
where and how they will be used. Then, the suitable items can be ordered with the correct IP
(Ingress Protection) Rating.

An IP rating is used by buyers in Europe to specify the extent of protection in an electrical

enclosure has against environmental conditions. [1]

4
Figure 2.1 Ingress Protection Ratings [1]

5
2.3 Training Project
A sample DCDU (Direct Current Distribution Unit) was designed by me & other trainees of
SLIIT. This is a reverse engineering project as its market price is not cheap & it is an
imported device to Sri Lanka. At first, the DCDU was re-designed by removing its non-
critical parts. Then, its non-critical parts were replaced to practically available parts in Sri
Lankan market. Due to the re-designing process, the unit’s operational cost was minimized
than its half of the market price.

2.3.1 Introduction to the Designed DCDU

Direct Current Distribution Unit supplies DC power to each component in the cabinet of the
signal tower. It inputs -48 V, 160 A and supplies power to BBU (Base Band Unit), RFUs
(Radio Frequency Unit), and fan box in the cabinet, but not external devices. It outputs 25 A,
-48 V to the components. All the DCDUs are 1-inch-high and 19-inch length.

Figure 2.2 Position of the DCDU in a Telecom Tower Site

There are two main types of DCDUs which are imported to Sri Lanka.
1. MCB type (Trip switch included) - DCDU-03
2. Fuse type (A fuse is included in the terminal) - DCDU-12B

The functions of DCDU-03:

 Provides nine -48 V DC outputs to meet multiple power distribution requirements in
scenarios of distributed and separated base stations through different MCB
configurations
 Provides surge protections through the built-in DC surge protection board
 Provides surge protection alarm signals and reporting the surge protection alarms in
time

6
 Figure 2.3 DCDU-03

Figure 2.4 20 A Trip Switch

The DCDU-12B provides ten -48 V DC outputs using same fuse configurations to meet the
power distribution requirements of different distributed base stations.

It uses the equipotential connection point and ground point in the following scenarios:
 Scenario 1: The DCDU-12B is installed on an open sub rack. An equipotential cable
connects the equipotential connection point near the mounting ear of the DCDU-12B
to the ground bar of the open rack.
 Scenario 2: The DCDU-12B is installed on a wall as a standalone power distribution
device. The ground point at the rear of the DCDU-12B is connected to the ground bar
in the cabinet.

Figure 2.5 DCDU-12B

7
 Figure 2.6 30 A Fuse

DCDU-03 DCDU-12B
1. Has MCB with different configurations 1. Fuses with different configurations
(Trip switch) 2. Terminals slots are used. Only working
2. Since screw terminals are used can work with these ports
with any ports 3. Cost low
3. Cost High 4. Maintenance is easy
4. Maintenance is hard 5. Has a LED bulb which indicate which
5. No indication terminals are working

Table 2.1 Comparison of Two Devices

2.3.2 Redesigned DCDU

The template, which was drawn by using AutoCAD 2017 package, was cut from a galvanized
steel sheet and bent it to build the enclosure. In order to do that we went to a workshop and
worked it out. A large bus bur, which had width as twice as for the requirement, was bought.
Therefore, it was needed to be cut through the middle of the bus bar. Then, it was cut into the
required sizes of pieces according to the decided lengths to fix the cables lugs. Before that,
the relevant components were searched in several shops to meet the specific technical
requirements of the DCDU. Also we had to the sizes and the dimensions of the components
were considered in order to fix/compatible each other perfectly.

Figure 2.7 Front View of the Redesigned DCDU

8
 Figure 2.8 Inside Appearance of the Redesigned DCDU
The New DCDU, re-designed by us, has following specifications: -

1. 30 A Bulb type fuse protection.

2. It can supply current up to ten DC loads (-48V).
3. Screw terminals (can work with any ports).
4. Maintenance and Repairing is easy.
5. It has a LED indication to identify working ports.
6. Cost is significantly low.

2.3.3 Timeline of the Training Project

This was the working plan throughout the Training Project. We were stick to this timeline as
much as we could.

