TCL

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LOWER PERIYAR POWER STATION
M.Tech(Power Systems)
Department of Electrical & Electronics Engg.
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CHAPTER-1 INTRODUCTION
The hydroelectric power plant, also called as dam or hydro power plant, is used for generation of electricity from water on large scale basis. The dam is built across the large river that has sufficient quantity of water throughout the river. In certain cases where the river is very large, more than one dam can built across the river at different locations .among the various renewable natural energy resources; the hydropower generation has emerged as the most potential option in terms of environmental cleanliness and cost-effective high capacity generation. The hydel power stations have the inherent ability for instantaneous starting, stopping and load variations, which ensures a high reliability of power system. Therefore, hydel power stations are the best option for meeting the peak demand. Further, the generation cost in hydroelectric projects is inflation free and reduces substantially over time after repayment of debt. With 41 rivers, flowing down (westward) from the Western Ghats joining the backwaters and the Arabian Sea, Kerala has tremendous potential for hydel-power generation. Power generation started in Kerala in 1947 with the commissioning of the Pallivasal hydro-electric project at the Ramaswami Ayer Headwork close to the tea county of Munnar in the erstwhile princely State of Travancore. The Kerala power system consists of 17 hydel stations including 2 captive power plants, 2 thermal stations, 3 independent power producers, 5 major inter-state transmission lines, one 400 KV subsection, and two 220 KV substations with the interconnecting grid. Kerala has a storage capacity of 3843mu and the present storage is about 72% of the full capacity. Mullaperiyar dam, Idukki Hydro-electric project, Idamalayar Hydro electric project and the Lower Periyar are constructed across the Periyar. Kundala Dam, Mattupetty Dam, Munnar head works, Ponmudi dam and the Kallarkutty Dam are constructed across the various tributaries of Periyar. Lower Periyar hydroelectric project (180 MW) envisages utilization of the tail waters from the existing Neriamangalam power station and the spill from Kallarkutty head works. The Sengulam hydroelectric project is situated downstream of Pallivasal Project in Mudirampuzha river, which is an important tributary of Periyar river. Panniyar hydroelectric project is developed on Panniyar, a tributary of Mudirampuzha river.
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1.1 Hydro-Electric Projects in Kerala Table 1.1 Hydro-electric Projects in Kerala

Project Idukki Sabarigiri Idamalayar Sholayar Capacity 6 x 130 MW 5 x 55MW + 60 MW 2 x 37.5 MW 3 x 18 MW 3 x 4.5 MW + 3 x 8 MW 3 x 25 MW + 3 x 50 MW 2 x 15 MW 3 x 17.55 MW + 25 MW 4 x 8 MW +16 MW 4 x 12 MW 2 x 25 MW Total 780 335 75 54 Dams Idukki, Cheruthoni Kakki,Anathodu,Pampa Idamalayar Sholayar-Main,SholayarFlanking,Sholayar-Saddle Dam Kandla,Madupetty Kuttiyadi Ponmudi,Anayirangal Kallarkutty PoringalkuttuShengulam Veluthodu, Moozhiyar
Pallivasal Kuttiyadi Panniar Neriamangalam Poringalkuthu Sengulam Kakkad
37.5 225 30 77.65 48 48 50
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CHAPTER-2 HYDEL POWER PLANTS
Fig 2.1 Hydroelectric Dam In hydroelectric power plants the potential energy of water due to its high location is converted into electrical energy. The total power generation capacity of the hydroelectric power plants depends on the head of water and volume of water flowing towards the water turbine The water flowing in the river possesses two type of energy: the kinetic energy due to flow of water and potential energy due to the height of water. In hydroelectric power and potential energy of water is utilized to generate electricity. The formula for total power that can be generated from water in hydroelectric power plant due to its height is given, P=rhg where, P is the power produced in watt and r is the rate of flow of water which in cubic meter/second h= height of water which is measured in meter and is also head of water .the difference between source of water (from where water is taken) and the waters outflow (where the water is used to generate electricity), it is the place near the turbines. g is the gravity constant 9.81 m/second square The formula clearly shows that the total power that can be generated from the hydroelectric power plants depends on two major factors: the flow rate of water or volume of flow of water and height or head of water. More the volume of water and more the head of water more is the power produced in the hydroelectric power plant. Based on the facts presented above, hydro-electric power plants can generally be divided into two categories.
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"High head" power plants are the most common and generally utilize a dam to
store water at an increased elevation. The use of a dam to impound water also provides the capability of storing water during rainy periods and releasing it during dry periods. "Low head" hydro-electric plants are power plants which generally utilize heads
of only a few meters or less. Power plants of this type may utilize a low dam or weir to channel water, or no dam and simply use the "run of the river". Run of the river generating stations cannot store water, thus their electric output varies with seasonal flows of water in a river.
Fig 2.2 Hydro power plant Basic components of a conventional hydropower plant can be categorized into three major parts: 1. 2. 3. Hydraulic Structures Hydro Turbines Electrical structures
2.1 Hydraulic Structures Hydraulic structures in a hydro electric power station include dam, spillways, head-works, surge tank, penstock and accessory works. Dam Dams are structures built over rivers to stop the water flow and form a reservoir. The reservoir stores the water flowing down the river. This water is diverted to turbines in power stations. The dams collect water during the rainy season and store it, thus allowing for a steady flow through the turbines throughout the year. Dams are also used for controlling floods and irrigation. The dams should be water-tight and should be able to withstand the pressure exerted by the water on it. There are different types of dams
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such as arch dams, gravity dams and buttress dams. The height of water in the dam is called head race. Spillway A spillway as the name suggests could be called as a way for spilling of water from dams. It is used to provide for the release of flood water from a dam. It is used to prevent over toping of the dams which could result in damage or failure of dams. Spillways could be controlled type or uncontrolled type. The uncontrolled types start releasing water upon water rising above a particular level. Penstock Or Tunnel Penstocks are pipes which carry water from the reservoir to the turbines inside power station. They are usually made of steel and are equipped with gate systems. Water under high pressure flows through the penstock. They are generally made of reinforced concrete or steel. Concrete penstocks are suitable for low heads (<30m) as great pressure causes rapid deterioration of concrete. Automatic butterfly valve shuts off water flow through the penstock promptly when it ruptures. Air valve maintains the air pressure inside the penstock equal to the atmospheric pressure. When water runs out of a penstock faster than it enters, vacuum is created which may cause the penstock to collapse. Under such situations, air valve opens and admits air in the penstock to maintain inside air pressure equal to the outside air pressure. They are usually made of steel and are equipped with gate systems. A tunnel serves the same purpose as a penstock. It is used when an obstruction is present between the dam and power station such as a mountain. Surge Tank Surge tanks are tanks connected to the water conductor system. It serves the purpose of reducing water hammering in pipes which can cause damage to pipes. The sudden surges of water in penstock are taken by the surge tank, and when the water requirements increase, it supplies the collected water thereby regulating water flow and pressure inside the penstock. When the turbine is running at a steady load, there are no surges in the flow of water through the conduit i.e. the quantity of water flowing through the conduit is just sufficient to meet the turbine requirements. However, when the load on the turbine decreases, the governor closes the gates of the turbine, reducing water supply to the turbine. The excess water at the lower end of the
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conduit rushes back to the surge tank and increases the water level. Thus the conduit is prevented from bursting. On the other hand when the load on the turbine increases, additional water is drawn from the surge tank to meet the increased load requirements. Hence a surge tanks overcomes the abnormal pressure in the conduit when load on the turbine falls and acts as a reservoir during increase of load on turbine. Open conduits leading water to the turbine require no protection. However, when closed conduits are used, protection becomes necessary to limit the abnormal pressure in the conduit. For this reason, closed conduits are always provided with a surge tank. A surge tank is located near the beginning of the conduit.
Fig 2.3 Surge Tank 2.2 Hydro Turbines The water strikes and turns the large blades of a turbine, which is attached to a generator above it by way of a shaft. The most common type of turbine for hydropower plants is the Francis Turbine, which looks like a big disc with curved blades. A turbine can weigh as much as 172 tons and turn at a rate of 90 revolutions per minute. The principal types of water turbines are: a) Impulse Turbines b) Reaction Turbines
a) Impulse Turbines change the velocity of a water jet. The jet pushes on the turbine's curved blades which changes the direction of the flow. The resulting change in momentum (impulse) causes a force on the turbine blades. Since the turbine is spinning, the force acts through a distance (work) and the diverted water flow is left with diminished energy. Prior to hitting the turbine blades, the water's pressure (potential energy) is converted to kinetic energy by a nozzle and focused on the turbine. Impulse turbines are most often used in very high (>300m/984 ft) head applications. The example of this type of turbine is the Pelton Wheel.
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Fig 2.4 Impulse Turbine b) Reaction Turbines as the name implies, is turned by reactive force rather than by a direct push or impulse. In reaction turbines, there are no nozzles as such. Instead, the blades that project radially from the periphery of the rotor are formed and mounted so that the spaces between the blades have, in cross section, the shape of nozzles. Since these blades are mounted on the revolving rotor, they are called moving blades. Fixed or stationary blades of the same shape as the moving blades are fastened to the stator (casing) in which the rotor revolves. The fixed blades guide water into the moving blade system and, since they are also shaped and mounted to provide nozzle-shaped spaces between the blades, the freed blades also act as nozzles. A reaction turbine is moved by three main forces: (1) the reactive force produced on the moving blades as the water increases in velocity as it expands through the nozzleshaped spaces between the blades; (2) the reactive force produced on the moving blades when water changes direction; and (3) the push or impulse of water impinging upon the blades. Thus, as previously noted, a reaction turbine is moved primarily by reactive force but also to some extent by direct impulse.
Fig 2.5 Reaction Turbine Most water turbines in use are reaction turbines and are used in low (<30m/98 ft) and medium (30-300m/98984 ft) head applications. The important types of reaction turbines are
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i) ii)
Francis Turbines Kaplan Turbines
The Francis turbine is one in which the working fluid changes pressure as it moves through the turbine, giving up its energy. It consists of an outer ring of stationary guide blades fixed to the turbine casing and an inner ring of rotating blades forming the runner. The inlet is spiral shaped. Guide vanes direct the water tangentially to the turbine wheel, known as a runner. This radial flow acts on the runner's vanes, causing the runner to spin. The guide blades control the flow of water to the turbine. Water flows radially inwards and changes to a downward direction while passing through the runner. As the water passes over the rotating blades of the runner, both pressure and velocity of water is reduced. This causes a reaction force which drives the turbine. The guide vanes (or wicket gate) may be adjustable to allow efficient turbine operation for a range of water flow conditions. As the water moves through the r unner, its spinning rad ius decreases, further acting on the runner. For an analogy, imagine swinging a ball on a string around in a circle; if the string is pulled short, the ball spins faster due to the conservation of angular momentum. This property, in addition to the water's pressure, helps Francis and other inward-flow turbines harness water energy efficiently. A Francis turbine is used for low to medium heads.
Fig 2.6 Francis Turbine A Kaplan turbine is used for low heads and large quantities of water. It is similar to Francis Turbine except that the runner of Kaplan turbine receives water axially. Water flows radially inwards through regulating gates all around the sides, changing direction in the runner to axial flow. This causes a reaction force which drives the turbine.
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CHAPTER-3 SALIENT FEATURES OF LOWER PERIYAR GENERATING STATION
Fig 3.1 Lower Periyar Generating Station Lower Periyar Power House which is situated at Karimanal is the third biggest generating station of K.S.E.B. The installed capacity of lower Periyar generating station is 3x60MW and there are 6 nos. 220kV out going feeders. This is the first generating station in KSEB using microprocessor controlled logic circuit for the automatic operation of the generators from shutdown status to generator status and from generator status to shutdown status. It is the second generating station in Kerala where static excitation system is adopted. These machines are designed for synchronous condenser operation also. It forms one of the most important tie station in the power grid of Kerala .The 220 kV feeders from Lower Periyar powerhouse are l) double circuit feeder to Idukki power house, 2) double circuit feeder to 400 kV substation Madakkathra, and 3) double circuit feeder to 220 kV substation Bhrahmapuram. During the tied operation of these lines, the 220kV bus will be the main inter linking bus for the 4 most important major grid stations of KSE Board viz. Idukki power house, 400kV substation Madakkathra, and 220 kV substations
Bhrahmapuram which is directly tied with Kayamkulam Thermal station.
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CHAPTER-4 HYDRAULIC SYSTEM OF LOWER PERIYAR

Average annual generation at the power station is approximately 69MW or 609 Mu. Reservoir at Pambla along Mudirampuzha river basin with dam of 31m high above nominal riverbed and 244m long across river Periyar about 5km downstream of Panamkutty Power House form the water conductor system. Storage level of reservoir is approximately 4.55 MCM. The dam is of concrete gravity type with a FRL of 253m.there are 5 motorized upper vents and 2 hydraulic lower vents for the operation of dam. The intake arrangement consists of an intake well provided with a trash rack, an intake gate and also an emergency gate. There is a level difference between dam level and intake well level. The system also comprises 6.05 m dia, D Shaped, 12.79 km long circular concrete lined Power Tunnel, a restricted orifice Surge Shaft of 18
meter diameter, a 5.25 meter finished diameter, pressure shaft of length 378 meter, branching in to three steel lined pressure shafts each of 2.96 meter diameter and of average length of 207 meter. A surface Power House with three machines located at Karimanal about 18km downstream of Mudirampuzha, Periyar confluence. The power house is of 180MW capacity with 3 units of 60 MW each mechanically coupled to Francis turbines. The generator output is stepped up to 220KV by a 66.6 MVA power transformer and is distributed among 6 feeder lines, two each to Idukki, Bhrahmapuram and the 400KV Madakkathra. 4.1 Specifications of the Hydraulic System Reservoir-Pambla River basin Storage Water usage Dam Type Scheme Maximum water level Full reservoir level Minimum Draw Down level Power Tunnel Size and shape Length Mudirampuzha 4.55 MCM 2.17 MCM/MU Concrete gravity run off river 256 m 253 m 237.76 m 6.05 m, D Shape 12.791 km
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Sill level at inlet Sill level at surge shaft Maximum velocity in tunnel for a discharge of 124.7m3/sec Surge Shaft Type Size Top level of surge shaft Minimum down surge level Bottom level of surge shaft Control gate Pressure shaft No. of pressure shaft Size and shape Length Manifold (steel lined) size and shape Branch lines No. of shafts Size Average length -
229.00 m 186.55 m 4.34 m/sec. restricted orifice 18m dia 285.00 197.99 194.10 Vertical lift gate One 5.25m, circular 378 m 5.25m dia. 3 Nos. 2.96 m dia., circular 207 m
Fig 4.1 Profile of the Water Conductor System
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CHAPTER-5 HYDRO-TURBINE
Fig 5.1 Francis Turbine The Lower Periyar Hydroelectric project employs the Francis Turbine. Francis Turbine has a circular plate fixed to the rotating shaft perpendicular to its surface and passing through its center. This circular plate has curved channels on it; the plate with channels is collectively called as runner. The runner is encircled by a ring of stationary channels called as guide vanes. Water is brought to the turbine and directed to guide vanes or wicket gates. Guide vanes are housed in a spiral casing called as volute. The exit of the Francis turbine is at the center of the runner plate. There is a draft tube attached to the central exit of the runner. The design parameters such as, radius of the runner, curvature of channel, angle of vanes and the size of the turbine as whole depend on the available head and type of application altogether. The modern Francis Turbine is an inward mixed flow reaction turbine i.e., the water under pressure enters the runner from the guide vanes towards the centre in radial direction and discharge out of the runner axially. The Francis turbine operates under medium heads and also requires medium quantity of water. The head acting on the turbine is transformed into kinetic energy and pressure head. Due to the difference of pressure between guide vanes and the runner (called reaction pressure), the motion of runner occurs. That is why a Francis turbine is also known as reaction turbine. The pressure at inlet is more than that at outlet. In Francis turbine runner is always full of water. The moment of runner is affected by the change of both the potential and kinetic energies of water. After doing the work the water is discharged to the tail race through a closed tube called draft tube. It is employed in the medium head power plants. This type of turbine covers a wide range of heads (30m to 450m). Francis turbine doesnt allow the water to fall freely
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to the tailrace level as in the case of Pelton turbine. The free end of the draft tube is submerged deep in the tail water, thus making the entire water passage, right from the head race up to the tail race totally enclosed. The draft tube converts kinetic head to pressure head. About 70% conversion is possible. By recovering pressure head in the draft tube the pressure at the runner exit is reduced below atmosphere. This makes it possible to install the turbine above the tail race without any loss in available head. This is an important advantage in the reaction over Pelton turbine. The turbine has its own thrust bearing capable of carrying the additional load of turbine shaft, runner and hydraulic thrust making a total of three guide bearings for the complete unit. 5.1 Specifications Type Rated/Max output Design Net head Max Gross head Min.net head Rated /Max. Discharge Rated speed Run away speed Direction of rotation Maximum pressure rise Maximum speed rise Vertical Francis 61300/67400KW 184m 204.58m 165m 36.2/40.2 Cub m3/sec. 333.3RPM 585RPM Clockwise 50% 50%
The vertical shaft Francis type turbine comprise of a draft tube, spiral casing and stay rings, guide apparatus, shaft, runner, guide bearing, shaft seal and auxiliary items. The guide apparatus regulates the flow of water with, change in load and also serves as a closing device. It includes top cover, pivot ring, guide vanes and turning machinery. The mechanism for turning the guide vanes (regulating ring) is designed to ensure simultaneous turning of guide vanes during opening or closing of guide apparatus. Two servomotors, housed inside the pit liner, actuate the regulating ring which in turn operates the guide vanes through regulating gear. To facilitate atmospheric
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air supply below the runner during part load operation of turbine, the necessary connections from the aeration valve are made in the upper cone. The shaft sealing prevents leakage of water through clearance between top cover and shaft sleeve. It is located below turbine guide bearing. To prevent the abrasive particles and dirty water corning in contact with the rubber-sealing ring, water at a pressure slightly higher than that above the runner is supplied at three points of the shaft seal through a micro filter from the main cooling water system. Oil level relay is provided on the bearing housing to indicate high and low oil levels of the bearings at Unit control board [UCB]. Temperatures of guide bearing pads are monitored by a set of resistance temperature detectors [RTD] and dial type thermometers [DTT]. Out of eight pads, temperatures of four pads are measured by RTDS and the remaining four by DTTS. Two RTDs measure temperature in the oil bath. 5.2 Guide Vane Servomotors Guide vanes are fixed aerofoils that direct air, gas, or water into the moving blades of a turbine or into or around bends in ducts with minimum loss of energy. The runner of turbine is encircled by a ring of guide vanes. Guide Vanes are installed in the turbine to regulate the quantity of water to the runner with change in load. These are operated by two servomotors through guide vane operating mechanism via links & levers. The servomotors get signals from Governor. The guide vanes are of aero flow section, which allows the flow of water without formation of eddies in all positions. Depending upon silt flow, the guide vanes may be made of mild steel or stainless steel with integral machined stems, which are drilled for grease lubrication of bushes. Two servomotors are provided for turning the regulating ring during regulation of load on turbine and closing /opening of the guide apparatus. When the turbine load changes during generating operation, the servo motor shall operate the guide vane smoothly coordinating with the speed governor
Fig 5.2 Guide Vanes
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.CHAPTER-6
GOVERNOR MECHANISM
The primary purpose of a governor for a hydroelectric unit is to control the speed and loading of the unit. It accomplishes this by controlling the flow of water through the turbine
by adjusting the opening of the Needles / Guide vanes and by sensing the Speed of the Machine. The governing system consists of two parts (i) the sensing and signal processing part. (ii) The operational part. In the operational part hydraulic oil pressure is used for operating vanes and valves.
Fig 6.1 Block diagram of electronic governor 6.1 Electro hydraulic transducer The electro- hydraulic transducer is the interface between the electronic signal processing part and the hydraulic operating part. This transducer receives the electric signal from electronic part and converts the signal into a hydraulic flow. This hydraulic signal is hydraulically amplified and used for operating the vanes or the jets and deflectors.
Feed Forward pull from Actuator Feed back push from servo motor
Servo motor
Floating liver
Arrangement of Distributing valve controlling a Servomotor.
Fig 6.2 Distributing valve controlling a Servomotor When an opening signal is received from the electronic governor, the actuator will pull the floating valve piston to go down and pressure oil is admitted to opening side of servomotor and servomotor gradually opens. As the servomotor opens, the feedback lever pushes the floating lever upwards. When feedback push equals the feed forward pull, the distributing valve piston will return to the original position and steady state is achieved .
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CHAPTER-7 VALVE GALLERY
Fig 7.1 Valve system On the upstream side there is valve gallery throughout the length of the floor. The main equipments on this floor are Butterfly [BF] valve, water operated servomotors, oil leakage units and the pipelines for the same. The access to the draft tube cone and the removal of the runner for maintenance is also from this floor. The station drainage system is installed on the left hand side of the Power Station when viewed from the downstream side. A 2.2 m dia. double door BF valve has been provided as main inlet valve on each penstock branch. Water operated double acting servomotor(20 kg/cm2) has been provided on the left hand side of the BF valve and is mechanically connected with a lever and keyed to the door turn-on of the BF valve. A 100 NB drain valve is provided on the bottom side of the BF valve to drain the water in between the two doors of the BF valves and is connected to the penstock drain pipe. The servomotor is water operated. An oil operated control valve (40 kg/cm2) is provided to adjust opening and closing of the valve. For the opening of the main inlet valve [MIV], water under pressure is taken from the spiral side and for the closing the same is taken from the penstock side through isolating 40 NB valves and duplex strainers. Time of closing is 50-55 sec. The operation of the control valve is carried out by oil pressure through a solenoid valve mounted on the MIV control panel. If the oil pressure is low due to control failure or any other fault, when the MIV is open, the control spring will force the operating piston down to its closed position. This will close the MIV automatically. All these assembly has been provided on the left side of
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BF valve. From the upstream of inlet pipe of the BF valve tapping and connections are taken with isolating valves, for operating control valve, ejector, and pressure gauges.
Fig. 7.2 Bypass Valve Oil operated by-pass valve and piping are provided over the top of the BF valve for balancing the pressure on either side of the BF valve. The opening and dosing of the valve is carried out with the help of pressurized oil taken from the oil pressure system through a solenoid valve which is mounted on the MIV control panel. Limit switches are provided to get the opening and closing indications for the by-pass valve and BF valve.
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CHAPTER-8 GENERATOR
An alternator is an electromechanical device that converts mechanical energy to electrical energy in the form of alternating current. Alternators generate electricity based on the principle that, when the magnetic field around a conductor changes, a current is induced in the conductor. Typically, a rotating magnet, called the rotor turns within a stationary set of conductors wound in coils on an iron core, called the stator. The field cuts across the conductors, generating an induced emf (electromotive force), as the mechanical input causes the rotor to turn. The rotating magnetic field induces an AC voltage in the stator windings. Often there are three sets of stator windings, physically offset so that the rotating magnetic field produces a three phase current, displaced by one-third of a period with respect to each other. The rotors magnetic field may be produced by induction (as in a "brush-less" alternator), by permanent magnets (as in very small machines), or by a rotor winding energized with direct current through slip rings and brushes. In alternators, the armature may be the rotor or stator. The rotating-field alternator has a stationary armature winding and a rotating-field winding. The advantage of having a stationary armature winding is that the generated voltage can be connected directly to the load. The stationary armature, or stator, of this type of alternator holds the windings that are cut by the rotating magnetic field. Rotating-field ac generator consists of an alternator and a static excitation system. In the case of a machine with field coils, a current must flow in the coils to generate the field; otherwise no power is transferred to or from the rotor. The process of generating a magnetic field by means of an electric current is called excitation. The output of the alternator section supplies alternating voltage to the load. The only purpose for the exciter is to supply the direct current required to maintain the alternator field. Thus, a fixed-polarity magnetic field is maintained at all times in the alternator field windings. When the alternator field is rotated, its magnetic flux is passed through and across the alternator armature windings. There are two types of rotors used in rotating-field alternators. They are called the turbine-driven and salient-pole rotors.
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The windings can be lap or wave. Generators can be installed horizontally as well as vertically based on the weight. The Generators installed at Lower Periyar Power House are of vertical type, salient pole, and suspended type construction. The stator winding is of two-layer bar type wave winding. The Generator has a guide bearing positioned above the rotor, and one guide bearing below the rotor. Hydro Static [HS] lubrication system for injection of oil to the thrust bearing pads have been provided for use during starting and stopping. The generator slip rings and speed signal generators are located at the top. The generator excitation is provided by separate static excitation equipment. 8.1 Technical Data Of The Generator Maximum continuous rating Rated power Rated voltage Rated power factor Rated frequency Rated speed No. of poles Direction of rotation Air gap at pole centre Stator Resistance/Phase Stator winding connection Field winding Resistance Excitation current at no load Excitation current at rated load Stator current at rated load 8.2 Stator The different parts are Frame-The stator frame is used to hold the armature windings in alternators, and in case of larger diameter alternators (which are slow speed) the stator frame is cast out of sections and there are holes for ventilation in the casting itself. The recent trends towards 66.67 MVA 60 MW 11000 volts 0.9 lagging 50 Hz 333.33 RPM 18 clockwise 26 mm 0.00505 Ohm Star (Wave) 0.14255 Ohm 607 Amps 1250A,230V 287.5kW 3500 A
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such stator construction are more in favour of using mild steel plates which are welded together rather than castings. The stator frame is built of welded steel structure and to facilitate transport, it is dispatched from the factory in three parts. It has adequate depth to prevent distortion during transport and under any operating conditions. Core- Another integral part of the stator is the stator core. The core is constructed in the form of laminations and the material used for the same is either magnetic iron or steel alloy. The main purpose of lamination is to prevent loss of energy in the form of eddy currents. There are different types of armature slots provided in the core to insert the conductors and the three various types are as follows.

