Industrial Electrical Cables and Power Systems

Electrical cables and power systems are the lifelines of industrial operations, ensuring reliable energy transmission, operational efficiency, and safety. This course provides a comprehensive understanding of the design, installation, testing, maintenance, and repair of electrical cables and power systems in industrial environments. Participants will learn how to select appropriate cables, design robust power systems, conduct inspections, perform preventive maintenance, and troubleshoot common issues. Through lectures, hands-on tutorials, case studies, and practical exercises, this course equips participants with the skills to manage industrial electrical systems effectively.

Audience

This course is designed for:

Electrical engineers and technicians working in industrial plants.
Maintenance personnel responsible for electrical installations and power systems.
Plant engineers and operators involved in power distribution and control systems.
Energy consultants and project managers overseeing industrial electrical projects.
Graduates and postgraduates in electrical engineering seeking practical expertise.

Course objectives

By the end of this course, participants will be able to:

Understand the principles and components of industrial electrical cables and power systems.
Design and install safe and efficient electrical systems for industrial applications.
Perform routine inspections, preventive maintenance, and repairs on electrical cables and systems.
Troubleshoot common issues in electrical systems and implement corrective actions.
Apply industry standards (NEC, IEC, IEEE) and best practices for safe and reliable operation.
Use diagnostic tools and techniques to assess system performance and health.

Course contents

Day–1: Fundamentals of Industrial Electrical Cables and Power Systems

Overview of industrial electrical cables and power systems, including their importance.
Types of cables: Low, medium, high-voltage, and specialty cables.
Key power system components: Transformers, switchgears, circuit breakers, and busbars.
Cable selection criteria: Voltage ratings, current capacity, insulation, and environmental factors.
Hands-on cable identification, case study on power failure due to incorrect cable selection, and a quiz.

Day–2: Design and Installation Practices

Industrial power system design principles: Single-line diagrams, feeders, and distribution networks.
Cable routing methods: Underground, overhead, and conduit-based installations.
Best practices for installation: Proper bending, pulling tension, and terminations.
Earthing and bonding system design and implementation.
Group exercise on single-line diagram design, case study on cable installation failures, and a quiz.

Day–3: Testing and Commissioning

Electrical cable testing methods: Insulation resistance, continuity, and high-potential (Hi-Pot) tests.
Commissioning procedures: Pre-commissioning checks, functional testing, and handover.
Testing tools: Megohmmeters, thermal imaging cameras, and fault locators.
Safety protocols during testing and commissioning.
Practical insulation resistance testing, case study on commissioning failures, and a quiz.

Day–4: Maintenance and Repair

Routine inspection methods: Visual checks, thermal imaging, and vibration analysis.
Preventive maintenance schedules: Cleaning, lubrication, calibration, and component replacement.
Common cable and equipment issues: Overheating, insulation degradation, and mechanical failures.
Repair techniques: Replacing faulty cables, rewinding motors, and transformer reconditioning.
Practical transformer inspection, case study on power line maintenance, and a quiz.

Day–5: Troubleshooting and Final Assessment

Common electrical faults: Overloads, short circuits, ground faults, and insulation breakdowns.
Root cause analysis techniques: Data logging, fault diagnostics, and predictive analytics.
Step-by-step troubleshooting methodologies for electrical power systems.
Safety protocols during troubleshooting and repair.
Final assessment, post-test evaluation, and group discussion on key takeaways.

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