November December
Week 2 Week 3 Week 4 Week 1
1
2
3
4
5
6
7
8
Table 2.2 Timeline of the Training Project

9
 Task No. Task Description
1 Understanding of the Problems to Solve
2 List of Requirements
3 Planning
4 Analysis of Previous or Similar Solutions
5 Evaluation of Possible New Solutions
6 Rational Selection of Tools, Methods, Components, etc.
7 Implementation
8 Presentation of the Project
Table 2.3 Task Description of the Timeline

2.3.4 Protection Methods

In the field of electronics or electrical, a fuse is an essential device used in various electrical
circuits which gives the protection from the overcurrent. It comprises a strip or a metal wire
that dissolves when the heavy flow of current supplies through it. Once this device has
functioned in an open circuit, it ought to rewire or changed based on the type of fuse. A fuse
is an automatic disconnection of supply which is frequently shortened to ADS. The
alternative of the fuse is a stabilizer or circuit breaker, but they have many different
characteristics.

These are used to prevent the appliances from the high current or overload damage. If we use
a fuse, the electrical faults cannot happen in the wiring and it doesn’t damage the appliances
from the fire of wire burning. When the fuse gets break or damage, then an abrupt sparkle
happens which may direct to damage your appliances. That is the reason we require different
types of fuses to guard appliances against damage.

The working principle of the fuse is “heating consequence of the current”. It is fabricated
with a lean strip or thread of metallic wire. The connection of the Fuse in an electrical circuit
is always in series.

Figure 2.9 Diagram of Working Principle a Fuse [2]

10
When the too much current is produced due to the heavy flow of current in the electrical
circuit, the fuse gets soften and it opens the circuit. The extreme flow of current may direct to
the collapse of the wire and prevents the supply.

The fuse can be changed by the new fuse with an appropriate rating. It can be designed with
the elements like Cu (copper), Zn (zinc), Al (aluminium) and Ag (silver). They also perform
like a circuit breaker for breaking the circuit while the abrupt fault happens in the circuit.
This works like a safety measure or protector for humans from risks. Like this, the fuse
works.

𝑷𝒐𝒘𝒆𝒓 (𝒘𝒂𝒕𝒕𝒔)
𝑭𝒖𝒔𝒆 𝒓𝒂𝒕𝒊𝒏𝒈 = × 𝟏. 𝟐𝟓
𝑽𝒐𝒍𝒕𝒂𝒈𝒆 (𝒗𝒐𝒍𝒕𝒔)

The selection of a fuse can be done by calculating the fuse rating by using the above formula.
The main function of the fuse is to protect the electrical circuits from the overflow of current.
In a real-time situation, the flow of current during the wires may not be consistent all the
times. In that situations, the device may get damage from overheat. While the equipment has
highly developed with the handling of a circuit breaker, these types of fuses are still
employed in various places like fundamental electrical components.

2.3.5 Problems Encountered

 An enclosure couldn’t be found for the re-designed sample DCDU similar to the
Huawei DCDU-03 or Huawei DCDU-12B. The factory product was built to a
standard measurement called 1U 19 inches. It was hard to find an enclosure to meet
the requirements of the AutoCAD design.
 A copper bus bar was unable to find from the specific thickness and the width.
Especially available widths of the bus bars were too large for the DCDU. And, they
were very expensive.
 The components, which were inside the DCDU, couldn’t be found. Most of the
components were only manufactured by Huawei specially for their DCDU type
according to their dimensions.

2.3.6 Estimated Budget

Amount (Rs.)
Components’ Cost Enclosure 3,500.00
Copper Bus Bar 1,200.00
Electrical Components 3,028.00
Transport Cost Bus 3,000.00
Three wheel 800.00
Total Cost 11,528.00
Profit Margin 3,458.40
Estimated Price of the Re-designed DCDU 14,986.40
Table 2.4 Budget of the Re-designed DCDU
Profit Margin was calculated as the 30% of the Total Cost according to the guidance of the
Project Engineer. And, charges for powder coating are not included.