Wide open type slots Semi closed type slots Close type slots The core is securely clamped by a large number of studs. Ventilation ducts
are provided at intervals along the stator core, being formed by mea ns of non magnetic steel spacing is securely welded to adjacent steel stampings. Jacking screws are provided at the outer edge of end plates to enable the pressure of the teeth to be adjusted.
Fig 8.1 60 MW Alternator Windings-The stator winding is of two layer bar type wave winding. All the bars are formed, insulated and tested before being placed in the slots. Each bar consists of a number of individual copper strands of rectangular section to minimize eddy current losses. Each strand is insulated with polyesterimide varnished glass brainding. The bars are insulated along the slot portion by adequate presses and consolidated in a heated press. This ensures complete elimination of voids and high factor of safety against breakdown. The end portion of the bar have flexible insulation consisting of polyester film and glass backed mica flake tape, reinforced at intervals with layers of
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varnish treated terylene tape and with glass tape for protection and finish. The joints between the bars are made by brazing and are insulated. All connections between bars and terminals are securely clamped. Both ends of each phase windings are brought out to suit the terminals near the top of the stator frame.
Fig 8.2 Stator 8.3 Rotor The rotor consists of a coil of wire wrapped around an iron core. Current through the wire coil - called "field" current - produces a magnetic field around the core. The strength of the field current determines the strength of the magnetic field. The field current is D/C, or direct current. In other words, the current flows in one direction only, and is supplied to the wire coil by a set of brushes and slip rings. The magnetic field produced has, as any magnet, a north and a south pole. The rotor is driven by the alternator pulley, rotating as the engine runs, hence the name "rotor." The rotor is constructed with a high strength alloy steel shaft forging that is precision machined, ground and finished to exact tolerances.
Fig 8.3 rotor Poles-There are 18 magnet blocks on each rotor. Each magnet block has a north pole and a south pole. The poles are arranged alternately, so north faces the stator on one block and south on the next. The poles on the other magnet rotor are arranged in the opposite polarity so that the north poles face south poles across the stator. In this way, a strong magnetic flux is created through the stator between the magnet rotors. The coils
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embedded in the stator are dimensioned such as to encircle the flux from one magnet pole at a time. As the magnet blocks pass a coil, the flux through the coil alternates in direction. This induces an alternating voltage in each turn of the coil. The voltage is proportional to the rate of change of flux. Damper Winding-The rotor is equipped with damper windings. They stabilize the speed of AC generator to reduce hunting under changing loads. If speed tends to increase induction-generator action occurs in damper winding. This action places a load on the rotor tending to slow down the machine. In case of speed decrease induction-motor action takes place. The damper winding is of major importance to the stable operation of the generator. While the generator is operating in exact synchronism with the power system, rotating field and rotor speed exactly matched, there is no current in the damper winding and it essentially has no effect on the generator operation. If there is a small disturbance in the power system, and the frequency tends to change slightly, the rotor speed and the rotating field speed will be slightly different. This may result in oscillation, which can result in generator pulling out of step with possible consequential damage. Damping bars are of circular sections of copper which are semi closed in the pole faces. The ends of the bars are short circuited together by copper stamp ings. The damper winding is inter-connected between poles. Field Winding-The magnetic field in the synchronous generator is created by field winding. The field coils are square ended being fabricated from a straight length of copper strips dove tailed and braced at the ends. At intervals down each coil the copper is increased in width to give fins for cooling purposes. All connections between adjacent field coils and also between field coils and slip rings are firmly secured to the rotor. Temperature detectors- Resistance temperature detectors are built into the generator stator core and windings. The detectors are of three wire resistance type having 100 ohms resistance at 0 0 C and 138.5 ohms at 100 0 C. The loads from the detectors are brought out to a metal clad terminal box located in a conveniently accessible position from which cables could be run to the indicating instrument via generator marshalling box.
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CHAPTER-9 BEARINGS
Conventional alternators comprise of top-mounted thrust and guide bearing supported on heavy brackets, capable of supporting total weight of generator. A guide bearing is a plain bearing used to guide a machine element in its lengthwise motion, usually without rotation of the element. A bottom guide bearing combined with turbine shaft is usually provided. This conventional design is used for high speeds (up to 1000 rpm) generators. 9.1 Thrust Bearing Thrust bearing in any turbo machine is used to prevent axial tolerance on the shaft. The thrust bearing is a spring supported type in which the stationary part consist segmental pads supported on mattress of helical springs. The rotating bearing surface is machined accurately perpendicular to the axis of the shaft. The bearing surface is polished to fine surface finish. The thrust pads are of stress relived mild steel and are faced with a high quality white metal. Each pad rests on a number of springs which are precompressed by a permanently locked centre screw and finished to a standard overall length. The springs are assembled on a heavy fabricated spring plate which is an integral part of the thrust bearing housing. The thrust pads are prevented from moving circumferentially by pad stops secured to the spring plate. Radial movement is prevented by-dog damps which would also prevent the pad from rising with the thrust block during rotor jacking operation. The thrust bearing pads are completely immersed in oil bath. The oil is cooled by plug in oil coolers.
Guide Bearing Thrust Bearing
Transferring the weight of Rotating mass through the thrust bearing, upper Bracket & to the Foundation.
Fig 9.1 Generator Bearing
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9.2 Top Guide Bearing The top and bottom guide bearings are of the pivoted pad type consisting of a row of white metalloid pads arranged in a support ring. Top guide bearing is located above the thrust bearing, on a journal surface machined on the periphery of the thrust collar. Sufficient insulation and protection is provided in top guide bearing to prevent flow of shaft current through the bearing pads. The same oil bath for the thrust pads is used for the guide bearing. 9.3 Bottom Guide Bearing Bottom guide bearing is located on a journal integrally forged with the shaft. A pivot bar is bolted to the back or each guide bearing pad to enable the pad to rock slightly to take up a suitable position and facilitate formation of the oil film, when running. The clearance between individual pads and the journal is set by adjusting the shims between the back of the pad and the pivot bar. The pads are cooled by an oil bath with plug in type coolers.
Rotor Poles
Rotor Fan
Coupling Flange
Lower Guide Bearing.
Fig 9.2 Lower Guide Bearing 9.4 Hydro Static [HS] Lubrication System Lubricants (solid or fluid film) are deliberately applied to produce low friction and low wear. In hydrostatic lubrication, a thick fluid film is maintained between two surfaces, with little or no relative motion, by an external pumping agency: a pump, which feeds pressurized fluid to the film. Hydrostatic lubrication requires an external pumping agency. HS bearings provide high load-carrying capacity. Since HS bearings do not require relative motion of the bearing surfaces to build up the load-supporting pressures as necessary in hydrodynamic
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(HD) bearings by viscous shear/drag, HS bearings can be used in applications with little or no relative motion between the surfaces. The hydro static lubrication system has been designed to provide an oil film between the thrust pads and the runner disc during starting and stopping when there is little likelihood of formation of hydrodynamic oil film. Therefore, it should always be put on service before starting the unit. However, if for any reason the HS lubrication system is out of order, the rotor shall be jacked up and released just before starting the unit, to ensure formation of oil film. This operation is not necessary If the machine has been at stand still for less than 12 hours. 9.5 Brakes and Jacks The generator brakes consists of a number of 'Ferodo' lined shoes which operates against a polished circular steel brake track to the underside of the rotor spider hub. Each brake shoe is mounted on a vertical piston moving in a small cylinder. To apply/release the brakes, air would be forced into the brake cylinder in appropriate direction from the station compressed air supply. The brake cylinders are mounted on the bottom bracket. The brakes are to be applied continuously starting from 30 rpm, with HS. Lube ON and with air pressure of 4 to 5 bars for minimizing brake -dust problems. When the machine has come to a full stop, the brake should be left on for about 5 minutes more, to flow static friction to be established between the rotating parts and the bearing pads. If sufficient time is not allowed for the oil to squeeze out from between the bearing surface to establish static friction, the turbine gate leakage torque may cause the rotor to creep, which could cause damage to the thrust bearing pads. No. of units Brake material Brake pad and size Brake operating pressure Jacking oil pressure required Brake application speed Time to bring the machine to rest after brake Rotor jacking limit 6 Ferodo India Grade 325mmx325mm 4 to 5 Kg/ sq. cm 70 Kg/sq. cm 30 RPM with HS 3 to 5 minutes 15mm
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CHAPTER-10 STATIC EXCITATION

Lower Periyar is the second power house using static excitation in Kerala State Electricity Board. The static excitation system consists of excitation transformer, thyristor converter and voltage regulator. A complete system also includes control and de-excitation circuits. It is called static excitation when you make use of solid state components like diode and thyristors to convert to pure dc and to use this dc for field excitation of synchronous generators. The Thyristor-type static excitation system, due to its many advantages, excellent response characteristics, easy maintenance and simplified main machine construction, is now extensively used for medium-and large-capacity hydro-or steam-turbine generators. In the case of synchronous machine protection circuits activation the automatic quick field suppression via a de-excitation D.C. circuit breaker and a discharge resistor is accomplished. The excitation system is equipped with a microprocessor control system that enables voltage control, supervision, protection, communication and signalization. The system is completely automated and adapted for no-crew plants and for remote control from the superimposed control centre. The main types of Exciters are: 1) Conventional D.C. Exciter. 2) Static Exciter. 3) Brushless Exciter In modern generators, magnetic field is produced by an electromagnet. Equipments required to produce a controlled amount of field current is known as Excitation System. 10.1 Static Excitation Equipment It consists of Regulation Cubicle, field flashing & field breaker cubicle, thyristor cubicles, and transformer cubicle. All excitation power is normally derived from the synchronous machine terminals through the step down excitation transformer of 850 kVA rating, generally termed as the rectifier Transformer or the Excitation Transformer, housed inside a cubicle and the thyristor converter. The voltage regulator via pulsetriggering unit controls the thyristor converter.
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As synchronous machine has low remnant voltage, the voltage built-up in the selfexcitation mode is accomplished by flashing the field from an external D.C. supply (station battery) or with A.C. supply (station auxiliary) through a diode rectifier. The control circuit is suitable to accept supervisory command signal contacts from remote Supervisory control equipment. The AC input supply of all electronic power supplies are given from the secondary of the Excitation Transformer through suitable intermediate transformers. The secondary of the Excitation Transformer feeds the thyristor bridge which consists of parallel connected bridges to meet the field current requirement of the Machine. The DC output of the Thyristor Bridge is fed to the generator field through field breakers. The discharge resistance in the field circuit enables faster suppression of stored energy in the field.
Fig.10.1 Static Excitation Power Rectifier-Three phase 6-pulse fully controlled thyristor bridges with fuse RC circuit, gate circuit and de coupling reactors are provided with conduction monitoring unit to indicate with the help of LEDs the non-conduction of any thyristor in the bridge. Decoupling reactors provided in each arm of the bridge for di/dt protection also improves the paralleled sharing between thyristor bridges. One redundant bridge is built in the system such that in the event of -failure of one bridge rest of the bridges can carry full rated excitation requirement of the machine. With 2 bridges out of service, machine can be operated at reduced load with the remaining bridge. Voltage Build up/ field flashing- Electrical generators that are self excited depend on residual magnetism in the field to start generating. If the residual magnetism has been lost, it may be restored by briefly applying power from an external source. The brief
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application of power for that purpose is called "flashing the field." Flashing is sometimes done manually to start a small generator. Voltage build up (field flashing) can be done either with the help of station battery supply through a dropping resistor and blocking diodes stack or Station Auxiliary supply through a step down transformer and diode bridge. At 30% of the rated generator voltage pulses to the thyristors in the main circuits are released and they take over the build process at about 40% of the rated generator voltage. For checking the healthiness of the main circuit, the field flashing is kept in circuit up to 70% of the rated generator voltage after which the field flashing circuit is automatically disconnected. If a successful start up is not achieved during this period of time, a timer provided in the excitation circuit, switches off the field flashing process. It is to be noted that a minimum period of 10 minutes must elapse before field flashing is resorted once again. For AC field flashing a diode bridge stack consists of six screws in type diode mounted on suitable heat sink assembled side by side and can be easily replaced from the front. The six diodes are connected to from a three-phase bridge. 10.2 Modes of Operation Two independent modes of operation are envisaged namely 1. Automatic mode
2. Manual mode.
Automatic mode:-In the Automatic Mode excitation is regulated by the AVR. The AVR compares the actual value of generator voltage which is sensed through PT after suitably stepping down and converting into DC with the reference value set on the Auto Reference Potentiometer. The amplified error (output of AVR) is used as control signal to control the Grid control unit (Firing Circuit) for the Auto Channel. The output pulse of the Grid control unit is amplified to boost the voltage level in the pulse Intermediate amplifying stage and power supply unit. The power supply unit of me pulse Intermediate Amplifying Stage feeds the AVR and the Auto; / and is termed as supply A. Manual mode:-In the manual mode the Grid control unit of the Manual channel is directly controlled by the Manual reference potentiometer. The pulse generated by the Manual Grid Control unit is amplified in the pulse Intermediate stage and power supply
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unit of the manual channel. The power supply unit of the pulse Intermediate Amplifying stage feeds reference voltage to the manual channel etc., and is termed as supply M.
Fig 10.2 Block Diagram Static Excitation
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CHAPTER-11 STATION AUXILIARIES