11
2.3.7 Conclusion
In conclusion, the re-designed sample DCDU is cost effective when it is comparing with
Huawei DCDU-12B, which is the cheapest DCDU in the market (The market price of
Huawei DCDU-12B is Rs. 29,000.00). And, the operating cost can be minimized, if DCDUs
are manufactured in a large scale by using the above techniques and this will be resulted to
save the foreign exchange.

Surge protector or a proper earthing method was not manufactured for the product due to the
lack of knowledge. It will be added to the design in future developments as it should be in the
circuit. 30 A fuses were used in the design as an alternative for the trip switches. By doing
this project, necessary workshop operations and the functions of were learnt. Useful
Drawings were done by using AutoCAD 2017 package. The total budget for the whole
project was minimized because this DCDU was designed by using reverse engineering
concepts.

2.4 Different Types of Fuses

The fuses are classified into several types based on the application namely AC type fuse and
DC type fuse. Again these fuses are classified into several types. The following diagram
illustrates the electrical fuse types chart based on the AC fuse and DC fuse.

Figure 2.10 Classification of Fuses [2]

12
2.4.1 DC Fuses
DC fuses are available superior in size, and DC supply has a stable value over 0 volts. Thus,
it is tough to remove and deactivate the circuit. There will be a chance of generation of an
electric Arc between dissolved wires. Electrodes located at better distances to conquer this.
For this reason, the size of DC fuse gets amplified. [2]

2.4.2 AC Fuses
The AC fuse is slighter in size and oscillated 50 to 60 times in each and every second from
least to highest. As a result, there is no scope for Arc generation between the dissolved wires.
For this reason, they can be crammed in small size. Further, AC fuses are classified into two
parts namely HV fuses and LV fuses. LV& HV indicates the low voltage and high voltage.

2.5 Lightning Risks

Scientists & scholars alike have had a longstanding fascination with lightning. Of course, the
most famous student of this natural phenomenon, Benjamin Franklin, was also one of the 1st
to study & document the dangers & effects of lightning. His research dates back to the 1700s.

Technology & knowledge have evolved since Franklin’s time, when the only method of
protection was a simple lightning rod. Today, electrical engineers know the need for full
facility lightning protection to defend everything from the structure, to personnel, to valuable
electronic equipment, from strikes.

Before implementing a lightning protection systems, it’s important to understand the risks
associated with lightning. Three types of lightning risks that can cause injury or facility
downtime.

2.5.1 Step Potential

An indirect lightning strike that is potentially lethal. Step potential refers to the ground
current that occurs when the lightning strike dissipates into the earth, which can be
transmitted into a person in the area of the strike.

2.5.2 Touch Potential

A direct lightning strike that is captured and carried by a metallic object, which a person
comes into contact with directly. Commonly occurs in fences and support towers.

2.5.3 Side Flashing

During a lightning flash, the rapid rate of current rise can cause down conductors or natural
objects to flashover to a nearby person or object.

While no system can completely ward off the lightning risks above, proper protection
systems can help safeguard your facility, personnel and electronic devices. [3]

13
2.6 Lightning Protection Systems (LPS)
In general, a lightning protection system must perform the following in order to be
considered effective:
 Intercept lightning flashes
 Conduct the lightning current to the earth
 Dissipate the current to the earth
 Create an equipotential bond to prevent potential differences between the system,
structure and internal circuits

The function of a lightning protection system is to protect structures from fire or mechanical
destruction and to prevent that persons in buildings are injured or even killed. An overall
lightning protection system consists of external lightning protection (lightning
protection/earthing) and internal lightning protection (surge protection).

2.6.1 Functions of an External Lightning Protection System

 Interception of direct lightning strikes via an air-termination system
 Safe discharge of lightning current to earth via a down-conductor system
 Distribution of the lightning current in the ground via an earth-termination system

Furthermore, a lightning protection system is categorized into two parts. The first is the
external lightning protection system, which intercepts, conducts and dissipates the lightning
flash to the earth. Second, the internal system that prevents flash over within the structure
using equipotential bonding.

Also note that while lightning protection systems are generally implemented via a network of
bonded air terminals and down conductors, alternative systems that capture the strike and
conduct the discharge through an insulated conductor to the ground are available.

2.6.2 Internal Lightning Protection System

Prevention of dangerous sparking in the structure by establishing equipotential bonding or
keeping a separation distance between the LPS components and other electrically conducting
elements.

2.6.3 Lightning Equipotential Bonding

Lightning equipotential bonding reduces the potential differences caused by lightning
currents. This is achieved by interconnecting all isolated conducting parts of the installation
by means of conductors or surge protective devices.

2.6.4 Elements of a Lightning Protection System

According to the EN/IEC 62305 standard, a lightning protection system consists of the
following elements:
 Air-termination system
 Down conductor
 Earth-termination system
 Separation distances
 Lightning equipotential bonding

14
2.6.5 Classes of Lightning Protection System (LPS)
Classes of Lightning Protection System (LPS) I, II, III and IV are defined as a set of
construction rules based on the corresponding Lightning Protection Level (LPL). Each set
comprises level-dependent (e.g. radius of the rolling sphere, mesh size) and level-independent
construction rules (e.g. cross-sections, materials).

To ensure permanent availability of complex data and information technology systems even
in case of a direct lightning strike, additional measures are required to protect electronic
devices and systems against surges. [4]

2.7 Lightning Protection Methods

Main essential principles of lightning protection consist of forming one or more preferred
attraction points for a direct lightning strike by using low impedance and complementary
conductor items. Afterwards these parts conduct and transfer the high lightning currents into
the ground at the safest way. This type of coherent system enables the lightning strike to be
arrested and transferred while providing maximum protection to the structure and human
beings as well.

In a nutshell, there are three main types of lightning protection/prevention methods for
protecting structures and human being against lightning.

2.7.1 Lightning Air Terminals

Lightning Air Terminals are designed to provide protection to structures against physical
damage from lightning strikes. They are critically placed on a structure and connected to a
lightning conductor and earthing system to safely receive a strike, safely conduct the
lightning current to the earthing system and safely dissipate it in the earth. Various
technologies are now available for air terminals that allows a lightning protection system to
be designed for regular shielding, proactive interception of lightning strikes at early stages
and for reducing the probability of a strike on the lightning protection system.

Figure 2.11 Lightning Air Terminals [5]

15
Three types of lightning air terminals:
1. Static Early Streamer Emitting Terminal
2. Electronic Early Streamer Emitting Terminal
3. Franklin Rod (Conventional Lightning Rod) [5]

2.7.2 Residual Current Circuit Breaker (RCCB)

A Residual Current Circuit Breakers is another different class of Circuit Breakers. A Residual
Current Circuit Breaker (RCCB) is essentially a current sensing device used to protect a low
voltage circuit in case of a fault. It contains a switch device that switches off whenever a fault
occurs in the connected circuit.

Residual Current Circuit Breakers are aimed at protecting an individual from the risks of
electrical shocks, electrocution and fires that are caused due to faulty wiring or earth faults.

RCCB is particularly useful in situations where there is a sudden earth fault occurring in the
circuit. e.g. A person accidentally comes in contact with an open live wire in the circuit.

In such situation, in absence of an RCCB in the circuit, an earth fault may occur and the
person is at the risk of receiving an electrical shock.

However, if the same circuit is protected with RCCB, it will trip the circuit in fraction of a
second thus preventing the person from receiving an electrical shock. Therefore, it is a good
and safe practice to install RCCB in your electrical circuit.

As explained above, RCCB is meant for protection from earth faults and associated risk to
human life such as electrical shocks.

The underlying fundamental principle behind operation of RCCB is that in ideal situations
the current flowing in to the circuit through live (hot) wire should be same as the returning
current from the neutral.

In case of an earth fault, the current finds a passage to earth through accidental means (such
as accidental contact with an open wire etc.). As a result, the returning current from neutral is
reduced. This differential in the current is also known as “Residual Current”.

RCCB is designed such way that it continuously senses and compares for difference (residual
current value) in current values between the live and neutral wires. Any small change in the
current value on account of such event would trigger the RCCB to trip off the circuit.