11.1 Cooling Water System Normally cooling water is tapped from the penstocks and connected to a common inlet header through a duplex strainer with isolating valves on either side. The inlet header is connected to an outlet header through many numbers of cooling water pumps and a non-return valve. Isolating valves are provided on either side of the pumps. Normally cooling water for generator and transformer is taken from the outlet header through valves. The cooling water pressure at outlet header is sufficient as the same is tapped from the penstock; hence the cooling water pumps are normally not started.
Fig 11.1 Cooling water system The cooling water system will be used for the following service. 1.Cooling water for turbine bearing and shaft seal. 2.Cooling water for Generator coolers and bearing. 3.Station services.
4. Transformers.
Cooling water for the above requirements is taken from cooling water pit which is connected to the tail races. The cooling water from the pit pushes through a -duplex strainer pump motor sets with non return valve [NRV]. Pressure switch has been provided in each line which helps in the automatic start/stop of main and stand by pump. Discharge of each pump is connected to common header. Cooling water is supplied to Generator and turbine components through motor (4 Nos. 110HP) operated valve. Cooling water connection for transformer and station services are provided on the common header. Out of 4 pumps 3 pumps works as main pump for each unit and one
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pump is common as stand by. An emergency cooling water system is also provided to feed the cooling during total shutdown of the power supply. 11.2 High and Low Pressure Air System H.P Air system consists of two H.P. compressor sets with air-cooled systems. Air from compressors pass through non-return valve, isolating valve, air cooled after coolers and finally to the H.P air receiver. Isolating valve in the H.P. airline shall be kept open. The H.P receiver has pressure gauge and safety valve mounted on it. Low pressure (LP) air receivers are provided to supply low-pressure air to shaft seal, Brake & Jack panel and station service. The feeding of air to the, LP receiver is earned out from the H.P. receiver through a pressure reducer. Pressure switches have been provided on the H.P. receiver to work the compressors automatically. The main compressor starts when the pressure drops below 37kg/sq cm and stop at 40kg/sq cm. The stand by compressor will start at 34kg/sq cm and stop at 40kg/sq cm. One pressure switch is set to give alarm at 32kg/sq cm 11.3 Dewatering System The de-watering system has been provided to remove water passage via. a dewatering pump to tailrace. The de-watering sump has two oil lubricated vertical turbine pump set (110HP) placed at turbine floor on the left hand side (near Unit -3) of the Power House. The discharge from the two pumps is connected to a common header via non-return valve and is lead to the tailrace. Level control relays nave been provided for the automatic operation or the pump sets. Pumps can also be operated manually by push buttons provided in the starter panels. A high level alarm is also provided in the sump to avoid flooding of the sump. 11.4 Drainage System Water from the seepage, turbine leakage delivery water during the operation of
BF
valve and ejectors are taken to the drainage sump. This sump has got two vertical
turbine pumps, (2x20HP) set with motors. The discharge from the two pumps is connected to a common header and leads to the tailrace. Level control relays have been provided for automatic starting and stopping of pump sets and can also operate manually by push buttons. A high level alarm is also provided in the sump.
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11.5 Centralized Grease Lubrication System To facilitate grease lubrication of every moving part of Inlet valve and turbine, a centralized grease lubrication system has been provided. The system is completely automatic with a synchronous time adjustable between 6 to 120 hours for repeating greasing cycles. The system consist of a heavy duty reciprocating pump drives plungers type pump with built in reduction gear, a four way solenoid valve, a set of dose feeders with high pressure pipes and fittings. The grease lubrication have provided on the valve door turnings on both sides with non return valves, servomotor lines of BF valve, guide vane lower bushing through non-return valves, upper bushings, guide vane servo
motor pins and the regulating ring supporting bushes. Lubrication systems increase the life span of machine components and they protect from wear and corrosion. As a result, they are an inevitable part of modern service and maintenance concepts. Lubrication systems have the task of bringing the lubricant to the appropriate point in an exact measured quantity, at the right time. In the field, single-line and progressive lubrication systems are largely used. The choice of a suitable lubricant is largely dependent on the operational method of the lubrication system and the application. This is why both these factors need to be carefully scrutinized. 11.6 Synchronous Condenser Operation A synchronous condenser (sometimes synchronous capacitor or synchronous compensator) is a device identical to a synchronous motor, whose shaft is not connected to anything but spin freely. Its purpose is not to convert electric power to mechanical power or vice versa, but to adjust conditions on the electric power transmission grid. Its field is controlled by a voltage regulator to either generate or absorb reactive power as needed to adjust the grid's voltage, or to improve power factor. Increasing the device's field excitation, results in furnishing magnetizing power (kVARs) to the system. Its principal advantage is the ease with which the amount of correction can be adjusted. The energy stored in the rotor of the machine can also help stabilize a power system during short circuits or rapidly fluctuating loads such as electric arc furnaces. Large installations of synchronous condensers are sometimes used in association with high-voltage direct current converter stations to supply reactive power.
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CHAPTER-13 MAIN CIRCUIT BREAKERS AND POWER TRNSFORMERS
Fig 13.1 11kV/220kV Transformer The combined electrical, physical, chemical and thermal properties offer many advantages when used in power switchgears. Some of the outstanding properties of SF6 making it desirable to use in power applications are: High dielectric strength Unique arc-quenching ability Excellent thermal stability Good thermal conductivity SF6 circuit breakers of capacity 1250 A, 40 kA, 245 KV are used in this power house. These are of air operated single break, with individual operating mechanism with one common air compressor unit coupled to the three limbs with pipe. AH control equipment and compressor are housed in the center limb. The opening of the breaker is done by 15 Kg/sq. cm air pressure. While opening, the closing spring is automatically charged this is used for subsequent closing. The breaker can be operated locally or remotely according to the switch position. Different air and gas pressure for the breaker operation is as follows. 1) 2) 3) 4) 5) 6) Low air pressure alarm Low air pressure cut off Auto re close cut off Normal SF6 gas pressure Low gas pressure alarm. Circuit Breaker lockout 13.2 to 14.2 Kg/sq. cm. 12 to 13 Kg/sq. cm 14.3 to 14.8 Kg/sq. cm. 6.5 to 6.8 Kg/sq. cm 5.5 Kg/sq. cm. 5 Kg/sq. cm.
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13.1 Power Transformer Technical data: Make No load voltage ratio Tap changing circuit Vector simple Type of cooling Constructional details: HV Line end bushing LV Line end HV Neutral end Supervisory Apparatus: A double float type Buchholz relay with a set of alarm and trip contacts A dial type oil temperature indicator with two sets of contacts for alarm and trip and maximum reading pointer A winding temperature indicator with maximum reading pointer, heater bulb/ and four sets of contacts for alarm, trip, fan control, and oil pump. A magnetic oil gauge, 2 oil flow indicators, 2 water flow indicators. A No pressure release valve, pressure gauges in oil and water circuits. Differential pressure gauge with a set of alarm contacts The oil is pumped through heat exchangers using motor. Water to the heat exchangers is taken from the cooling water system controlled by motor operated valve followed by gate valve. While putting the transformer in service first oil pump must be started and then only the cooling water valve is opened. 3Nos, 24kV, 4000A, Outdoor type bushing 1 outdoor type bushing 3 Nos., 245kV Oil filled condenser type Crompton greaves make 11 KV/220 kV. OFF load provided on HV side Ynd1 OD WF [Oil drive, water forced].
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CHAPTER-14 PROTECTION SYSTEM

14.1 Protection of Generator and Line In this powerhouse modern solid-state type protection relays are installed for generators and feeders. All the protective relays are of ABB make. Generator - Transformer differential relay It is s three phase differential relay intended for all types of auto- transformers, multi winding transformers, generator with step up transformer over all protection, often including the auxiliary transformer in the protected zone. In our power house overall protection of generator and transformer is adopted. The CT wiring is taken from the generator neutral side and from 220 kV side of the corresponding unit. A differential relay is connected so that it is supplied with current proportional to the current to the power transformer, and current out from the transformer. The relay is connected to the current transformers and possible auxiliary current transformers. For transformers with tap- changers for voltage control, the average ratio of the taps should be used for calculation. During normal operating conditions, small current flows through the differential circuit of the relay. This current corresponds to the excitation current of the transformer and to a current depending on the ratio error to the current transformers. Normally these two currents only comprise a small percentage of the rated current. The duty of the relay is to detect the internal faults (that is the faults within the generator, power transformer, or on the connecting lines and bus duct etc) and then rapidly initiate disconnection of the power supply. The internal faults that can occur are 1. Short circuit. 2. Ground faults 3. Turn-to- turn faults. When faults arise outside the current transformer, the differential circuit of the relay maybe supplied with a relatively large current, which can be caused by ratio errors in the current transformers or by the tap changer not being in the centre tap position. If the tap changer is in a position 20% from the centre tap position, and the short circuit current is 10 times the rated current/a differential current of twice the rated current is obtained. The differential shall not operate for this differential current. In order to make an operate value
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setting for such high over current unnecessary, the differential relay is provided with a through fault restraint with restraining circuits. The relay then will not react for the absolute value of the differential current, but for a certain percentage differential current related to the current through the power transformer. When energizing a power transformer, it is possible to obtain a large inrush current in the exciting winding and then proportionally large-current in the differential circuits of the relay. The magnitude and direction of the inrush current depends on the instant of switching in the power transformer, power transformer remanance, the design of the transformer, the type of the transformer connection, the method of neutral grounding, the fault MVA rating of the power system and power transformers connected in parallel. In modern system the current can be 5 to 10 times the rated current when switching in into the high voltage side, and 10- 20 times the rated current when switching to the low voltage side. To prevent the relay from operating when energizing power transformer, it is not possible, as a rule, to delay the operation during such a long time as required. Thus an instantaneous relay must have a magnetizing Inrush restraint and there by utilize a certain characteristic difference between the inrush current and the fault current. Auxiliary CTs are used to balance the current to the relay. In addition auxiliary CT may be used to reduce the effective leakage burden of the long secondary leads. The differential zone of the relay can include up to one kilometre of high voltage cable since adequate filtering provides security against high current oscillations. Bus bar protection differential relay Internal bus faults occur less frequently than line-faults. On the other hand, a bus fault tends to be appreciably more severe, both with respect to the safety of personnel, system stability and the damage at the point of fault. The fact that bus faults occur relatively seldom is therefore of little comfort to the engineer in-charge subsequent to a major system shutdown caused by the Sack of adequate bus relay. When an internal bus fault occurs the magnitude of the fault current and its D.C. component may be so large that the line CT's (current transformers) saturate within 2-3ms. In such cases it is essential that the bus differential relay operates and seals in within 2ms, i.e. Prior to the saturation of the line CT's. This high speed is necessary because when a line CT saturates its output e.m.f. tend to drop to zero.
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In the event of an external fault, just outside the line CT's of a relatively small feeder, the fault current may in an extreme case be as large as 500 times the rating of the feeder. The line CT's of the faulty feeder are then likely to saturate at an even higher speed, particularly so if the remanence left in the core from a previous fault has an unfavourable polarity. The response of the restraint circuit of the differential relay must therefore be at least the same high speed as that of the operating circuit, if mal-operation is to be avoided. Distance relay for feeder protection Distance relaying is used to a large extent to provide protection against ground and phase faults on
HV
and
EHV
networks, The operation of all distance relays is based
on information available through main current and voltage transformers. Sometimes additional information may be required from other apparatus such as receiver equipment in a communication link between two distance relays. But, the action of a protective relay cannot only be based on the sole estimation of currents and voltages in the primary system/ but must also take into consideration the steady-state and transient characteristics of the relay input sources, namely the instrument current and voltage transformers. The demands made on protective relays are steadily increasing owing to such factors as the growing short-circuiting power and the demand of consumers for greater reliability in their power supply.
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CHAPTER-15 COMMUNICATION
15.1 Power Line Carrier Communication (PLCC) PLCC System is established at LP Power Station through the 220 KV feeders LPBrahmapuram, LP-Madakkathara & LP-Moolamattom. Inter Circuit phase to phase coupling is used for the system. The feeders are provided with carrier inter trip protection coupler system. BPL make 9505 and 6515 model panels are used for the communication system. An exchange MDX 50 BPL make is used for linking PLCC phones to the panels. The station code of LP is 055. The communication system works on power supply of 48V DC. The data and status of Generators and feeders are transmitted to the Load Despatch (LD) station Kalamassery through the PUNCOM make PLCC panel established the scheme up to Madakkathara and from there to LD station through optical fibre cable. AC Supply fail alarm for the PLCC Battery charger is wired to Unit No 1 annunciation panel. On initiation of this alarm in the C/R, the operator must inspect the carrier room for the reason of power failure.
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CHAPTER-16 OPERATION OF DIFFERENT EQUIPMENTS

16.1 Procedure For Stand By Cooling Water Pump Operations In case the main pump of any unit is not functional, Stand by Cooling Water Pump (CW4) can be used for starting and running of any machine. Stand by Cooling Water Pump runs on station auxiliary supply. Sequence of Operation During Starting Switch OFF the MCCB of the faulty C.W.P and put the selector switch in NORMAL position. Start the machine as usual. When the C.W. Valve of the machine is opened, Switch ON the Stand By Pump from the UCB of the respective machine. (The Stand By Pump can be Switched ON locally by putting switch to TEST position and pressing the START button locally from the C.W. Pump control panel at Turbine floor). At the same time short the terminals 64 & 67 in terminal block TB3 of the respective machine in Auto Sequencer Panel in Control Room, for getting the command from the sequencer for executing next step. When next step is executed the shorting can be removed. The remaining procedures are same as usual for starting the machine. While changing the machine supply Stand By Pump will not be affected. After synchronization of the machine, if the Stand by pump is switched on in TEST position, the selector switch can be put back to norma Note: - If a machine is to be run using Stand By Pump it is better to put the machine in service as last one. Sequence Of Operation During Stopping While Stopping Switch OFF the machine having Stand By Pump first. Do the Stopping procedure as Usual. After breaking, when the machine comes to stand still, Switch OFF the stand by pump either from the UCB ( Stop command is to be given from the UCBs of all machines ) or by putting the Selector Switch in TEST position and press the OFF push button locally. When Machine comes to standstill change the selector switch, of Stand by Pump, back to NORMAL. 16.2 Starting Of Machine During Black Out Using Emergency Cooling Water System Avail the Station Supply from DG Set.
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To start a machine from Black Out, Switch OFF the CWP MCCB of the concerned machine and Switch OFF the MCCB of Stand By Pump. The selector switch of both the Pumps should be in NORMAL position. Initiate machine Start Up sequence from Control Desk. When the CW Valve of the machine opens, OPEN the Emergency Cooling Water Valve fully. ( If required the Emergency Cooling Water Pumps can be put in to service from DG supply) Short the concerned terminals of the Main and Stand pumps at Sequencer panel. (Main pump TB3 64,67, Stand by TB3 68,71- if required). When the machine Voltage and Frequency reaches the required level (before synchronization) change the supply from G A to G B. Put the Main Cooling Water Pump selector in TEST, Switch ON the Main Cooling Water Pump MCCB and put the selector to NORMAL (the CWP will start automatically). Close the Emergency cooling water valve. Synchronize the Machine and Normalize the Auxiliary supply. 16.3 Procedure To Be Followed During Tripping Of All MACHINES If auxiliary Supply is Available Switch off the MCCBs of the Standby and any of the two (say #2 and #3) Main Cooling Water Pumps immediately and then change the station supply (otherwise the LT Breaker may trip). Change the Auxiliary supply of all Machines. Open the Emergency Cooling Water valve (Emergency Cooling Water Pump can be put into service if required). Confirm that all the Governor Pumps are running. If not try to switch ON locally. Otherwise close the Isolation valve at Pressure Receiver Tank. Now stop the Machines one by one. After the machines comes to standstill, close the Emergency Cooling Water valve. Give stop command to the Cooling Water Pump of U#2 and U#3 from UCB. Close the cooling water valve from UCB and confirm. Check the Break Dust collector in OFF condition. If auxiliary Supply is Not Available Switch off the MCCBs of the Standby and all the Main Cooling Water Pumps immediately. Then only avail DG Set Supply and change the station supply (otherwise
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the LT Breaker/DG Set may trip). Change the Auxiliary supply of all Machines. Open the Emergency Cooling Water valve (Emergency Cooling Water Pump can be put into service if required). Confirm that all the Governor Pumps are running. If not try to switch ON locally. Otherwise close the Isolation valve at Pressure Receiver Tank. Now stop the Machines one by one. After the machines comes to standstill, close the Emergency Cooling Water valve. Give stop command to the Cooling Water Pumps from UCB. Close the cooling water valve from UCB and confirm. Check the Break Dust collector in OFF condition. 16.4 Procedure For Pneumatic Breaking Breaking of Machine during Stopping When the Machine speed reaches 10 Hz (20% of rated speed) and getting confirmation from Chief Operator, (AE should confirm that the HS Pump is ON, if not, start locally). Fully open the Air valve Near the LP air receiver Tank in Turbine Floor. Open the Air admission Valve near the Brake & Jack panel in the Shaft Room. Press the RESET Button until the pressure inside the Brake cylinder fully released (the hissing sound stops). Apply brakes by pressing APPLY push button. Confirm that ANY ON and ALL ON indications are obtained. When the machine speed reaches Zero and Mechanical Brakes Off status is displayed on the CD, the Chief Operator should inform the concerned to release the Brakes. For releasing the brakes, apply RESET button as above. Apply RELEASE push button until the ALL OFF indication is obtained. If ALL OFF indication is not getting, close the air valve at shaft room and apply RELEASE until the pressure gauge reads Zero, then conduct a visual checkup inside the Barrel to confirm that, all brakes are released. Procedures to be followed at Brake Jack panel before Starting of Machine Fully open the Air valve Near the LP receiver Tank in Turbine Floor. Open the Air admission Valve near the Brake & Jack panel in the Shaft Room. Press the RESET Button and confirm that ANY ON and ALL ON indications are OFF and ALL OFF indication is ON. The indications GEN Start Not Ready and Syn. Start Not Ready in Control desk should get OFF. In the Display panel at CD Air Pressure Normal and Mechanical Brakes reset status will vanish. Now the Machine is ready for Starting.
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16.5 Machine Start Procedure Status check before starting machine Select Display ON/OFF Select Spin Generator Select Accept Select Recall criteria Again Select Recall criteria - Status Shutdown in Display Unit - Sel. Not Permitted indication glows - Status Start not ready in Display Unit - Status Mechanical brakes Reset - Status Brakes air pressure normal - Status Shutdown
Check for any other conditions to be satisfied in display unit Select Pre Sel. Reset Select Display ON/OFF Start procedure: Close the 220 KV Isolator of machine from Control Desk. Select Release + Close (A or B Bus) Physical verification of Isolator contacts for proper closing must be done by AE. Give direction to the Generator Floor AE to make ready the machine for Starting OPEN Air Valve and RESET brakes. Now the glowing Gen. Start Not Ready indication lamp in CD will fail. The Machine is now READY for Starting. Set the Speed Setting Indicator in its marked position using Raise-Lower Speed Setting push button Switch ON the MCBs in the Transformer Annunciation Panel, Machine Annunciation panel and Vibration & Rotor Temperature Indicator Panel Switch ON Transformer Oil Pump and Cooling water Valve from the Transformer Control Desk. Synchronizing Put the key, open the lock and put the Synchronising Selector S/W in CD to CHECK position. Select Release + Synch Adjust the voltage and frequency of the incoming M/c to that of Bus using excitation auto sel. and speed setting Raise-Lower Push Button When the Incoming Machine frequency approaches the Bus frequency, Switch ON the Synchronoscope Selection Switch in Vertical panel.
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When the machine frequency matches system frequency and the green lamp of synchroscope glows steadily, Synchronize the machine .Select Release + CB ON Increase the Load Suddenly to 15MW using R-L of Guide vane position (MW) Increase the Load gradually to 45MW using G.V limit PB. Change the Auxiliary supply from Bus to Machine 16.6 Shut Down Procedure (Normal Stopping) Load reduced to 45MW for All Machines (Change the station auxiliary to other Machine or Karimanal Feeder) Change Machine Auxiliary to Station Auxiliary Select Display ON/OFF Using Speed Setting Push Button Reduce the Load to 40 MW By using Guide Vane Raise - Lower (MW) reduce the load to 20 MW (During this time the Output Setting must be >50) Select Shutdown Select Recall Criteria Release +Execute Guide vane closes Main CB OFF Field Breaker OFF Select Release + Open Isolator Push Button Select Release + Close MIV When speed reduced to 10 Hz Apply brake When Speed Zero and when status comes in the display as Mechanical Breaks OFF Release Brakes. Shut down Push Button Glows Display Status Shutdown Select Display ON/OFF S/OFF the MCBs in Panels and Transformer Control Desk Reset the annunciation panels. Status Start program
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SINGLE LINE DIAGRAM OF LOWER PERIYAR POWER HOUSE
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BRAHMAPURAM DIESEL POWER PLANT

31st DECEMBER 2012-11th JANUARY 2013-03-28
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CHAPTER 1 INTRODUCTION
Kerala depends on Hydro electric, Thermal, Diesel and non-conventional methods for power. We have our main supply of power from hydroelectric power plants which are 19 in number. We use hydroelectric plant for the base load and thermal and diesel for peak loads. The Brahmapuram Diesel Power Project comes at a time when Kerala badly needs it. This, the first non hydro project in the State will bring welcome relief to a critical power situation. In Kerala, we have 3 diesel power plants in Kozhikode, Brahmapuram and one in Kasarkode (private). BDPP generates a maximum power of 106.6 MW. It was commissioned in the year 1998. The power is generated using five 21.32 MW engines. A low voltage system is provided for the internal power demands. The prime mover used is SEMT Pielstick. Alternators are of GEC-Alstom. The whole control of the plant is controlled and monitored by PLC system.
Fig.1.1 Brahmapuram Diesel Power Plant Brahmapuram Diesel Power Project was commissioned on 24/11/1998, followed by the commissioning of Kozhikode Diesel Power Project at Nallalam. The third unit of the combined cycle power project of NTPC at Kayamkulam was also synchronised to the grid. The 100MW Brahmapuram Diesel Power Plant will contribute 585MU to the States power grid. BDPP will be the second power project of its kind in India to use LSHS, a low cost, high efficiency fuel, after Yelehankai in Karnataka.
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Table 1.1 Sections of Power Plant Consists of the storage tanks, transfer, treatment 1 Auxiliary system and pumping system and testing Lab for HFO/DO/lube oil/water required for the plant and fire fighting system.
Consists of 5 Nos, 21.32 MW capacities Diesel 2 Power House generating set and its auxiliaries for generation of 100 MW power at 11kV. Consists of 5 Nos, 25 MVA, 11/110kV Generator 3 Transformer (GT) Yard Generator transformers for receiving,
transformation and evacuation of power to the 110kV grid of the Kerala power system via the 220/110kV WB S/s. Consists of LSHS/DO/LO storage tanks/
unloading pumps, LSHS, DO/LO decanting bays IOC Fuel and Lub 4 oil handling area (for unloading of fuel from tracks to IOC owned tanks) and transferring pumps of LO and fuel oil to KSEB auxiliary system. (The IOC owned installation is located in KSEB land on lease held to IOC). 1.1 General Operating Principle The total power output of the BDPP is 100 MW from 5 Nos Diesel generating set units of 20MW capacity. Each unit consists of a medium speed diesel engine of capacity 21870kW driving a 3 phase AC generator of capacity 23690 KVA (21.32 MW at 0.9pf) controlled by a 11kV SF6 gas circuit breaker (main generator incoming CB) supplying the generated electrical power to the KSEB network through a 25MVA, 11/110kV power transformer (generator transformer with on load tap changer) to a 110kV Bus controlled
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by a 110kV SF6 gas circuit breaker at the 110kV World Bank S/s (double bus single breaker system). Each generator unit is coupled to the system via the main 11kV generator incoming CB of the 11kV switchgear. The unit transformer and generator transformer outgoing feeders are connected to the 11kV Bus of the 11kV switch gear. The unit transformer feeder is controlled by all kV SF6 gas CB whereas the generator transformer feeder is directly connected to the bus and does not have a feeder breaker. The generator transformer 110kV side is provided with a 110kV SF6 gas circuit breaker to isolate the GT from the KSEB grid (The 110kV grid is always live and is controlled from the 110kV, World Bank S/s control room). If a unit is in stopped condition (main generator 11kV CB in OFF condition) the unit transformer and the generator transformer will not be live if the 110kV CB is open. Since the generator is not coupled (synchronized) at the 110kV side, the grid (system) supply from 110kV side, is back fed up to the 11kV switch gear with 110kV CB in closed condition. The 11kV bus of the 11kV switchgear and UT (if the UT feeder CB is kept closed) and GT are always kept live for the healthiness of the transformers. The satisfactory operation of the 5 units are ensured by running its unit auxiliary equipments (separate for each unit) connected to the unit Motor control Centre fed from the unit auxiliary 1 MVA transformer and by running the common auxiliary equipments (common for 5 units) connected to different common MCCs in power house/auxiliary area, all of which are connected to the main common LV switch board designated as 4000A power control centre (PCC). The PCC is fed from 2 Nos. 2.5 MVA 11kV/415V common auxiliary transformers. 1.2 Diesel Engine Constructional Details and Working The diesel engine used in Brahmapuram diesel power plant is SEMT Pielstick. S.E.M.T Pielstick, with a worldwide network of Licensees and authorized repairers, has installed over 14 000 Diesel engines ranging from 500 to 26 500 kW per unit in power plants, naval vessels, merchant ships and railways. No. of cylinders = 18 V-groove with an angle of 45 in bank A and B Bore diameter = 46
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In BDPP alternators are designed by GEC-Alstom. Here the fuel used is LSHS. Fuel is classified as HFO and LFO. HFO has higher viscosity than LFO. In BDPP HFO has higher viscosity than LFO. In BDPP HFO is LSHS and LFO is diesel. There are mainly two advantages of LSHS:1) 2) LSHS is cheaper than diesel. LSHS has low sulphur content hence less pollution. When we switch off generation for long period, for maintenance we use diesel for stop the engine. We use diesel to start the engine also. This is because; the LSHS solidifies at normal atmospheric pressures and become difficult to remove it from engine cylinders. The steam produced in boilers can either be by fuel combustion of using exhaust gas, which is normal at high temperature of 340oC. Using damper we pass the exhaust gas to boiler and the rest of gas escapes to the air through a stack situated as high as about 86m. For starting an engine an initial torque has to be given as a kicker does in two wheelers and starting motor in 4 wheelers we use staring air, which consists of air vessels, H.P vessels and L.P vessels. H.P has a pressure range of 18 bars 30 bars and L.P vessels have a pressure of 5 bars. This pressurized air is to top of piston, hence rotates the flywheel. These are again controlled by valves. Diesel engine works on the principle of diesel cycle. The power equation for an IC engine is: P = (PmLAN/n) / 60 Pm = mean effective pressure N/m2 (average pressure on piston during expansion stroke) L = length of stroke (58 cm) A = area of piston N = rpm, 500 n = no. of rev/cycle
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1.3 BDPP Technical Details at a Glance Table 1.2 BDPP Technical details Total integrated project area Power house buildings Switch yard area Alternator and switch gear Generator transformers (from TELK ) Diesel engine and generators (from SEMT Pielstick / MAN Diesel) Chimneys Project cost Unit Contribution to Power Grid 1.4 Commissioning Dates Table 1.3 Commissioning Dates Unit 1 Unit 2 Unit 3 Unit 4 Unit 5 1.5 BDPP: An eco friendly project Environmental safeguards have been insisted upon at every stage of planning and execution of the Brahmapuram Diesel Power Project. The low sulphur content fuel (LSHS) used, assures that sulphur emissions are minimal. Continuous computerized monitoring of chimney emissions are in place to keep check on pollution levels. 1,00,000sq.ft of land around the plant has been identified for green belt development. Treated effluent water from the plant will be used for nurturing the green belt. A pollution biomonitoring facility has been established at the site. 5th June 1997 2nd September 1997 12th November 1998 9th January 1998 24th November 1998 78.55 hectares 70m / 80m / 20.5m 9850 sq.m From GEC Alsthom 6 Nos(25 MVA each) 5 Nos Output capacity 21.32MW each, weight 447MT/ set 5 Nos, Each of 52m height Rs.281 crores 585 MU
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CHAPTER 2 ELEMENTS OF BRAHMAPURAM DIESEL POWER PLANT