Types of RCCBs:
 2 Pole RCCB: It is used in case of a single phase supply that involves only a live and
neutral wire. It is as displayed in image below. It contains two ends where the live and
neutral wires are connected. A Rotary switch is used to switch the RCCB back to ON
or OFF positions. A test button helps to periodically test the RCCB functionality.

 4 Pole RCCB: It is used in cases of a three phase supply connection involving three
phase wires and a neutral. It is as displayed in image below. It consists of two ends
where the three phases and neutral wire is connected. Besides this it is similar in
construction and operation as 2 Pole RCCB.

16
RCCBs come in different ratings like: 30 mA, 100 mA, 300 mA.

The most widely used are 30 mA (milliamp) and 100 mA devices. A current flow of 30 mA
(or 0.03 amps) is sufficiently small that it makes it very difficult to receive a dangerous
shock. Even 100 mA is a relatively small figure when compared to the current that may flow
in an earth fault without such protection (hundreds of amps).

A 300/500 mA RCCB may be used where only fire protection is required. E.g., on lighting
circuits, where the risk of electric shock is small. [6]

It is possible to get a combined MCB (Miniature Circuit Breaker) and RCCB in one device
(Residual Current Breaker with Overload RCBO), the principals are the same, but more
styles of disconnection are fitted into one package

RCCB is primarily designed for protection from earth fault and its consequence to human life
such as electrical shocks.

As per studies, a person is able to sustain electrical shocks only to the magnitude of 30 mA.
Thus, RCCBs in low voltage protection are designed such a way that they will trip off the
circuit even for small change in residual current value of up to 30 mA. The response time is
usually within 40 milliseconds, thus ensuring that the person is fully protected from electrical
shocks at all times.

Higher values of 300 mA are used in cases where a protection from fire hazard is sought.
This is useful in places where a lot of flammable material is stored.

In conclusion, RCCB is an essential protective device in your electrical circuit that helps to
prevent electrical hazards in cases of earth faults. A properly set RCCB will ensure that there
is no fatal injury caused to human being in case of an accidental touch to live wires. [7]

2.7.3 The Surge Protection Device (SPD)

The Surge Protection Device (SPD) is a component of the electrical installation protection
system. Surge Protection Devices (SPD) are used for electric power supply networks,
telephone networks, and communication and automatic control buses.

Figure 2.12 Principle of Protection System in Parallel [8]

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This device is connected in parallel on the power supply circuit of the loads that it has to
protect. It can also be used at all levels of the power supply network.

This is the most commonly used and most efficient type of overvoltage protection. SPD
connected in parallel has a high impedance. Once the transient overvoltage appears in the
system, the impedance of the device decreases so surge current is driven through the SPD,
bypassing the sensitive equipment.

SPD is designed to limit transient over-voltages of atmospheric origin and divert current
waves to earth, so as to limit the amplitude of this overvoltage to a value that is not hazardous
for the electrical installation and electric switchgear and control-gear.

SPD eliminates over-voltages

i. in common mode, between phase and neutral or earth;

ii. in differential mode, between phase and neutral.

In the event of an overvoltage exceeding the operating threshold, the SPD

i. conducts the energy to earth, in common mode;

ii. distributes the energy to the other live conductors, in differential mode. [8]

The most enhanced range of surge protection devices for power, data and communication
lines:

Protection of Power Line:

1. Type 1 SPD
2. Type II SPD
3. Type III SPD

Protection of Data and Communication Lines:

1. Telephone Lines
2. Data Lines
3. Computer Lines
4. Coaxial Lines [9]

2.8 Site Visits

Throughout the training period, two telecom tower sites, which were situated in Rannugala &
Gonapola, were visited to measure the resistance of the tower legs as those telecom towers
were affected by lightning on the previous day. Rannugala site is owned by both Mobitel &
Dialog but Gonapola site is owned only for Dialog.