The major elements of the Brahmapuram Diesel power plant are the following: 2.1 Prime Mover The Prime Mover used in the BDPP is a 4 Stroke, 18 Cylinder, 36Valve V type marine diesel engine, made in France. It uses diesel for starting and is run on Low Sulphur Heavy Stock (LSHS) heavy fuel oil that assures minimal sulphur emission. The engine uses the turbo charging principle in order to achieve more volumetric efficiency.
Fig.2.1 Prime Mover Table 2.1 Technical details of the prime mover Type Number of Cylinders Cylinder Arrangement Cylinder Bore(mm) Stroke (mm) Cylinder Volume Rated Power / Cylinder Engine Rated Power Piston mean velocity at 428 rpm Vol. Compression ratio Max. Combustion Pressure Mean Effective Pressure Fuel Used Fuel Injection Pressure Engine Length (Overall) Engine Width (Overall) Engine Height (Overall) Dry Weight 18PC4 - 2B 570 18 V- 450 570 660 170000cc / 170litre 1215kW 1650hp 21870kW 9.42m/s 13.3:1 150 bar 20.81 bar D.O / H.F.O 300 +/- 5 bar 11000mm 5172mm 5435mm 313.6tonnes
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The engine frame is a welded steel monoblock structure. Each cylinder comprises a liner of the bore cooling type made of a special cast iron located inside a water jacket, which is also made of cast iron, to avoid any contact of the cooling water with the frame. Cooling of the upper part of the liner is designed to minimize heat strain. The major parts located in the engine are connecting rods, pistons, rocker arms, piston rings cylinders with cylinder heads, cylinder liners, exhaust valves, fuel oil injection pumps, fuel pump plungers and barrels, fuel rack, spur gears, wheels, turning gears etc. The two part piston has a forged steel crown, oil cooled by the shaker effect, and a skirt made of light alloy. The piston pin is of the floating type. The two exhaust valves per cylinder, are fitted with rotating devices. All of the cooling water circulating in the cylinder flows through the valve cages. This latter feature ensures satisfactory valve seat behaviour when the residual fuel has high vanadium content. The camshaft bearings are fixed directly under the engine pump supports. This arrangement avoids transmission of injection strain to the engine frame. The two lateral camshafts are driven by a set of hardened spur gears and the camshaft wheels are driven through elastic couplings. These parts connected and located outside the engine are 1) Two MAN NA-57 turbocharger, waste heat recovery boiler, connecting boxes, bellows, silencer, chimney stacks, air to air cooler, lube oil / jacket water coolers, exhaust gas regulating valves, air inlet damper valves, air intake oil bath filters, various electrically driven pumps, oil tanks, starting compressed air receivers, control air buffer tanks etc. Engine Operation: The engine is started up by feeding 30 bar compressed air into the line B side cylinders via the cylinder head launching valves. Before start-up a slow turning gear sequence ensures that no water is present in the cylinders. The launch order from the start-up solenoid triggers opening of the main launch air valve only if the turning gear is disengaged. Compressed air then reaches the cylinder head supply ramp and the start-up solenoids. These solenoids, electrically piloted via, proximity sensors energized by a pulse finger attached to the camshafts, control opening of the launching valves. The engine settings such as the air/fuel ratio, injection advance and compression ratio have been designed to optimize fuel consumption while maintaining pollution limits.
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The main systems associated with the prime mover are as follows: 1.Fuel Oil System, 2.Cooling Water System, 3.Lube Oil System, 4.Compressed Air System, 5.Turbo Charger System, 6.Steam System, 7.Governing System 2.1.1 Fuel Oil System
Fig.2.2 Fuel Storage General The engines are started and stopped on Diesel and the main fuel for power generation being LSHS/LSFO. The engine demands a fuel of viscosity ranging from 11.5 to 16 centistokes. At room temperature the viscosity of LSHS is 700cst. Fuel Used - HSD/LSHS/LSFO. Using LSHS/LSFO of less than 1% sulphur content. Liquid Fuels Liquid fuels contain a large number of hydrocarbons, usually with long chains of carbon and hydrogen. They may also contain other elements such as Sulphur (S), Nitrogen (N) and Vanadium (V). Liquid fuels have widely varying properties depending on their source and method of refining. Liquid fuels are generally classified according to their viscosity. Plant Fuel System The prime mover is designed to operate with fuel having a viscosity of 11 to 16cst (centistokes). Diesel has a viscosity of 12cst. The machine is initially run using diesel for about half an hour and then the fuel is change over to LSHS. The machine is reverted back to operate with diesel half an hour prior to shutting down to avoid the presence of highly viscous LSHS in the engine cylinders and parts. The fuel required for the operation of the machine, both diesel and LSHS are stored primarily in the IOCL (Indian Oil Corporation) storage tanks located near to the power plants. The fuel from the IOCL storage tanks are then pumped to the buffer storage
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tanks situated at the backyard of the plant, using centrifugal screw pumps. The fuel in the buffer storage tanks, after treatment are pumped to service tanks. The LSHS having a viscosity of 700cst stored in the service tank is heated using steam to achieve a viscosity in the range of 16cst to be used in the engine and then pumped into the fuel rings. The diesel service tank is situated in the fuel handling area and the LSHS service tanks are situated near to each engine. Initially the engine runs on diesel. Each engine gets separate line from the ring header and this line comes up to a change over valve .From this point onwards there is only common line for DO and LSHS. Fuel oil from the change over point goes to a mixing tank from there to the inlet of a booster pump. This booster pump increases the pressure and with the help of pressure regulating valve the fuel oil pressure at engine inlet is maintained at 5-5.5 bar. When the temperature of jacket water is at 75 0C and heavy fuel oil viscosity is 18cst and machine is loaded to 70 % authorization for changing the fuel to heavy fuel is obtained. At this point the change over valve, which is a three way valve, starts admitting LSHS to the mixing tank The LSHS mix up with DO in the mixing tank and concentration of DO reduces and that of LSHS increases and finally machine runs in LSHS. The reverse occurs during stopping for rinsing. 2.1.2 Cooling Water System The cooling water system is to ensure the cooling of engine parts, especially cylinders, cylinder heads, exhaust valves, injector nozzles which undergo very high temperature during the combustion phase.
Fig.2.3 Cooling Water System The used materials for manufacturing these parts do not allow them to resist to such high temperatures without being damaged, therefore they need cooling. The fluid used, water, which provides the best quality to-price ratio, is well adapted for cooling diesel engines. The water source for the Brahmapuram diesel power plant is the Kadambra River.
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Cooling System There are two systems for engine cooling: 1. Jacket water cooling, 2. Injector water cooling Jacket water cooling: Ensures (a) Cooling engine and engine parts - cylinders, cylinder heads, liners, exhaust valves, turbo chargers. (b) Pre heating of diesel engine to avoid a cold start. This system comprises with make-up lines expansion tanks, jacket water circulation pumps, pre heating jacket water pumps, jacket water line heaters. This system heats up the jacket water to 750 C by passing the jacket water through a heat exchanger using steam. After attaining the temperature the thermostatic valve provided changes the flow direction to the radiators for cooling. The system keeps inlet water temperature at about 75 o C and outlet temperature of 90o C. Injector water cooling system: This system is used for cooling the fuel injector nozzle and injector body. Transferring the heat to jacket water system through a heat exchanger and does the cooling. Major components 1. Jacket Water circulating System, 2.Pre heating Jacket Water Pump, 3.Thermostatic Valve, 4.Radiator, 5.Vapour trap.
Fig. 2.4 Radiator for Jacket water & Lube oil 2.1.3 Lube Oil System The main function of the lube oil is to lubricate the engine (bearings, piston liners, connecting rods, timing gears) and the auxiliaries (turbocharger bearings, pumps etc.).
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- To keep the engine inside clean (piston grooves) as well as the circuit (clogging of filters). - To keep piston heads cool - To set an oil seal on the injection pump - To fight against the corrosive action of acid combustion products - To withstand oxidation and water. This engine uses Mobil Guard 440 oil supplied by IOC. For each engine, the lube oil is stored in sump tanks with capacity of 40m3. This oil is pumped to the engine using 120kW lube oil circulating pump. This system is provided with radiator coolers, post lube oil tanks, lube oil seal circulating pumps, lube oil separator etc. Pre lubricating pump provided does the initial lubrication while starting and fill up the pipe lines to avoid high pressure difference while starting the circulating pump. Before the lube oil enters the engine it passes through a self cleaning filter to filter away the heavy particle that may mix up in the oil. Major Components 1.Pre lubrication pump.2. Main lube oil circulating pump.3. Pressure Regulating Valve.4. Radiator.5. Vapour traps.6. Lube oil filters.7. Post Lube oil tank Oil Treatment The residues of combustion, particularly for engines operating on heavy fuel oil bring the lubricating oil great quantities of insolubles and particularly of carbon. Centrifuging is presently considered as the most efficient method for eliminating these particles. Filtering, a complimentary operation in dissociable from centrifuging, is indispensable for protecting the main mechanical units of the engine. 2.1.4 Compressed Air System This system ensures the distribution of 30bar compressed air to start the Diesel engine, 7bar compressed air to control the start and stop of diesel engine and for the pneumatic operation of control valves. The 30bar air system consists of 2 Nos. of 30bar (1 working and 1 standby) and 1 No. of 7bar reciprocating compressor of Ingersoll-Rand make. The compressed air system of each engine includes starting air receiver, over speed receiver and set of solenoid valves. The 30bar air receiver of each engine supplies
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the starting air for the initial running up to a speed of 90rpm. The minimum air pressure required for the startup is 18bar and a low pressure alarm set at 18bar for each receiver.
Fig.2.5 Compressed Air System The over speed receiver stores air at 7bar by the use of a pressure reducing valve from the 30bar air receiver and is used for the safety operation of the engine. Other pneumatic operations are done by 7bar air receiver located at compressor room fed from the 7bar low pressure compressor. All of these compressors are non lubricated type reciprocating compressors of Ingersoll-Rand, USA. There are also provisions for reducing 30bar air to 7bar air using pressure reducing valve at the compressor room in case of 7bar compressor breakdown. The compressor cooling system consists of water circulation pump and a cooling tower for the cooling of the compressors as a common cooling system. Specifications of Air Compressors HP Compressors Make: Ingersoll-Rand, U.S.A Rating: 200Nm3/Hr, 32 bar Motor: 55kW, 415V, 1475rpm LP Compressors Make: Ingersoll- Rand, U.S.A Rating: 200Nm3/Hr, 7 bar Motor: 30kW, 415V, 1465rpm 2.1.5 Turbo Charger System Turbo charger is used to increase the volumetric efficiency. The exhausts from the engine cylinders enter at the turbine side of the turbocharger and run its turbine and goes to chimney via boiler or by passing the boiler. As turbine runs, the compressor coupled to it, works. The intake airline is connected to turbo charger at compressor side. The filtered air through oil bath air filter, which get sucked by this compressor action, gets
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compressed to about 3bar. The compressed air is passed through the hot compressor air duct to radiators for cooling. After cooling to about 46 o C, it comes back to engine inlet through the SS duct. As the intake air gets compressed to about 3 bars, we get optimum fuel air ratio without the increase of cylinder size and thus we can reduce overall size of engine.
Fig.2.6 Turbocharger The fouling of the blades and blast pipe rings depends on the quantity of fuel and combustion. The fouling of compressor and turbine leads to a bad turbine efficiency and consequently an increase of exhaust gas temperature and reduction of air charging pressure. Also running of the engine at low loads leads to stronger fouling of turbocharger gas side. The fouling of the turbine side also leads to undesirable vibration of turbocharger due to extreme deposit of dirt. Washing of turbocharger adopted using fresh clean water to reduce the fouling, vibrations, exhaust temperature and to increase the inlet air pressure. Separate procedure is adopted for washing of turbine side (gas side) and compressor (cold) side The turbine side is washed at 0% load after idling the engine after 150 hrs of operation or before an anomaly of the above nature occur when the turbine blades are not too hot (below 230deg.C) and compressor side is cleaned at full load at maximum speed of the compressor. 2.1.6 Steam System The system products heat from the recovery boiler to the common steam drum for heating different systems. The steam system mainly includes: a) Water heat recovery boiler, b) Boiler, c) Boiler Circulating Pumps, d) Condensate Drum and e) Steam drum feed water pump
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Fig.2.7 Steam System (a) Water Heat Recovery Boiler: Boiler generates steam for heating the fuel, by utilizing exhaust gas of Diesel Engine. Boiler house consists of 84 tubes arranged in 4 rows, each row having 21 finned tubes. The design of the recovery boiler had been done to heat one engine and the necessary equipments when diesel engine runs at 90% of rated power. The heat recovery by one boiler is 1290 kW (2000kg/h of steam). The average heat per diesel engine running (excluding the common system) is 244 kW (425 Kg/h of steam). (b) Boiler: Boiler converts the chemical energy of a fuel into a useful output. It is used to heat water, thermal oil or generate heat. (c) Boiler circulating pump: The pump is used to circulate boiler water from steam drum to boiler tubes for generating steam. The Boiler has water inlet and steam outlet. The Boiler water enters the tubes through water inlet header and steam generated comes through steam headers. The boiler is protected by two safety valves. The start and stop of pump are automatically done by the PLC. The pump starts after 5min, after the main auxiliaries start up sequence is on and before the diesel engine start order. It stops 12 hours after diesel engine stop.
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(d) Steam Drum: Steam storage tank of all 5 boilers and also supplying boiler water to the Boilers for generating steam. The rating of steam drum is 8m3 and maximum pressure is 14bar. (e) Condensate Drum: It is used to maintain the level of steam drum by recovering the condensate. The condensate coming from the heat exchangers are recovered and collected in Condensate drum. (f) Steam drum feed water pump: It pumps water from condensate drum to steam drum for maintaining steam drum level. 2.1.7 Governing System The governing system used in conjunction with the machine is a constant speed governing speed system and is of Woodward make. A hydraulic governor controls the engine speed and load. The control linkage is provided with two pneumatic jacks one stop jack and other the limiting jack. The Governor used is a mechanical hydraulic, pressure compensated and equipped with a speed setting motor for remote speed adjustment. Provision is also given for manual speed setting, manual speed droop adjustment and load limit control. The major components of Governor are an oil pump, two accumulators, speeder spring, flyweight assembly, thrust bearing, pilot valve plunger, rotating bushing, buffer compensative system and a power cylinder. Depending on the speed, the pilot valve plunger is lowered or raised which will force the piston of the power cylinder to increase or decrease the fuel supply.
Fig.2.8. Hydraulic Governor The governor controls the fuel rack position through a combined action of the hydraulic piston and a set of mechanical flyweights, which are driven by the engine
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blower shaft. Figure 2.9 provides an illustration of a functional diagram of a mechanical-hydraulic governor. The position of the flyweights is determined by the speed of the engine. As the engine speeds up or down, the weights move in or out. The movement of the flyweights, due to a change in engine speed, moves a small piston (pilot valve) in the governors hydraulic system. This motion adjusts flow of hydraulic fluid to a large hydraulic piston (servo-motor piston).The large hydraulic piston is linked to the fuel rack and its motion resets the fuel rack for increased/decreased fuel.
Fig.2.9 Simplified diagram of a hydraulic governor 2.2 Generator The generator used in the Brahmapuram diesel power plant is a 3 phase, 50Hz, 428rpm synchronous generator using brushless excitation. The technical details of the generator are given in the table shown below: Table 2.2 Technical details of generator Generator GEC Alsthom Type 3Phase Apparent Power 23690 KVA Rated Voltage 11000V Rated Current 1243A Power Factor 0.9Cos Speed 428 Rpm Frequency 50Hz Class of Insulation F Duty Continuous Excitation 116V, 1000A Protection IP21S NFC 51.115
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Fig.2.10 Generator 2.2.1 Stator Stator Cage: The cage is built starting from the magnetic circuit formed by special low magnetic loss silicon steel laminations. These laminations are press-cut, pre-varnished and arranged in superimposed and offset layers to constitute homogenous annular packs. The packs are separated by radial vents forming cooling channels. The stack formed as above is firmly clamped between two plates via bars welded at both ends on the plates. These bars immobilize the lamination packs in the radial direction and in the tangential direction and constitute also the stator cage. The stator cage is then wound and globally impregnated. The wound assembly is then positioned on a cradle carrying the fixing feet. Finally, the two assemblies are assembled by electric welding at plates and constitute the stator. Winding: The copper stator winding is of the continuous insulation two-looms per slot imprecated type. The insulation is defined by a technique called Global Impregnation. Table 2.3 Technical details of Stator Apparent Power Rated Power Voltage Current Power Factor Frequency Excitation Air-gap Class of insulation Number of phases 23690 kVA 21320 kW 11000V 1243.4A 0.9 50 Hz 116 V,1000A 15 mm F 3
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Cooling
Self ventilated open circuit
Table 2.4 Winding Characteristics Insulation Number of Conductors per slot Winding Pitch Type of Winding Number of terminals (phases) 2.2.2 Rotor Shaft and Magnetic section: The shaft is made out of forged steel and includes the coupling plate. The rotor spider made out of moulded steel clamped and bound onto the shaft, without keying. This rotor spider with axial holes includes the contour of the poles at the periphery and radial ducts for ventilation. This arrangement enables to ensure adequate cooling at the rear of the inductor coils. Inductor Coils: They are made of brazed flat copper; the turns forming the coil are insulated between each other by a material ensuring also the cohesion of the coil after prior curing under press. The serially connected coils are led back to the rectifier holder rings. Each inductor coil is insulated from the ground by insulating shims. The fixing of the coils against the effects of the centrifugal force is ensured on the one hand by the pole shoes for the lateral parts, and on the other hand by the rods anchored in the disks for the front parts. All the coils are identical, and for this reason, a spare coil may be mounted indifferently either on a north pole or on a south pole. Table 2.5 Technical Details of rotor Excitation 116 V,1000A Class of insulation F Number of poles 14 Speed 428.6rpm Overspeed 514rpm No: of fans 2 Nos with 36 blades on each Air flow rate 20 m3/sec Table 2.6 Mechanical Characteristics Number of Poles 14 Class F 20 0 to 11 Y-connection 3
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Rotation Speed Over speed Number of fans Number of blades/fan Internal air flow rate Air gap Poles outer diameter Total length 2.2.3 Exciter General
428 rpm 514 rpm 2 36 20m3/sec 15 mm 2760 mm 1022 mm
Its installation inside the generator ensures a very small volume of space and allows having full benefit of an efficient cooling. The advantages of the rotating diodes inverted generator excitation system are well known: Elimination of rings and brushes, and therefore suppression of sliding parts and of maintenance needs Elimination of brush dust and therefore of contamination through dust particles. Low excitation power to be drawn from the mains. Table 2.10 Exciter Electrical Characteristics Excitation Voltage Excitation Current Stationary inductor voltage Current Electrical operation The stationary inductor carries 24 serially connected poles. The poles are solid. The number of 24 poles leads to a frequency of 85.7 Hz. The armature is rotating, the winding is three-phased and the current is rectified by silicon diodes connected in a Graetz bridge configuration, whose components are secured to the rectifier holder ring and secured by wedging. Stationary inductor (stator) The magnetic yoke and the poles are made of oxygen-cut mild steel in one single piece. Two lugs welded at the bottom part are provided for its fixing to the support with interposed shimming plates. The inductor magnetic circuit includes 24 poles. Each pole 116 V 1000 A 65 V 42 A
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carries a coated and enameled flat copper wire excitation coil. Impregnation with an epoxy resin is globally made under vacuum. Rotating armature (rotor) The magnetic circuit consists of a stack of 0.7 thick varnished laminations, clamped between two mild steel plates via insulated tie-rods. The assembly is keyed to the shaft. 144 slots are punched to receive the armature winding bars. The armature winding is made of coated enameled copper wire bound with fibreglass tape against the effects of the centrifugal force. Impregnation with an epoxy resin is globally performed under vacuum. Cooling The exciter assembly is located in the path of the generator cooling air flow. Vent holes, provided in the rotor spider, allow the cooling air to flow in the axial direction. Exciter Characteristics: Table 2.7 Exciter General Characteristics Power (rectified side) Voltage (rectified side) Current (rectified side) Frequency Speed 116 kW 116 V 1000 A 85.7 Hz 428.6 rpm
Degree of protection IP 21S Air gap 2.5 mm Losses to be dissipated at rated speed (exciter 20 kW and diodes) Table 2.8 Exciter stator (stationary inductor) Characteristics Voltage Current Outer Diameter Bore Diameter Length of active part Number of poles Number of turns per coil Sectional area of bare conductor Resistance when cold 65 Volts 42 Amps 1100 mm 865 mm 200 mm 24 54 5 x 2.8 mm 1.12 Ohm
Table 2.9 Exciter Rotor (rotating armature) Characteristics
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Outer Diameter Number of slots Number of phases Phase configuration Resistance when cold 2.2.4 Brushless Excitation System
860 mm 144 3 Y- connection 0.00205 Ohm
A brushless alternator is composed of two alternators built end to end on one shaft. Smaller brushless alternators may look like one unit but the two parts are readily identifiable on the large versions. The larger of the two sections is the main alternator and smaller one is the exciter. The exciter has stationary field coils and rotating armature (power coils).The main alternator uses the opposite configuration with rotating field and stationary armature. The exciter field coils are on the stator and its armature on the rotor. The AC output from the exciter armature is fed through a set of diodes that are also mounted on the rotor to produce a DC voltage. This is fed directly to the field coils of the main alternator, which are also located on the rotor. With this arrangement brushes and slip rings are required to field current to the rotating field coils. This can be contrasted with a simple automotive alternator where brushes and slip rings are used to supply current to the rotating field.
Fig 2.12 Brushless Excitation System The main alternator has a rotating field and stationary armature. Here the armature is stator, not the rotor. With the armature in the stationary portion of the alternator, the high current output does not have to go through brushes and slip rings. Although the electrical design is more complex, it results in a very reliable alternator because the only parts subject to wear are the bearings. Varying the amount of current through the stationary excited field coils control the strength of the magnetic field in exciter .This is turn controls output from the exciter
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.the exciter output is fed in to the rotating field of the main alternator to supply the magnetic field for it. The strength of the magnetic field in the main alternator then controls the output. The result of all this is that a small current, in the field of the exciter indirectly controls the output of the main alternator and none of it has to go through brushes and slip rings 2.3 Generator Transformer (GT) The generator transformer in Brahmapuram Diesel Power Plant takes the role of stepping up the 11kV generated by the diesel engine droved generators to 110kV and transferring the power to the 110kV bus situated in the 110kV yard. The GT has a capacity of 16.75 MVA without forced air cooling and a capacity of 25 MVA with forced air cooling. It is of ONAN/ONAF type. The winding configuration of this TELK made transformer is Ynd11, having a grounded high voltage star winding and a low voltage delta winding configuration.
Fig.2.13 Generator Transformer Table 2.11 Technical details of Generator Transformer Rated output Make Vector Cooling Volt Ampere (HV) Ampere (LV) No: of phases Frequency Impedance voltage 25 MVA TELK YN d 11 ONAN /ONAF 11kV/110kV 88.0 / 880 LV 131/1214 3 50 12.5%
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The GT, 11kV cable is connected to the transformer through an open air 11kV bus formed with rigid tubular copper fixed on 22kv heavy duty supporting insulations on a detachable frame in level with the bushings which will facilitate sufficient clearance for outdoor cable connections, provision for providing 11kv lightening arrestors and will avoid mechanical strains, bimetallic actions and damage to bushings due to loose contact arching etc. 3 Nos heavy duty 11kv lightening arrestors and 110kv lightening arrestors are provided for the cable and transformer protections from switching /line surge voltage. The GT is provided with bushing CTs (in built CTs) for its different protection and winding temperature measurement. The generator transformers are provided with the following protections. 1. 2. 3. 4. 5. 6. Oil temperature alarm setting 80 0C. & Trip 85 0C Winding temperature alarm setting 90 0C Winding temperature, temp settings 95 0C. Main Buchholz alarm and trip OLTC Buchholz alarm and trip Minimum oil level alarm
2.4 Control and Automation The main functions of the controller for automation is to execute starting and the shut down sequences under normal and emergency conditions. In addition to these operating sequences, certain control actions like speed control for synchronization (off line control) and speed control when the machine is put on the grid are also to be performed for frequency control and load sharing. The excitation system should respond with respect to the system requirement that is either to control the voltage or to share the reactive power with the other units operating in parallel. The Programmable Logic Controller (PLC) is used for control and automation purpose in Brahmapuram Diesel Power Plant. The main reason for this is cost effectiveness. Various functions and controls can be achieved by programming the PLC. They can be used for full plant automation including governing of auto-operation includes speed control, load control, excitation control, and level control automatic start/stop sequencing, start/stop of auxiliary systems, and protection requirement etc. Functions other than control like continuous monitoring, data recording, instrumentation
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and protections can also be performed. For remote operation, communication with PLC can be performed. For continuous monitoring purpose, a personal computer can be interfaced with PLC and continuous data can be recorded regularly. Benefits of Automation Normally, we implement an automation system to improve the efficiency, productivity and the operating management of the system, this automation will then better answer to the production needs and services given. Following are the major benefits of automation System: (a) Flexibility of changing the mode of operation for example, kW Control, Level Control. (b) Remote operation possible. (c) Efficient utilization of Manpower. (d) Maintenance is easier and quick. (e) Reduction in down time due to online diagnostics. (f) Simplicity in installation. (g) Reduction in Manpower. (h) Reduced Panel space. (i) Improved performance (j) Provides security against wrong operations by the operator. (k) Automatic starting and stopping of machine sets are faster than manual starting and stopping. (l) Reduced wire and interconnection. (m) Reliable operation (n) Lower cost Programmable Logic Controller (PLC) Programmable logic controller is basically a digital electronic apparatus; it has a programmable memory for storing instructions to implement specific tasks for control. In early days of development of PLC, it was mainly used to replace hardwired relays in control panels. The main advantage of using PLC is the flexibility over hardwired relays. It is very easy to add or subtract or modify the relays and wiring in the form of ladder diagram. The modifications can be done simply by reprogramming of PLC which is very
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easy. The benefits from relay logic controllers to computer based controllers because of following reasons. (a) The input and output variables of discrete system control are binary in nature just as with a computer. (b) Most of the control relays of the ladder diagram can be replaced by software; it leads to less hardware failure. (c) It is easy to make changes in a programmed sequence of events when it is only a change in software. (d) Special functions such as time delay actions and counters are easy to form software. (e) With the development in semiconductor industry it is very easy to control high power ac/dc in response to low level commands from a computer, such semiconductor devices includes SCRs and TRIACs. Advanced PLCs are microprocessor based and can perform complex mathematical calculation and function as well as logic, sequencing, timing and counting. Programming of PLC is easy and usually done in ladder diagram or function chart. The ranges of PLCs available nowadays varies from small hand held unit to modular system with add on function modules. The add on modules may consist; Analog input/ output module, PID control module, Communication module, Graphics display module Additional memory. Components of PLC:
Fig.2.14 Schematic Diagram of PLC (a) Processor: Processor executes a program to perform the operation specified in ladder diagram. The processor performs arithmetic and logic operation on input variable data and determines the proper state of the output variables. The processor functions under a
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permanent supervisory operating system that directs the overall operations from data input and output to execution of user programs. The processor can perform only one operation at a time. It is a serial machine. So it, sequentially samples each of the inputs, evaluates the ladder diagram program and provides each output, and then repeats the whole process. The speed of processor is one of the major components which decide the efficiency of PLC. The speed of controller is dependent on the clock frequency of the processor. The higher, the clock frequency the greater is the speed and faster is the scan/execution time. (b) Input Modules: The input modules examine the state of physical switches and other input devices and put their state into a form suitable for the processor. The processor can accommodate a number of inputs. These inputs are called channels. Each of input modules has a certain number of channels per module. Each channel is often provided with an indicator light to show if the particular input is ON or OFF. (c) Output Modules: The output modules give signal to external devices as required in the ladder diagram. The output module can supply a certain maximum level signal. If required power is more, an external relay can be used. Internally, the output module accepts l or 0 inputs from processor. An output module also has several channels per unit. Each channel can also have indicator to show if the particular channel is being driven ON or OFF. There are two types of I/O digital and analog. The digital I/O is used for discrete control and analog I/O for continuous control. The digital outputs are driven by either thyristor or relays and can be directly connected to relays, contacts etc. In analog I/O modules, the analog input signal is converted into digital by analog to digital converters and digital signal from PLC is converted into analog signal by digital to analog converter for final control. (d) PLC Programming: PLC is first programmed before use for a particular system. There are two main components necessary for operation of any system one is hardware of the system and second is the sequence of events through which the hardware is taken. These two elements are combined to show how the hardware should be driven so that the proper
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sequence of events can be accomplished. A special representation of hardware and its connection can be developed which makes combination of the hardware and events sequence description clear. This schematic is called a ladder diagram. It is an outgrowth of early controllers that operated from ac lines and used relays as primary switching elements. Thus ladder diagram is a symbolic and schematic way of representing both system hardware and process controller. It is called a ladder diagram because the various circuit devices connected in parallel across the AC line from something that looks like a ladder, with each parallel connection a rung on the ladder. 2.5 Protection System (a) DG set safety stop: A safety order from the protective system of the unit, upon detection of an anomaly by a particular safety device, will trip the unit in order to prevent serious damages to the unit and auxiliaries. Both 110kV CB of GT and 11kV CB of the generator is opened and the unit will come to a standstill upon the safety stop order. (b) DG set Emergency stop: In case of a serious mechanical or electrical abnormality which can be a threat for the right running of the plant or human safety is detected, the operator can make use of the Emergency stop button on the respective control desk panel. Emergency stop can be made from the following points. a) b) c) d) Unit control desk in central control room Engine local control panel Engine control air compressed unit board. Unit motor control centre In case of an emergency stop order only the 11kV breaker will be opened and the engine will come to stand still.
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CHAPTER-3 START AND STOP SEQUENCES