Digital Earth Tester was used measure the resistance of the tower legs. At first, three colour
(green, yellow & red) cables were connected to the Digital Earth Tester via their probes.
Then, the tester was set to 20 Ω by using its rotary selector. After that, the green cable was
connected to a bus-bar/down conductor of one tower leg. Before connecting, the bus-
bar/down conductor was scrapped by using the crocodile probe of the cable to avoid
receiving wrong values due the oxide layer. Then, the yellow & red cables were carried to the

18
longest distance, which they could carried, to the direction, which was showed by the
engineer. They were connected to Cu Testing Rods via their crocodile probes & those Rods
were connected to soil which hadn’t stones. Finally, the orange colour button was press to
obtain the values.

Figure 2.13 Digital Earth Tester

The photographs of obtained resistance values were sent to the office. As they were higher
than 10 Ω, those telecom towers should be maintained.

Tower legs are earthed by using galvanized Cu bus-bars. But one tower leg in every telecom
tower has a down conductor except for a bus-bar.

The resistance of the tower legs must be less than 10 Ω. But it can be changed due to some
reasons; especially the soil condition in the area. Therefore, Cu Testing Rods were connected
to the places which hadn’t stones in the soil. The soil in these sites were affected by the
lightning which was happened on previous day.

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2.8 Summary of Duties
After attaching to the Telecom division, I have assisted to manufacture HRC Fuse Boxes,
ACDBs, ECBs, SPDs & one ATS in the workshop in my free time to gain the practical
experience. Before the manufacturing processes, everyone must get familiar with the
drawings, tools and installation procedure.

Tool Picture Function

Multimeter Used to check cabinet
insulation and cable
connection, and measure
electronic performance
specifications of a device,
such as voltage, current, and
resistance.
Phillips screwdriver
Used to tighten screws.
Flat-head screwdriver

Socket wrench

Torque wrench Used to tighten bolts.

Adjustable wrench

Hex key
Crimping tool Used to crimp cord end
terminals.

Diagonal pliers Used to cut cables

Wire stripper Used to strip the insulation

from electric wires.

Fuse extracting unit Used to install or remove

fuses.

Brush and oil brush Used to clean the shell and

plane and apply paint.
Table 2.5 Used Workshop Tools

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2.8.1 Assisted to Manufacture an ACDB
Main purpose of ACDB (Alternative Current Distribution Board) is to distribute the
alternative power which was given by the Ceylon Electricity Board. It supplies power mainly
to the Rectifier inside the cabin. Except that, it supplies power to,
i. 15A socket outlet
ii. 13A socket outlet
iii. 5A socket outlet
iv. 5W bulb

The ACDB was constructed in a metal enclosure. Several types of MCBs and one RCCB
were used to manufacture it. for distribution of power. A photo of a previously prepared
ACDB was sent via WhatsApp as the guidance & a copy of the Material Request Note was
given to collect the materials from the stores.

MATERIAL AMOUNT
I gang I way switch Kevilton 01
Bulk head light fittings with CFL bulb 01
Colour cap 2 mm 08
Colour cap 8 mm 20
Cable duct casing 33W × 45H mm 01
Earth cable 2.5 mm Sierra 3m
Earth link 12 way 01
MCB 16A 1P 6KA 01
MCB 6A 1P 10KA 01
MCB 16A 2P 10KA 02
MCB 32A 4P 10KA 02
Metal enclosure with cover 01
PVC distribution box surface type 16W 01
RCCB 40A 2P 3mA 01
Switchgear cable 1.5 mm 2m
Bolt 6 mm × 15 mm 20
Bolt 6 mm × 25 mm 04
Nut 6 mm 24
5A switched socket outlet orange 01
13A switched socket outlet orange 01
15A switched socket outlet orange 01
Switch sunk box single 04
Switchgear cable 6 mm 5m
Table 2.6 Used Materials with Their Quantities

The objects to be mounded such as the PVC distribution box, the earth link, bulk head light
fitting, sun boxes and duct were kept on the panel plate and adjusted specifically. Then, the
drilling positions were marked out by using markers. After that, the drilling positions were
drilled by using 6 mm drill thread. Then, the drum, created by the drilling, was smoothened
by using a higher drill thread as 8 mm. After that, the objects were kept on the panel plate and
fixed to the plate by using 6 mm nut and bolt. A PVC distribution box was mounded, inside
the metal enclosure on the panel plate, to hold the breakers. Cable duct casing was mounded
to place wires inside.

21
 Figure 2.14 The Photo of Previously Prepared ACDB
After the mounding process, the breakers were fixed on the aluminium rail inside the PVC
enclosure. Then, then wiring of the beakers were done with the assistance of the technicians.
Power from the CEB comes as three phases, from those three, one phase and neutral were
taken into distribution of power through the breakers. And, a three-phase current was taken to
the Rectifier inside the cabin from the panel.

A four core cable was used as the main cable, which supplies power to the Distribution
Board, was 3 phase. This cable consists of four wires. Including the earth cable there were
five wires. These cables have the following colours /colour caps.

 Phase 1 - Brown
 Phase 2 - Black
 Phase 3 - Grey
 Neutral - Blue
 Earth - Green

The earth cable was set along the common area on the cable tray. And, it was connected to
each component through the sleeve. After of all, the power was distributed to the socket
outlets and the 5W bulb. The cables were taken through the cable duct.

Channel cable tray was used to hold the main cable. The Insulation Test was done to check
the current leakages. 500 V was supplied & measure the resistance. Better insulation can be
obtained for the high resistance.

Before the panel plate was fitted into the metal enclosure box, it was cleaned with air vacuum
gun. Then, it is fitted inside the metal box. After that, the door of the metal box was also
earthed. Finally, the ACDB was wrapped with cellophane paper & load into the truck to
transport to the site.

22
Venora Telecom returns the damaged telecom devices of the telecom towers after
disassembling them from the towers. Then, they were stored in the yard until their owners
order to return them.

One ACDB’s inside components were lost/misplaced when it was stored in the yard. Then, it
could not be returned. Therefore, another engineer was requested to fix/arrange the
components of the ACDB properly. Some new components/materials were used to this task
since they were unable to find in the yard.

As this task was given few weeks later, it could finish in a small time.

2.8.2 Assisted to Manufacture a HRC Fuse Box

HRC stands for the meaning of High Rupturing capacity. The main purpose of the HRC fuse
box is safety as at a time of fault it disconnects the circuit very fast. HRC box contains four
large fuses; three of them for the 3 phase conductors and one for the neutral. This box is
made from metal same as ACDB.

Figure 2.15 HRC Fuse Box with Fuse Bases

Figure 2.16 HRC Fuse

The four fuses were fixed upon four fuse bases. These bases were first implanted on the metal
plate using nut and bolt. The procedure is same as the ACDB; the four bases were fixed on
the plate with equal distance to each other. The plate dimensions were equally distributed
before fixing the bases. They were also mounted by using 6 mm nut and bolt. After mounting
the bases, the fuses were fixed. Then, the plate was fixed to the metal box. Finally, the door is
earthed.

23
2.8.3 Assisted to Prepare an ECBs
ECB are very essential when it comes to earthing scenarios. ECBs are commonly called as
‘bus-bar’ at the industry. These bars are used to provide a convenient common earthing point
for electrical installations. Usually they are produced from Copper, Aluminium or Stainless
steel. Copper is a good conductor compared to Aluminium & it is cheap than Stainless steel.

Venora can produced ECBs (Earth Connecting Bars) depending on their requirement. At first,
required copper bar size was marked on the long copper bars. Then, the marked copper bars
were cut by using Hydraulic Bus-bar Cutting Machine. After that, the required number of
holes were drilled at the workshop. Holes were marked with the help the digital Vernier
caliper screw gauge and ruler. Digital Vernier caliper was used to measure the width of the
ECB to find its mid-point. After marking at least three mid-points by using a pencil, a line
was drawn through them.

The length of the ECB was divided according the number of holes needed and also concern
on the diameter of the hole’s. The dimensions of the ECB and the number of holes on it
depends upon the task.