3.1 Unit Starting Sequence In Auto 1. Check for alarms, if Red or Yellow windows are present normally Air filter line-
A, line-B (when the respective switches are in auto), Jacket water outlet low temperature and sometimes engine exhaust gas abnormal temperature, engine inlet low temperature alarms will be persisting in the annunciator; check if printers are on line. Confirm that 30 bar starting air is available and 110kV supply from WBP S/S (GT & unit 1 MVA Auxiliary transformer) is charged, (If 30 bar air is not available STARTING AIR LOW PRESSURE window w ill be on). Arrange for starting the Diesel oil/HFO circulating pump from auxiliary area. 2. Confirm at the unit MCC that all pumps/fans selections except boiler water
circulating pump are in AUTO, MCC is in pre-conditioning mode and in AUTO. Check that running mode switch in the control desk is in AUTO. CCR operation, Diesel oil running and End of stop sequence windows are indicating in the annunciator. 3. Push on Unit conditioning TPL. Genset shaft lifting pump, pre -lubricating
pump, pre-heating Jacket water pump and line A, B air filters will be on. Pumps starting may be verified from the status printer. 4. Turn and push on Unit control TPL at control desk. This will give automatic
start up order. This commences the startup sequence of genset main auxiliaries. Lub oil circulating pump will start immediately and pre-lubricating pump will go off, approximately 5 minutes after, injector cooling water pump will start; after another 5 minutes Lub oil seal circuit pump and in the next minute fuel oil booster pump will start and two minutes after the Jacket water circulating pump will start. Next the pre-heating Jacket water pump will go off. With this main auxiliary startup sequence will be over. (Note that once the start order is given within 15 minutes main auxiliaries start up sequence will be completed). Genset Ready to start indication (window in annunciator) will appear and go off. 5. Starting air receiver drain valve will open and close, after set starting solenoid
valve will open and slow barring will follow in sequence until the unit starts rotating and speed reaches 200 rpm. After a time delay of 10 min. speed will rise automatically to
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rated speed (428 rpm). At 95% rated speed machine will excite and terminal voltage will rise to rated voltage. 6. Put the synchronizing key in the slot; and turn the key to auto position. The
direction of rotation of synchroscope needle and voltage difference may be noticed. Voltage difference may be minimized using the voltage control +/- switch, and frequency adjusted using the engine speed raise / lower switch after watching the voltage and frequency difference in the, synchroscope Un/Hz meters. (Actually in auto position no manual adjustment is required for speed or voltage and only if there is much difference in voltage and frequency for reducing the synchronizing time the voltage/frequency need to be manually adjusted). The unit will get synchronized to the system automatically. 7. After synchronizing, the load may be increased, by (+) pulses at Engine speed
switch, to 2MW. Now synchronizing key may be turned to off position and removed from slot to safe custody. Refer loading curve of the engine (power buildup graph on page 15) and this may be strictly followed for increasing the load on the machine. The Engine Jacket water outlet temperature (JCWT) may be read from the meter on the supervisory panel. JCWT low alarm will be persisting till the temperature reaches 750. The unit MCC supply may be changed over to normal incoming (unit transformer) from preconditioning (PCC) at the common auxiliaries control desk using LV change over switch at a load of 5 MW on normalizing the generator terminal voltage to a load of 5 MW on normalizing the generator terminal voltage to >=10. 7kV but < 11kV. Using voltage control switch raise pulses can be given if the network requires voltage improvement more (MVAR) or by adjusting the tap position of the GT to limit VAR<=10MVAR. The load may be slowly raised to allow the load increase by approximately 1.5MW per minute, and gradually increased to 20MW (MCR) so that from a cold start the unit maybe allowed to take full load in about 40 min. with 5 minutes interval at & of full load. It may be noted that at >=35% load and Jacket water outlet temperature >=75 deg. C the change over authorization from DO to HFO will be received and if steam is available, (if one unit is always working as base load with boiler in service) The fuel change over order can be given by pushing the Fuel changeover TPL switch in turned to HFO position. 15 minutes after a change over order, the unit will change over to HFO
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mode and the indication DO running will disappear with appearance of HFO running. The auxiliary area in charge may be intimated about the time of starting and time of change over from DO to HFO. The lub oil separator may be switched on if no working, before or after a DO to HFO change over. 3.2 Unit Stopping Sequence in Auto 1.Load (MW) may be reduced slowly in steps to 1 MW per minute with corresponding decrease of MVAR. 2.If the unit is running in HFO, allow the unit to run in DO mode for about 30 minutes after a manual changeover at a load <20 MW to feed the pipes and injector pumps with Diesel oil (to replace HFO) by combustion in engine. 3.If the waste heat recovery boiler is working for steam production then, the unit steam pressure regulation selector control switch in CCR common auxiliary supervisory panel of the stopping unit may be switched off, allowing the Boiler circulating pump to continue running till the unit is stopped (By the switching off action, the By pass exhaust valve is opened by closing the Boiler inlet valve). 4.Generator 11kV CB can be switched off at a load of 1 MW & b pushing the circuit breaker control TPL switch in turned to off position. 5.Field breaker may be switched off next by a push action on the Exciter control TPL switch in turned to off position. 6.Engine speed may be gradually reduced to 200rpm (idle speed and Engine may be allowed to idle for about 5 minutes). 7.If a turbo charger gas side washing is to be done, then arrange to do the same at the idling speed at an exhaust temp below 230 degree. 8.Stop order may be given at the unit control TPL switch by a push action on the TPL switch is turned to off position. 9.At this stage, the unit conditioning stop order can be given [the unit conditioning if allowed, will keep the engine ready for a quick restart which allows the engine and lube oil conditioning by lub oil separator, pre-heating jacket water pump, if steam is available in the steam system. However if the stop is for a long duration >3 Hours, it will be better to give stop order to unit conditioning after 1 hour and start unit conditioning 1 hour before a start up of an engine if steam is available].
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10. On receipt of the End of stop sequence the unit MCC supply may be changed over to pre-conditioning supply from normal incoming manually at local and combustion air filters supply put in manual mode if the unit conditioning is to be switched off. 3.3 Detailed Procedure for Starting of a Unit The operator on duty shall do the following preliminary checks before the start up of a unit:110kV Generator Transformer Yard & Control room: 1. Check the SF6 Gas pressure in all the three limbs of GCB and ensure that it is normal. 2. Confirm the CB air pressure is normal. 3. Confirm all isolators are in perfectly closed condition. 4. Check and ensure that the working of transformer cooling fans, transformer conservator oil level and OLTC conservator oil level are normal. 5. Keep the cooler mode selection in AUTO. 6. Ensure that the GT Circuit breaker is closed. 7. In the control room, Confirm DC supply is healthy and all the relays are reset / healthy. Control Desk (Central Control room): 1. Running mode switch and AVR mode select ion switches are in Auto 2. Generator main 11kV CB is OPEN 3. Unit Aux. Transformer CB is closed. 4. No faulty light indication persists on the respective TPL switches on control desk in OFF position. 5. The healthiness of PCC supply. 6. Unit MCC is fed from unit auxiliary transformer. Common Auxiliary Supervisory Panel: 1. HP & LP compressors are healthy. 2. Plant water and fuel circuits are healthy. 3. Normal steam pressure and temperature exist if one unit with its boiler is running. 4. The PRINTERS are online and no other fault alarm persists. Unit Supervisory Panel: Check the following signals: 1. End of stop sequence.
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2. Control room operation. 3. Diesel oil running. 4. All relays are reset / healthy. 5. Confirm that no start lock alarms/trip indications (red) persists in the supervisory panel. Unit Start up Sequence: Starting up of a unit in AUTO includes the following sequence. a) Genset conditioning sequence b) Main auxiliaries start up sequence c) Diesel engine start up sequence d) Engine speed control e) Field contactor control Generator set conditioning sequence: 1. Inform the engine floor junior operator/Aux. area junior operator about units being started up and arrange to start the Diesel oil and HFO circulation pump 2. Give unit conditioning start order from the CR by a PUSH action on the conditioning TPL switch turned to ON position which will immediately start i) The Generator shaft lifting pump ii) The pre-lubricating lube oil pump iii) The pre-heating jacket water pump iv) Line A, Line B air filters Main Auxiliaries start up sequence: In the main auxiliaries start up sequence, pumps are started up for lubrication, cooling and fuel circulation. After informing the junior operator of engine floor, give unit start order to the engine by a PUSH action of a unit control TPL switch, turned in ON position. This will start the main auxiliaries pump in the following sequence: a) b) c) d) e) Lube oil circulating Pump (Immediately) Injectors cooling water pump (5 minutes after) Lube oil seal pump (10 minutes after) Fuel oil booster pump (11 minutes after) Jacket water circulating pump (13 minutes after)
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Confirm from the recorder / engine hall the auxiliaries are put into service as per the starting sequence order and right pressures are built up. With this, main auxiliary start up sequence is finished and Ready to start indication will appear on the annunciator. This indication will appear in the annunciator 14 to 15 minutes after unit start order. Diesel engine start up sequence The engine start up sequence begins after the disappearance of the Ready to start indication and ends on engine attaining 200 rpm speed. This sequence includes: a) b) c) d) e) Starting air receiver water drain sequence Slow barring sequence Engine start up sequence Speed increasing after ignition speed Radiator fans start up sequence. In the slow barring operation, crank shaft turns 3 turns within 55 seconds. After the slow baring operation, set starting solenoid valve actuates to operate main starting pneumatic valve and engine speed rises to 90 rpm. Fuel firing starts at 90 rpm and the engine speed reaches 200 rpm. When the speed reaches above 90 rpm, one group of (8 Nos) Jacket water/Lube oil cooling fans and at 5 seconds interval, other two groups will start in AUTO. But in t he day to day operation these cooling fans will be operated manually for getting a DO to HFO change over. Engine speed control & Field contactor control: The engine will run at idle speed for 10 minutes (for getting the lube oil temp. at engine inlet >450C and its speed rise. In 2 minutes, speed reaches 408 rpm (95%) of rated speed) and excitation authorization will appear on the annunciator. At this point, the Generator shaft lifting pump will automatically switched off and machine will excite by closing the field contactor in the exciter panel and voltage starts to build up. The unit start up sequence is complete and it is ready for synchronization. Synchronization: Synchronizing key may be put in the key slot and turn to Auto position. The 11kV breaker TPL switch should be turned to CLOSE/ ON position. The frequency and voltage will be adjusted automatically by the synchrocoupler which will give closing order to the 11kV CB and the machine will be synchronized to the grid in auto. Upon
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coupling of the unit to the network, the unit is to be initially loaded to 2 MW to meet the engine mechanical losses and at the same time, generator terminal voltage is adjusted to 11kV by increasing the reactive power input. The reactive power input is to be limited to a maximum of 5 MVAR. A unit can be synchronized to the grid within 28 to 30 minutes after a unit start order command is initiated. The synchronization key may be removed from the slot after synchronization. After allowing the generator to run at 2 MW for approximately 2 minutes, the power generated is to be gradually increased to 10 MW as per the power build up graph. The generator is allowed to run at 10 MW till the appearance of Diesel oil to HFO change over Authorization indication in the unit supervisory panel. Diesel oil to HFO change over Authorization will come under the persistence of the following conditions. 1. Load> 35% of MCR i.e., more than 7 MW 2. Jacket water outlet temp > 750C 3. HFO circulation temperature > 750C 4. No fuel oil mixing tank low pressure /engine inlet fuel oil low pressure. 5. Fuel pipe tracing solenoid valve energized on change over command. Fuel oil viscosimeter started on change over command. On appearance of the above alarm, a fuel change over order can be given by pushing the fuel change over TPL switch turning to HFO position. With a time delay of 15 minutes, Diesel oil to HFO changeover will takes place. If any of this conditions required for change over vanishes within this 15 minutes period, the machine will stay in Diesel oil running mode with an alarm Fuel change over alarm. In such an event, a second change over command is to be given from the control desk and to wait another 15 minutes for a change over. On getting a successful change over to HFO, generated power may be increased from 10 MW to the maximum continuous rating gradually. Note: - The thumb rule for increasing the generated power is at 1MW/ minute. 3.4 Detailed Procedure For Stopping Of A Unit Normal stop: A DG set normal stop includes: a) b) Load decreasing Fuel change over
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c) d) e) f) g)
HFO pipes rinsing 11kV CB tripping Field contactor tripping Reducing the engine speed to idle speed Diesel engine Stop order If the machine is running at full load, reduce the load slowly linearly at 1MW per
minute to 35% of MCR. At this load, give a command from the control desk by a push action on the DO/HFO change over TPL switch turned to DO position. For HFO pipe rinsing with Diesel oil, keep running the machine for minimum 30 minutes and reduce the load to 2 MW linearly. Adjust the MVAR at the same time for keeping the power factor to nearest rated value. Reduce the VAR to zero and at a load 1 MW; switch off the 11kV CB by a push action on this circuit breaker TPL switch turned in OFF position followed by field contactor breaker switched off by the action of the respective TPL switch turned in OFF position. Reduce the engine speed manually to idle speed at < 408 rpm Excitation Authorization alarm will vanish. When the speed is reduced to 200 rpm, allow the engine to turn at that speed till exhaust gas average temp is reduced to 165 0C. After that give the engine a stop order by a push action to unit control TPL switch in turned off position and within few seconds, Diesel engine will come to a standstill. When the engine is stopped, an automatic stop order by the PLC will be given to auxiliaries and auxiliaries will stop in the following sequence: a) Radiator fans immediately.
After 5 minutes the pumps will be stopped in the following sequence: b) c) d) e) Fuel oil booster pump. Injector cooling water pump. Lube oil seal pump Lube oil circulating pump. Within seconds, the pre-lubricating pump will start, after 10 minutes, Jacket water circulating pump will stop. Within few milliseconds, pre heating jacket water pump will start in Auto. After 13 minutes, End of stop sequence will appear and by a push action of the unit conditioning TPL switch turned in OFF position will stop the following conditioning auxiliaries.
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a) b) c) d)
Air filters Line A & B. Gen. shaft lifting pump Pre- lubricating lube oil pump Pre- heating Jacket water pump
3.5 Safety & Emergency Stop Of A Unit DG set safety stop: A safety order from the protective system of the unit, upon detection of an anomaly by a particular safety device, will trip the unit in order to prevent serious damages to the unit and auxiliaries. Both 110kV CB of GT and 11kV CB of the generator is opened and the unit will come to a standstill upon the safety stop order. DG set Emergency stop: In case of a serious mechanical or electrical abnormality which can be a threat for the right running of the plant or human safety is detected, the operator can make use of the Emergency stop button on the respective control desk panel. Emergency stop can be made from the following points. i) Unit control desk in central control room ii) Engine local control panel iii) Engine control air compressed unit board. iv) Unit motor control centre In case of an emergency stop order only the 11kV breaker will be opened and the engine will come to stand still. Note: - In all these cases, the fuel lines are to be rinsed manually with diesel oil
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CHAPTER-4 SINGLE LINE DIAGRAMS

4.1 SINGLE LINE DIAGRAM OF THE PLANT The single line diagram of the plant is depicted in the figure shown below. The 11kV generated by the diesel engine driven synchronous alternators are fed to an 11kV/110kV, 25MVA, OLTC regulated, ONAF type generator transformer (GT) with a provision of 17 taps, controlled by pneumatic mechanism. The generator transformer steps up the voltage to 110kV and feeds it to the 110kV double bus arrangement through an 110kV SF6 circuit breaker. The double bus arrangement implemented using a 726A rated Kundah conductor having a resistance of 0.074/km and weight of 1260.60kg/km. Out of the five units, each Unit except Unit 4 is provided with Unit transformers of 1MVA capacity to meet the power requirements of the auxiliary devices of each unit through the Unit motor control centre (MCC). The unit MCC is fed from either the unit transformer (normally) or the 415V, 4000A Power Control Centre (PCC) using an electromechanical interlock. The Power Control Centre is fed directly from the primary of the Generator transformer of Unit 4 (Incomer 1) on one side of the 2000A Bus coupler and the Incomer 2 is obtained either 11kV auxiliary feeder from the 220kV Substation Brahmapuram (normally) or the 11kV Karimugal feeder or else the 11kV Kusumagiri feeder. The Power Control Centre feeds the motor control centres involving the following equipments: a) Fire Fighting Pumps b) Fuel Treatment Pumps and Heavy fuel Oil Separators c) Water Pumps and Softeners d) Oil Water Separator Pumps e) Common system pumps 4.2 SINGLE LINE DIAGRAM OF THE 110KV BUS SYSTEM The 110kV double bus system fed by the 5 Nos of 21.32MW generators is implemented using a pair of 726 A rated Kundah conductors for each bus.
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220kV POOVANTHURUTHU SUBSTATION
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A substation is a part of an electrical generation, transmission, and distribution system. Substations transform voltage from high to low, or the reverse, or perform any of several other important functions. Between the generating station and consumer, electric power may flow through several substations at different voltage levels. The electric power is produced at the power station, which are located at favourable places, generally quite away from the consumers. It is delivered to the consumer through large transmission and distribution networks. A substation may include transformers to change voltage levels between high transmission voltages and lower distribution voltages, or at the interconnection of two different transmission voltages. 1.1 Types Substations may be described by their voltage class, their applications within the power system, the method used to insulate most connections, and by the style and materials of the structures used. Transmission substation: A transmission substation connects two or more transmission lines. The simplest case is where all transmission lines have the same voltage. In such cases, the substation contains high-voltage switches that allow lines to be connected or isolated for fault clearance or maintenance. A transmission station may have transformers to convert between two transmission voltages, voltage control/power factor correction devices such as capacitors, reactors or static var compensators and equipment such as phase shifting transformers to control power flow between two adjacent power systems. Distribution substation: A distribution substation transfers power from the transmission system to the distribution system of an area. It is uneconomical to directly connect electricity consumers to the main transmission network, unless they use large amounts of power, so the distribution station reduces voltage to a level suitable for local distribution. The input for a distribution substation is typically at least two transmission or subtransmission lines. Input voltage may be, for example, 115 kV, or whatever is common in
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the area. The output is a number of feeders. Distribution voltages are typically medium voltage, between 2.4 kV and 33 kV depending on the size of the area served and the practices of the local utility. The feeders run along streets overhead (or underground, in some cases) and power the distribution transformers at or near the customer premises. Collector substation: In distributed generation projects such as a wind farm, a collector substation may be required. It resembles a distribution substation although power flow is in the opposite direction, from many wind turbines up into the transmission grid. Usually for economy of construction the collector system operates around 35 kV and the collector substation steps up voltage to a transmission voltage for the grid. The collector substation can also provide power factor correction if it is needed, metering and control of the wind farm. In some special cases a collector substation can also contain an HVDC converter station. Collector substations also exist where multiple thermal or hydroelectric power plants of comparable output power are in proximity. Converter substation: Substations may be associated with HVDC converter plants, traction current, or interconnected non-synchronous networks. These stations contain power electronic devices to change the frequency of current, or else convert from alternating to direct current or the reverse. Switching substation: A switching substation is a substation which does not contain transformers and operates only at a single voltage level. Switching substations are sometimes used as collector and distribution stations. Sometimes they are used for switching the current to back-up lines or for parallelizing circuits in case of failure. A switching substation may also be known as a switchyard, and these are commonly located directly adjacent to or nearby a power station. In this case the generators from the power station supply their power into the yard onto the generator bus on one side of the yard, and the transmission lines take their power from a feeder bus on the other side of the yard.
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Classification by insulation: Switches, circuit breakers, transformers and other apparatus may be
interconnected by air-insulated bare conductors strung on support structures. The air space required increases with system voltage and with the lightning surge voltage rating. For medium-voltage distribution substations, metal-enclosed switchgear may be used and no live conductors exposed at all. For higher voltages, gas-insulated switchgear reduces the space required around live bus. Instead of bare conductors, bus and apparatus are built into pressurized tubular containers filled with sulfur hexafluoride (SF6) gas. This gas has a higher insulating value than air, allowing the dimensions of the apparatus to be reduced. In addition to air or SF6 gas, apparatus will use other insulation materials such as transformer oil, paper, porcelain, and polymer insulators. Classification by structure: Outdoor, above-ground substation structures include wood pole, lattice metal tower, and tubular metal structures, although other variants are available. Where space is plentiful and appearance of the station is not a factor, steel lattice towers provide low-cost supports for transmission lines and apparatus. Low-profile substations may be specified in suburban areas where appearance is more critical. Indoor substations may be gasinsulated switchgear (at high voltages), or metal-enclosed or metal-clad switchgear at lower voltages. Urban and suburban indoor substations may be finished on the outside so as to blend in with other buildings in the area.
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CHAPTER-2 FEATURES OF THE SUBSTATION