Then, lines were drawn vertically against the length. At crossing points, the pointer was kept
and taped by hammering to mark a small dot as cavity. After that, the bar was taken to the
drilling machine to drill out the holes by using 8 mm drill thread. After drilling the holes, 10
mm drill thread was used to remove the drums which were created by drilling. Finally, they
were galvanized to avoid the corrosion & protect them from thieves by indicating that they
were not made by Copper.

Figure 2.17 ECBs

24
2.8.4 Performed Logistic Tasks
Before 20th of December 2019, Venora Group has not a Logistic Officer. Therefore, the
logistic tasks were done by other officers. One day the Marketing Executive was requested to
buy plastic dc tape clips from Rotax (Pvt) Ltd. I have accepted that task as a help & our
Training Supervisor was permitted me to leave. The Accountant was given Rs. 10,000/- to
buy the required item & pay for buses.

At first, a photo of a plastic dc tape clip was shown & sent to me by the Marketing Executive
as I was not familiar about it. Then, the location of the company was shown by using the
Google Map. I could find buses to the location & relevant buses were selected from them by
me as I was familiar with Google Maps & the location.

Figure 2.18 Plastic Dc Tape clips

Due to the traffic, I was late to return the bought items. Therefore, the Marketing Executive
ordered to handover them to the guardroom with the invoice.

After nearly a one week ago, another engineer requested to buy a Meter Board & hand over it
to Mobitel site at Homagama. Its dimensions should be 1 Ft. & 11 inches in both length &
width. Its thickness can be 1 or 1.5 inches. But it should be handed over to the site on or
before 3.00 p.m. However, it must be cost around Rs. 2,000 & the material isn’t concerned. A
Crew Cab & a driver was provided.

It has taken lot of time as most of saw-mills were not opened on Monday morning & some
low quality timber boards had not the enough thickness. Finally, a board could be found,
which has 1inches thickness, & it was handed over before 3.00 p.m. to the site.

Figure 2.19 Prepared Meter Board

Except for the above tasks, I have accepted to perform several logistic works & gain the
knowledge from such activities. Some of them were done when the newly recruited Logistic
Officer was doing another task at that time.

25
 3.0 CONCLUTION

It is obvious that I had a great experience during my industrial training period at Venora
Telecom (Pvt) Ltd., as this was my second industrial training experience. Throughout the
training I have got vital knowledge and experience in this field. Also, I determined to deploy
my theoretical knowledge and skills, to put into practice.

As an undergraduate, I have gained some theoretical knowledge in the university. But

throughout the training period, I have been familiarized to the industrial environment. And
my experience was basically related to the methods and practices adopted in the field and not
to the detail theoretical aspects behind those. Thus, in presenting my experiences of training I
have given a particular emphasis on practical considerations given less priority to the
theoretical aspects related.

26
 References

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https://www.elprocus.com/what-is-fuse-different-types-of-fuses-and-applications/.
[Accessed 28 11 2019].

[3] “A Beginner’s Guide to Lightning Risks and Protection Methods,” Nvent, 23 02 2018.
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risks-and-protection-methods/. [Accessed 15 11 2019 ].

[4] “Lightning Protection Systems,” Dehn, [Online]. Available: https://www.dehn-

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[6] Jiguparmar, “What is the difference between MCB, MCCB, ELCB, and RCCB,” 2020 01
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between-mcb-mccb-elcb-and-rccb. [Accessed 25 10 2011].

[7] “Residual Current Circuit Breaker,” 2020. [Online]. Available:

http://engineering.electrical-equipment.org/electrical-distribution/residual-current-circuit-
breaker-rccb.html. [Accessed 16 01 2020].

[8] “The Surge Protection Device,” 20 12 2019. [Online]. Available: https://www.electrical-

installation.org/enwiki/The_Surge_Protection_Device_(SPD). [Accessed 07 11 2019].

[9] “Surge Protection Devices,” Dhruva Technologies (Pvt) Ltd. , 2020. [Online]. Available:
https://www.dhruvatec.com/surge-protection.html#1. [Accessed 28 12 2019].

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