2.1 Outgoing Feeders 110 kV Feeders: 1.) Two lines to Chenganoor 2.) One line to MRF 3.) One line to Chengalam 4.) One line to Punnapra 5.) One line to Sengulam 66 kV Feeders: 1.) 2.) 3.) 4.) Two lines to Mavelikara Two lines to Ettumanoor One line to Kuttanad One line to Peerimade
11 kV Feeders: 1.) 2.) 3.) 4.) 5.) 6.) 7.) 8.) Station Auxiliary Punja South Punja Central Aymanam Travancore Cements Punja North Mooledom Kodimatha
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Table 2.1 Outgoing feeders of substation Conductor and its FEEDER BREAKER CT RATIO maximum capacity
220 kV FEEDER Tie feeder Moozhiyar-Pallom Brahmapuram-Pallom SF6 SF6 SF6 1600/1 800/1 800/1 110KV FEEDER Pallom-Chengannur No 1 Pallom-Chengannur No 2 Pallom-Punnapra Pallom-Chengalam Pallom-MRF Pallom -Sengulam SF6 400/1 Wolf [343A] Double moose [2X880A] Kundah [726 A] Kundah [726 A]
SF6 SF6 SF6 SF6 SF6
400/1 400/1 400/1 400/1 400/1 66KV FEEDER
Wolf [343A] Wolf [343A] Wolf [343A] Wolf [343A] Wolf [343A]
Pallom-Mavelikara No.1 Pallom-Mavelikara No.2 Pallom-Kuttanad Pallom-Ettumanoor No.1 Pallom-Ettumanoor No.2 Pallom-Peermade
SF6
200/1
Stranded copper
SF6 SF6 SF6
400/1 200/1 200/1
DOG[254 A] DOG[254 A] DOG[254 A]
SF6
200/1
DOG[254 A]
SF6
200/1
DOG[254 A]
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11kV FEEDER Pallom - Punja South Pallom - Punja Central Pallom Aymanam Pallom - Travancore Cements Pallom - Punja North Pallom - Mooledom Pallom-Chingavanam Pallom kodimatha SF6 SF6 SF6 SF6 200/1 200/1 200/1 200/1 RACOON[200A] RACOON[200A] RACOON[200A] RACOON[200A] SF6 SF6 SF6 SF6 200/1 200/1 200/1 200/1 RACOON[200A] RACOON[200A] RACOON[200A] RACOON[200A]
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CHAPTER- 3 ELEMENTS OF A SUBSTATION

3.1 Lightning Arrester A lightning arrester is a device used on electrical power systems
and telecommunications systems to protect the insulation and conductors of the system from the damaging effects of lightning. The typical lightning arrester has a high-voltage terminal and a ground terminal. When a lightning surge (or switching surge, which is very similar) travels along the power line to the arrester, the current from the surge is diverted through the arrestor, in most cases to earth. Smaller versions of lightning arresters, also called surge protectors, are devices that are connected between each electrical conductor in power and communications systems and the earth. These prevent the flow of the normal power or signal currents to ground, but provide a path over which high-voltage lightning current flows, bypassing the connected equipment. Their purpose is to limit the rise in voltage when a communications or power line is struck by lightning or is near to a lightning strike.
Fig 3.1 Lightning Arrester Working:Lightning, is a form of visible discharge of electricity between rain clouds or between a rain cloud and the earth. The electric discharge is seen in the form of a brilliant arc, sometimes several kilometers long, stretching between the discharge points. The negative charge at the base of the cloud induces a positive charge on the earth beneath it, which acts as the second plate of a huge capacitor.
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When the electrical potential between two clouds or between a cloud and the earth reaches a sufficiently high value (about 10,000 V per cm or about 25,000 V per in), the air becomes ionized along a narrow path and a lightning flash results. Buildings are protected from lightning by metallic lightning rods extending to the ground from a point above the highest part of the roof. The conductor has a pointed edge on one side and the other side is connected to a long thick copper strip which runs down the building. The lower end of the strip is properly earthed. When lightning strikes it hits the rod and current flows down through the copper strip. These rods form a low-resistance path for the lightning discharge and prevent it from travelling through the structure itself along a narrow path and a lightning flash result 3.2 Isolator Switches In substation, it is often desired to disconnect a part of the system for general maintenance and repairs. This is accomplished by an isolating switch or isolator. An isolator is essentially a kniff switch and is design to often open a circuit under no load, in other words, isolator switches are operate only when the line in which they are connected carry no load. For example, consider that the isolator are connected on both side of a cut breaker, if the isolators are to be opened, the C.B. must be opened first. In electrical engineering, a disconnector or isolator switch is used to make sure that an electrical circuit can be completely de-energised for service or maintenance. High-voltage isolation switches are used in electrical substations to allow isolation of apparatus such as circuit breakers, transformers and transmission lines for maintenance. In some designs the isolator switch has the additional ability to earth the isolated circuit thereby providing additional safety.
Fig 3.2 Isolator
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The major difference between an isolator and a circuit breaker is that an isolator is an off-load device intended to be opened only after current has been interrupted by some other control device. Safety regulations of the utility must prevent any attempt to open the disconnector while it supplies a circuit. 3.3 Instrument Transformer The lines in Sub-Station operate at high voltage and carry current of thousands of amperes. The measuring instrument and protective devices are designed for low voltage (generally 110V) and current (about 5A). Therefore, they will not work satisfactory if mounted directly on the power lines. This difficulty is overcome by installing Instrument transformer, on the power lines. There are two types o f instrument transformer. 3.3.1 Current Transformer A current transformer is essentially a step-down transformer which steps-down the current in a known ratio, the primary of this transformer consist of one or more turn of thick wire connected in series with the line, the secondary consist of thick wire connected in series with line having large number of turn of fine wire and provides for measuring instrument, and relay a current which is a constant fraction of the current in the line. Current transformers are basically used to take the readings of the currents entering the substation. This transformer steps down the current from 800 amps to1ampere.This is done because we have no instrument for measuring of such a large current. The main use of this transformer is (a) distance protection; (b) backup protection; (c) measurement. The primary circuit is largely unaffected by the insertion of the CT. The rated secondary current is commonly standardized at 1 or 5 amperes. Table 3.1 Rating of a Current transformer Nominal system voltage Highest system voltage Frequency Earthing of system Insulation level Rated Short circuit current Rated continuous thermal current 220kV 245kV 50Hz Effective 1060kVp 40kA for 3 sec 120%
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Impulse withstand voltage 1 min PF withstand voltage Transformation ratio
1050kvp 460kV rms 1600-800/1A(5C)&800400/1A(5C)
Fig.3.3 Current transformer 3.3.2 Potential Transformer It is essentially a step down transformer and step down the voltage in known ratio. The primary of these transformer consist of a large number of turn of fine wire connected across the line. The secondary way consist of a few turns and provides for measuring instruments and relay a voltage which is known fraction of the line voltage. Voltage transformers are designed to work without excessive exciting current up to 110% of rated voltage.
Fig 3.4 Potential Transformer 3.3.3 Capacitor Voltage Transformer A capacitor voltage transformer (CVT), or capacitance coupled voltage transformer (CCVT) is a transformer used in power systems to step down extra high voltage signals and provide a low voltage signal, for measurement or to operate a protective relay. In its most basic form the device consists of three parts: two capacitors
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across which the transmission line signal is split, an inductive element to tune the device to the line frequency, and a transformer to isolate and further step down the voltage for the instrumentation or protective relay. The tuning of the divider to the line frequency makes the overall division ratio less sensitive to changes in the burden of the connected metering or protection devices. The device has at least four terminals: a terminal for connection to the high voltage signal, a ground terminal, and two secondary terminals which connect to the instrumentation or protective relay. CVTs are typically single-phase devices used for measuring voltages in excess of one hundred kilovolts where the use of wound primary voltage transformers would be uneconomical. In practice, capacitor C1 is often constructed as a stack of smaller capacitors connected in series. This provides a large voltage drop across C1 and a relatively small voltage drop across C2.
Fig 3.5 Circuit of a CVT The CVT is also useful in communication systems. CVTs in combination with wave traps are used for filtering high frequency communication signals from power frequency. This forms a carrier communication network throughout the transmissio n network. 3.4 Power Transformer Step-up power transformers are used at generating stations to step up the voltage for transmission whereas step down transformers are used at receiving end stations to step down the voltage for secondary transmission and primary and secondary distribution. In case of transformers of large kVA rating, a single three-phase unit or three singlephase units are used. Single three-phase units are economical and occupy less space. The connections are also relatively simpler. But three single-phase units are easier to handle. They are, however, more expensive and require more space.
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Fig 3.6 Power transformer (a) Cores Transformers for use at power or audio frequencies have cores made of many thin laminations of silicon steel. By concentrating the magnetic flux, more of it is usefully linked by both primary and secondary windings. Since the steel core is conductive, it, too, has currents induced in it by the changing magnetic flux. Each layer is insulated from the adjacent layer to reduce the energy lost to eddy current heating of the core. A typical laminated core is made from E-shaped and I-shaped pieces, leading to the name "EI transformer".Certain types of transformer may have gaps inserted in the magnetic path to prevent magnetic saturation. These gaps may be used to limit the current on a shortcircuit. Solid cores: In circuits that operate above mains frequencies, up to a few tens of kilohertz, such as switch-mode power supplies, powdered iron cores are used. These materials combine a high magnetic permeability with a high bulk material resistivity. At even higher frequencies, typically radio frequencies, other types of core made of nonconductive magnetic materials, such as various ceramic materials called ferrites, are common. Air cores: High-frequency transformers may also use air cores. These eliminate the loss due to hysteresis in the core material. Such transformers maintain high coupling efficiency (low stray field loss) by overlapping the primary and secondary windings. Toroidal cores: Toroidal transformers are built around a ring-shaped core, which is made from a long strip of silicon steel or from ferrite, depending on frequency. The strip construction
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ensures that all the grain boundaries are pointing in the optimum direction, making the transformer more efficient by reducing the core's reluctance. The ring shape eliminates the air gaps inherent in the construction of an EI core. The primary and secondary coils are wound concentrically to cover the entire surface of the core. This minimises the length of wire needed, and also provides screening to prevent the core's magnetic field from generating electromagnetic interference. (b)Windings In most practical transformers, the primary and secondary conductors are coils of conducting wire because each turn of the coil contributes to the magnetic field, creating a higher magnetic flux density than a single conductor.The winding material depends on the application. Windings on both primary and secondary of a power transformer may have external connections (called taps) to intermediate points on the winding to allow adjustment of the voltage ratio.Taps may be connected to automatic on-load tap changer switchgear for voltage regulation of distribution circuits. (c)Insulation The conductor material must have insulation to ensure the current travels around the core, and not through a turn-to-turn short-circuit. In power transformers, the voltage difference between parts of the primary and secondary windings can be quite large. Insulation is inserted between layers of windings to prevent arcing, and the transformer may also be immersed in transformer oil that provides further insulation. (d)Coolant All transformers must have some circulation of coolant to remove the waste heat produced by losses. Small transformers up to a few kilowatts in size usually are adequately cooled by air circulation. Larger dry type transformers may have cooling fans. Some dry transformers are enclosed in pressurized tanks and are cooled by nitrogen or sulphur hexafluoride gas. The windings of high-power or high-voltage transformers are immersed in transformer oil,a highly-refined mineral oil that is stable at high temperatures. Large transformers to be used indoors must use a non-flammable liquid. Formerly, polychlorinated biphenyl (PCB) was used as it was not a fire hazard in indoor
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power transformers and it is highly stable. Due to the stability of PCB and its environmental accumulation, it is no longer permitted in new equipment. (e)Insulating Oil Transformer oil or insulating oil is usually a highly-refined mineral oil that is stable at high temperatures and has excellent electrical insulating properties. It is used in oil-filled transformers, some types of high voltage capacitors, fluorescent lamp ballasts, and some types of high voltage switches and circuit breakers. Its functions are to insulate, suppress corona and arcing, and to serve as a coolant. The oil helps to cool the transformer. Because it also provides part of the electrical insulation between internal live parts, transformer oil must remain stable at high temperatures for an extended period. (f)Winding The type and arrangement of the windings are determined based on the following considerations, normal current rating, short circuit strength, temperature rise, overload conditions, surge strength and transportation requirements. (g)Tank Transformer tank is generally made from rolled steel plate. For large transformers coolers are separately fabricated and assembled at site. (h)Bushing A bushing is a hollow insulating liner through which a conductor may pass. The bushing is a hollow insulator, allowing a conductor to pass along its centre and connect at both ends to other equipment. Bushings are often made of wet-process fired porcelain, and may be coated with a semi-conducting glaze to assist in equalizing the electrical stress along the length of the bushing. The inside of the bushing may contain paper insulation and the bushing is often filled with oil to provide additional insulation. Bushings for medium-voltage and lowvoltage apparatus may be made of resins reinforced with paper. The use of polymer bushings for high voltage applications is becoming more common. (i)Dehydrating Breather Air in the air cell of conservator Type OH-D is exposed to the open atmosphere through a dehydrating breather to prevent dew condensation. To display the extent of moisture absorption of the moisture absorbent, it is also mixed the kind of moisture
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absorbent which is blue color under a dry state and changes to pink as moisture absorption progresses. When no breathing is conducted, the breather is isolated from the open air by oil to prevent the moisture absorbent from needlessly absorbing moisture. (j)Tap Changer Off-circuit Tap Changer: Off-circuit tap changer is used for regulating the voltage after the transformer has been completely de-energized. At Toshiba, two standard types of off circuit tap changers are available, a wedge-type off-circuit tap changer and a slide-type off-circuit tap changer. The wedge-type is used when taps are provided halfway on the winding; the slide-type is used when taps are provided on the end of the winding.
Fig 3.7 Off-circuit Tap Changer On-load Tap Changer: The entire on-load tap changer can be built in a tank to facilitate assembly and transport of the transformer. By performing resistance-type breaking, arcing time is short, and both oil contamination and contact wear can be considerably reduced. Further, this tap changer ensures high reliability and long life. The tap selector is provided with contact pieces structured to permit conducting large current; each contact piece is provided with a shield electrode on its upper and lower sides for needs of insulation. (k)Tertiary winding Tertiary winding is an additional winding in power transformers, normally delta connected. Tertiary winding is required for the following reasons. 1.) To reduce the triple harmonic contents of the output voltage, thereby stabilizing
potential of the neutral point, and reducing communication interference.
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2.) 3.)
To permit the transformation of unbalanced three phase load. To reduce system zero sequence impedance for effective grounding, where solid
ground is not provided. 4.) To supply additional auxiliary loads, which for some reason must be kept isolated
from that of secondary? 5.) 6.) To function as a voltage coil in a testing transformer. To load large split-winding transformers.
(l) 220/110 kV transformer In 220 kV/110 kV side there are two 200 MVA transformer. So station capacity is 400MVA.Again one 200 MVA transformer has three units, one for each phase. Each has the capacity 66. 6 MVA. Therefore total 6 units are there. Table: 3.2 Specification of a 200 MVA, 220/110 kV transformer FORM TYPE KVA Voltage on no load Phases Type of cooling Frequency Imp. Voltage Mass of Core and Windings Mass of Oil Transformer Mass Total Mass Total oil (m)110kV/66 kV Transformers Specification In this side three 63 MVA transformers are used. Table: 3.3 specification of a 110kv/66 kV transformer FORM KVA 3ANYCP HV 42000/63000 LV 42000/63000 ANYCCP SALOCR 44450/66670 HV 220 LV 110 1 ONAN/ONAF 50 Hz 11.72% 34,000 Kg 20,060 Kg 44,500 Kg 76,000 Kg 22,290 l
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TV 14000/21000 Voltage HV 110000 LV 66000 TV 11000 HV 221/331 LV 368/552 ONAN/ONAF 50 Hz 9.91 % 3 YNaod11
Ampere Type of cooling Frequency Imp. Voltage No of phases Connection Symbol (n)66 kV/11 kV Transformers Two 10 MVA transformers are used.
Table: 3.4 Specification of a 66/11kV transformer KVA Voltage Ampere Type of cooling Frequency Imp. Voltage No of phases 3.5 Circuit breaker A circuit breaker is an equipment, which can open or close a circuit under normal as well as fault condition. These circuit breaker breaks for a fault which can damage other instrument in the station. It is so designed that it can be operated manually (or by remote control) under normal conditions and automatically under fault condition. When manual or motor-drive is used, the circuit breaker will be ready to close. The closure can be actuated pressing the closing button located on the circuit breaker. The opening can be HV 10000 LV 10000 HV 66000 LV 11000 HV 87.5 LV 525 ONAN 50 Hz 9.446% 3
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performed either by opening button or remote controlled opening coil. In case of a fault, the relay signal actuates the opening coil and circuit breaker opens. After all, the following procedure must be performed: 1. Open the isolator of circuit breaker, 2. Prepare the circuit breaker for closing operation by driving mechanism, 3. Close the isolator of circuit breaker firmly, 4. Send the closing signal to the circuit breaker (a) Classification of circuit breakers SF6 circuit breakers: The use of SF6 circuit breaker is mainly in the substations which are having high input kv input, say above 220kV and more. The gas is put inside the circuit breaker by force ie under high pressure. When if the gas gets decreases there is a motor connected to the circuit breaker. The motor starts operating if the gas went lower than 20.8 bar. There is a meter connected to the breaker so that it can be manually seen if the gas goes low. The circuit breaker uses the SF6 gas to reduce the torque produce in it due to any fault in the line. The circuit breaker has a direct link with the instruments in the station, when any fault occur alarm bell rings. Sulphur Hexafluoride (SF6) is an excellent gaseous dielectric for high voltage power applications. It has been used extensively in high voltage circuit breakers and other switchgears employed by the power industry. Applications for SF6 include gas insulated transmission lines and gas insulated power distributions. The combined electrical, physical, chemical and thermal properties offer many advantages when used in power switchgears. Some of the outstanding properties of SF6 making it desirable to use in power applications are: a) Very High dielectric strength b)Very Unique arc-quenching ability c) Very Excellent thermal stability d)Very Good thermal conductivity
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Fig 3.8 SF6 Circuit Breakers Construction: It consists of fixed and moving contacts enclosed in a chamber called arc interruption chamber containing SF6 gas. This chamber is connected to SF6 gas reservoir. When the contacts of breaker are opened the valve mechanism permits a high pressure SF6 gas from the reservoir to flow towards the arc interruption chamber. The fixed contact is a hollow cylindrical current carrying contact fitted with an arc horn. The moving contact is also a hollow cylinder with rectangular holes in the sides to permit the SF6 gas to let out through these holes after flowing along and across the arc. Working: In the closed position of the breaker the contacts remained surrounded by SF6 gas at a pressure of about 2.8 kg/cm2. When the breaker operates the moving contact is pulled apart and an arc is struck between the contacts. The movement of the moving contact is synchronized with the opening of a valve which permits SF6 gas at 14 kg/cm2 pressure from the reservoir to the arc interruption chamber. The high pressure flow of SF6 rapidly absorbs the free electrons in the arc path to form immobile negative ions which are ineffective as charge a carriers. The result is that the medium between the contacts quickly builds up high dielectric strength and causes the extinction of the arc. After the breaker operation the valve is closed by the action of a set of springs. Table 3.5 Rating of SF6 breaker Rated short circuit breaking current 40 kA
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Rated operating Pressure Rated duration of SC current Gas weight Rated line changing breaking current Rated Voltage Rated normal current Rated closing voltage Rated SF6 gas pressure Rated voltage for arc circuit 3.6 Busbar
15 Kg/cm 40 kA for 3sec 21 kg 125 A 245 V 2500 A 110V DC

2 o
6 kg/cm upto 20 C 415 VA
When a number of lines operating at the same voltage have to be directly connected electrically, bus-bar are used, it is made up of copper or aluminum bars (generally of rectangular X-Section) and operate at constant voltage. The bus is a line in which the incoming feeders come into and get into the instruments for further step up or step down. The first bus is used for putting the incoming feeders in LA single line. There may be double line in the bus so that if any fault occurs in the one the other can still have the current and the supply will not stop. The two lines in the bus are separated by a little distance by a conductor having a connector between them. This is so that one can work at a time and the other works only if the first is having any fault and at the same time have sufficient structural strength to withstand the maximum stresses that may imposed on the conductors and in turn in structures by heavy current under short circuit conditions.
Fig 3.9 Busbar
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3.7 Insulator The insulator serves two purposes. They support the conductor (or bus bar) and confine the current to the conductor. The most commonly used material for the manufactures of insulators is porcelain. There are several type of insulator (i.e. pine type, suspension type etc.) and there used in Sub-Station will depend upon the service requirement. Insulators must support the conductors and withstand both the normal operating voltage and surges due to switching and lightning. Insulators are broadly classified as either pin-type, which support the conductor above the structure, or suspension type, where the conductor hangs below the structure strain, shackle and stray. The invention of the strain insulator was a critical factor in allowing higher voltages to be used. In olden times, the limited electrical strength of telegraph-style pin insulators limited the voltage to no more than 69,000 volts. At higher voltages only suspension-type insulators are common for overhead conductors. Insulators are usually made of wet-process porcelain or toughened glass, with increasing use of glass-reinforced polymer insulators. However, with rising voltage levels and changing climatic conditions, polymer insulators (silicone rubber based) are seeing increasing usage. Suspension insulators are made of multiple units, with the number of unit insulator disks increasing at higher voltages. The number of disks is chosen based on line voltage, lightning withstand requirement, altitude, and environmental factors such as fog, pollution, or salt spray. In cases where these conditions are suboptimal, longer insulators must be used. Pin Insulator: A pin insulator consists of a non conducting material such as porcelain, glass, plastic, polymer, or wood that is formed into a shape that will isolate a wire from a physical support (or "pin") on a telegraph, utility pole or other structure, provide a means to hold the insulator to the pin, and provide a means to secure the conductor to the insulator. By contrast to a strain insulator, the pin insulator is directly connected to the supporting pole. Pin insulators of one piece or multi piece construction are widely used in low cost distribution lines. The Pin type insulator is designed to be mounted on a pin which in turn is installed on the cross-arm of the pole.. These pieces form what we call
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petti-coats. These are designed to shed rain and sleet easily. These are available for use up to 50,000 volts. Strain Insulator: The strain insulator looks exactly like the suspension insulator but is designed to hold much heavier physical loads. Strain insulators are used when a pull must be carried as well as insulation provided. Such places occur whenever a line is dead-ended, at comers, at sharp curves, at extra long spans, at river crossings, or in mountainous country. In such places the insulator must not only be a good insulator electrically but it also must have sufficient mechanical strength to counterbalance the forces due to tension of the line conductors. Sometimes a line is to withstand great strain, for instance at a dead end or at a corner or on sharp turns. In such a circumstance for LT (low tension) lines shackle insulators are used but H T (high tension) transmission lines strain insulators consisting of an assembly of suspension type insulators are used. Because of its peculiarly
important job, a strain insulator must have considerable strength as well as the necessary electrical properties. Two or more strings of suspension insulators are used in parallel when the tension is exceedingly high. The discs of strain insulators are employed in a vertical plane where as the suspension insulators are used in horizontal plane. Suspension Insulators: The suspension insulator, as its name implies, is suspended from the crossarm and has the line conductor fastened to the lower end. It is designed for ease of linking units together. Linking of these insulators gives you the versatility of ordering one insulator to be used with varying voltages. . At voltages greater than 220 kV the pin type insulators become bulky, cumbersome and costly. Besides, the pin which must hold it would have to be in ordinarily long and large. In order to meet the problem of insulators for these high voltages, the suspension insulator was developed. The suspension insulator hangs from the cross arm, as opposed to the pin insulator which sits on the top of it. The line conductor is attached to its lower end. Because there is no pin problem, we can put any distance between the suspension insulator and the conductor just by adding more insulators to the string. The entire unit of suspension insulators is called a stri ng. How
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many insulators the string consists of depends upon the working voltage, the weather conditions, the type of transmission construction, and the size of insulator used. Shackle Insulators: The shackle or spool-type insulator, which is easily identified by its shape, is usually used on it lines. Both the low voltage conductors and the house service wires are attached to the shackle insulator. Stay Insulators: Such insulators are of egg shape and used in guy cables, where it is necessary to insulate the lower part of the guy cable from the pole for the safety of the people on the ground. These are provided at a height of about 3 m from the ground level.
Fig 3.10 Insulators 3.8 Coupling Capacitors The coupling capacitors are used in the transmission of high frequency signals in a high voltage power system, by enabling connection of coupling device to the high voltage line. Connects high frequency (carrier) equipment to one of the line conductors. It Isolate the carrier equipment from the high frequency line voltage. Provides a low reactance to the high frequency currents about 150 at 500 KHz and a high reactance to the power frequency about1.5 M at 50 Hz. It is permanently energized by the normal voltage of the power line and should be able to withstand, without damage, the over voltages due to steep fronted waves, which may on occasions reach several times the rated voltages. Coupling capacitor used in modern PLCC system has a capacity between 2000pf to 10000pf.The coupling capacitor units are designed to have very low loss. They are usually mounted on pedestals below the line conductor where the line enters the station. One end of coupling capacitor must be securely connected to ground. Otherwise
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over voltage up to the magnitude of the operating voltage may occur on the equipments side of the capacitor
Fig 3.11 Coupling Capacitors In many cases, the capacitive voltage transformers used for the measurement of line voltages are used as coupling capacitor for PLCC also. Capacitor voltage transformers are constructed in single or multi unit porcelain housing with their associated magnetic units. For EHV systems CVT`s are always supplied in multi unit construction. CVT`s are available for system with voltages 32kV to 420kV. 3.9 Temperature Measuring Device Liquid Temperature Indicator: Liquid temperature indicator is used to measure oil temperature as a standard practice. With its temperature detector installed on the tank cover and with its indicating part installed at any position easy to observe on the front of the transformer, the dial temperature detector is used to measure maximum oil temperature. The indicating part, provided with an alarm contact and a maximum temperature pointer, is of airtight construction with moisture absorbent Winding Temperature Indicator: The winding temperature indicator relay is a conventional oil temperature indicator supplemented with an electrical heating element. The relay measures the temperature of the hottest part of the transformer winding. If specified, the relay can be fitted with a precision potentiometer with the same characteristics as the search coil for remote indication. The temperature sensing system is filled with a liquid, which changes in volume with varying temperature. The sensing bulb placed in a thermometer well in the transformer tank cover senses the maximum oil temperature. The heating element with a matching resistance is fed with current from the transformer associated with the loaded winding of the transformer and compensates the indicator so that a temperature increase of the heating element is thereby proportional to a temperature increase of the
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winding-over-the maximum- oil temperature. Therefore, the measuring bellows react to both the temperature increase of the winding-over-the-maximum-oil temperature and maximum oil temperature. In this way the instrument indicates the temperature in the hottest part of the transformer winding.
Fig 3.12 (a) Oil temperature indicator (b) Winding temperature Indicators 3.10 Pressure Relief Device When the gauge pressure in the tank reaches abnormally to 0.35-0.7kg/c m2 the pressure relief device starts automatically to discharge the oil. When the pressure in the tank has dropped beyond the limit through discharging, the device is automatically reset to prevent more oil than required from being discharged.
Fig 3.13 Pressure relief device 3.11 Switch Gear In an electric power system, switchgear is the combinations of electrical disconnect switches, fuses or circuit breakers used to control, protect and isolate electrical equipment. Switchgear is used both to de-energize equipment to allow work to be done and to clear faults downstream. This type of equipment is important because it is directly linked to the reliability of the electricity supply. Typically switchgear in substations is located on both the high voltage and the low voltage side of large power transformers. One of the basic functions of switchgear is protection, which is interruption of shortcircuit and overload fault currents while maintaining service to unaffected circuits.
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Switchgear also provides isolation of circuits from power supplies. Switchgear is also used to enhance system availability by allowing more than one source to feed a load.
Fig 3.14 Switch gear and control room 3.12 Vibration Dampers Vibration dampers are used to add damping to the motion and reduce the amplitude of vibration below the fatigue danger level. The purpose of this note is to illustrate the methodology for assessing limits of performance for such dampers. They reduce stresses on Vibrating Conductor to avoid structural damage due to vibration on transmission lines. It is manufactured of Aluminium Alloy and Cast Iron Galvanized and the messenger wire is manufactured of High Tensile Galvanized Steel.
Fig 3.15 Vibration damper 3.13 Auto Closure It has been found that most of the line faults on overhead transmission system are transient in nature. About 90% of faults are caused by lightning, birds, vines, tree branches etc. these conditions result in such arcing faults that if the fault energy is interrupted for a short period, the arc extinguishes and the line can be re-energised. This fact is employed as a basis for auto reclosure schemes. In such schemes, after the relays at both ends of the line have picked up, the circuit breakers are tripped as far as possible at the same time and reclosed after time has been allowed for deionization. The fault disappears if it is transient, and line is fully restored to service after the reclosure. If the fault is not cleared after the first reclosure, a double or triple attempt of isolation and
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reclosure can be made. If the fault persists, the breaker may permanently open till it is reset manually. An auto reclosure consists essentially of an oil switch or breaker actuated by relays which make it open when predetermined current values flow through it. Reclosures are usually connected to protect portions of primary circuits and may take the place of line fuses. Auto reclosing may be single phase or three phase type. Mostly single phase auto reclosing breakers are preferred as most of the transmission faults are single phase to ground faults. Auto reclosing of three phase improves stability as the power remains transmitted through the two healthy phases when one phase is interrupted. 3.14 Protective Relays In electrical engineering, a protective relay is an electromechanical apparatus, often with more than one coil, designed to calculate operating conditions on an electrical circuit and trip circuit breakers when a fault is detected. Unlike switching type relays with fixed and usually ill-defined operating voltage thresholds and operating times, protective relays have well-established, selectable, time/current (or other operating parameter) operating characteristics. Protection relays may use arrays of induction disks, shaded-pole magnets, operating and restraint coils, solenoid-type operators, telephonerelay contacts, and phase-shifting networks. Protection relays respond to such conditions as over-current, over-voltage, reverse power flow, over- and under- frequency. Types of Relays based on Construction: Type of relays based on construction, used in 220kV substation are Electromagnetic Relays, Static Relays and Numerical Relays Operating principle:Electromechanical protective relays operate by either magnetic attraction, or magnetic induction. Armature type relays have a pivoted lever supported on a hinge or knife-edge pivot, which carries a moving contact. These relays may work on either alternating or direct current, but for alternating current, a shading coil on the pole is used to maintain contact force throughout the alternating current cycle. Because the air gap between the fixed coil and the moving armature becomes much smaller when the relay has operated, the current required to maintain the relay closed is much smaller than the current to first operate it. The returning ratio or differential is the measure of how much the current must
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be reduced to reset the relay. A variant application of the attraction principle is the plunger-type or solenoid operator. A reed relay is another example of the attraction principle. Moving coil meters use a loop of wire turns in a stationary magnet, similar to a galvanometer but with a contact lever instead of a pointer. These can be made with very high sensitivity. Another type of moving coil suspends the coil from two conductive ligaments, allowing very long travel of the coil. Induction disc meters work by inducing currents in a disk that is free to rotate; the rotary motion of the disk operates a contact. Induction relays require alternating current, if two or more coils are used, they must be at the same frequency otherwise no net operating force is produced Electromechanical Relays: In electromechanical relays the switching element is a mechanical contact, actuated by an electromagnet. This is the most widely used type of relay design. The principal internal functions of the electromechanical relay are: a) Conversion of electrical current (input, coil current) to a magnetic field b) Conversion of the magnetic field into a mechanical force c) This force operates the contacts (secondary side) d) Contacts switch and conduct electrical current (output, load current). Static Relays: The conventional relay type of electromagnet relays can be replaced by static relays which essentially consist of electronic circuitry to develop all those characteristics which are achieved by moving parts in an electro-magnetic relay.For example, in an induction type relay, the operating time can be adjusted by adjusting the distance travelled by the disc whereas in a static relay it can be achieved by adjusting the value of the resistance in the R-C time delay circuit. In other words static relays are capable of performing the same functions with the use of electronic circuit control as an electromagnetic relay performs with the use of moving parts or elements. Static relays are superior to electro-magnetic relays in the following aspects: 1. The moving parts and the contacts are largely eliminated. The only moving
element in a static relay is the final tripping contact. 2. C.T.s and P.T.s employed are of lesser VA rating as static relays require a very
little volt-ampere for their operation.
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3.
More precise and high speed operation.
Figure 3.16 Static relay Numerical relays: In electrical engineering of power systems, a digital protective relay uses a microcontroller with software-based protection algorithms for the detection of electrical faults. Such relays are also termed as microprocessor type protective relays. The digital protective relay, or numeric relay, is a protective relay that uses a microprocessor to analyze power system voltages and currents for the purpose of detection of faults in an electric power system. The relay applies A/D (analog-to-digital) conversion processes to the incoming voltages and currents. The relay analyzes the A/D converter output to extract, as a minimum, magnitude of the incoming quantity, commonly using Fourier transform concepts. Digital relays often have some form of event recording. The event recording would include some means for the user to see the timing of key logic decisions, relay I/O (input/output) changes, and see in an oscillographic fashion at least the fundamental frequency component of the incoming AC waveform. Digital/Numerical relays also provides LCD Display, or display on a terminal through serial interface. This is used to display current/voltage values in real-time, and relay settings etc. More complex digital relays will have metering and communication protocol ports. In some solid state relays, a simple microprocessor does some of the relay logic, but the logic is fixed and simple. For instance, in some time overcurrent solid state relays, the incoming AC current is first converted into a small signal AC value, then the AC is fed into a rectifier and filter that converts the AC to a DC value proportionate to the AC
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waveform. An op-amp and comparator is used to create a DC that rises when a trip point is reached. Then a relatively simple microprocessor does a slow speed A/D conversion of the DC signal, integrates the results to create the time-overcurrent curve response, and trips when the integration rises above a set point. Though this relay has a microprocessor, it lacks the attributes of a digital/numeric relay, and hence the term "microprocessor relay".
Figure 3.17 Block diagram of a microprocessor based relay
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3.15 Types Of Relays For Various Components (a)For transformers Differential relay: Current differential protection provides an overall transformer protection deriving phase current from each transformer winding, calculating the differential current on a per phase basis and detecting phase-to-phase and phase-to-earth faults. The current differential protection is based on Kirchhoffs first law that the vector summation of all currents flowing into a protected zone must be zero. Figure shows the principle of current differential protection. Differential current (id) is the vector summation of all terminal current of the transformer. The differential current (id=i1+i2) is zero because the current (i1) equals current (i2) during a load condition or an external fault. During an internal fault, the differential current (id) is not zero because the current (i1) does not equal to the current (i2), and the DIFT operates
Fig 3.18 Differential Relay In order to restrain erroneous differential currents, the currents supplied to the differential elements must be matched in phase and amplitude under through-load and through-fault conditions. It is necessary to compensate for phase angle difference among line currents on each side of the transformer when the transformer windings have both star- and delta-connections. Static Differential Relay: The differential relay measures the phasor difference between two similar electrical quantities (voltage-voltage or current-current). The rectifier bridge amplitude comparator is the most common static form for applications as a differential relay element. Inputs I and II are supplied to the comparator. The output of the comparator phasor difference of inputs I and II is amplified and used to operate the relay.
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Fig 3.19 Static Differential Relay The static differential relays are most commonly used for the protection of generators and transformers for any type of internal faults ( two-and three-phase faults, earth faults with solidly grounded neutral or low resistance grounded neutral-inter-turn faults). Restricted Earth Fault Relay: Restricted earth fault protection (REF) is a zero-phase current differential scheme and applied for a star-connected winding whose neutral is earthed directly or through a low impedance. It gives highly sensitive protection for internal earth faults. REF employs a low impedance current differential scheme which detects the differential current between the residual current derived from the three-phase line currents and the neutral current in the neutral conductor as shown in Figure 3.21
Fig 3.20 REF Relay Static Over-Current Relay: Directional relay senses direction of power flow by means of phase angle between V and I. When the phase angle between V and I exceed certain predetermined value, the directional relay operates with a condition that the current is above the pick-up value.
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Thus directional relay is a double actuating quantity relay with one input as current I from CT and the other input V from PT.
Fig 3.21 Static Over Current Relay The inputs are supplied to the phase comparator. A phase shifter is included in the voltage input circuit, whose output is fed to the phase comparator; so the output from the phase comparator under phase faults, earth fault condition is maximum. The output of the phase comparator is fed to the level detector. The output of the level detector is amplified and in case a timer is necessary, the output is applied to the output device through the timer. Distance Protection: Distance-relay group is perhaps the most interesting and versatile family of relays. Principal types of distance relays are (i) Impedance relays (ii) Reactance relays (admittance or mho relays). Distance relays differ in principle from other forms of protection in that their performance is not governed by the magnitude of the current or the voltage in the protected circuit but rather on the ratio of these two quantities. Distance relays are actually double actuating quantity relays with one coil energized by voltage and the other coil by current. The current element produces a positive or pick-up torque while the voltage element produces a negative or reset torque. The relay operates only when the VI ratio falls below a predetermined value. During fault on a transmission line, the fault current increases and the voltage at the fault point decreases. The V/I ratio is measured at the location of the CTs and PTs. The voltage at PT location depends on the distance between PT and the fault. If the fault is nearer, measured voltage is lesser and if the fault is farther, measured voltage is more. Hence assuming constant fault impedance, each value of V/I measured from relay location corresponds to distance between relaying point
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and the fault along the line. Hence such protection is called the distance protection or impedance protection. Buchholz relay: Buchholz relay is a gas- actuated relay installed in oil-immersed transformers for protection against all kind of faults. It is used to gives an alarm in case of slow developing faults or incipient faults in the transformer and to disconnect the transformer from the supply in the event of severe internal faults. It is installed in the pipe between the conservator and main tank. This relay is used in oil-immersed transformers of rating above 750 kVA. In Poovanthuruthu substation there are two buchholz relays. One is between Conservator and the main tank and other one is between conservator and OLTC. Construction: Figure shows the constructional details of buchholz relay. It consists of a domed vessel placed in the pipe between the conservator and main tank of the transformer. The device has two elements. The upper element consists of a mercury type switch attached to a float. The lower element contains a mercury switch mounted on a hinged type flap located on the direct path of flow of oil from the transformer to the conservator. The upper element closes an alarm circuit during slow developing faults whereas the lower element is arranged to trip the circuit breaker in case of severe internal faults.
Fig 3.22 Buchholz Relay Operation: The operation of buchholz relay is as follows: In case of slow developing faults within the transformer, the heat due to the fault causes decomposition of some transformer oil in the main tank. The products of decomposition mainly contain 70 % of hydrogen gas. The hydrogen gas being light tries to go into the conservator and in the
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process gets trapped in the upper part of the relay chamber. When a predetermined amount of gas gets accumulated, it exerts sufficient pressure on the float to cause it to tilt and close the contacts of mercury switch attached to it. This completes the alarm circuit to sound an alarm. If serious fault occur in the transformer, an enormous amount of gas is generated in the main tank. The oil in the main tank rushes towards the conservator via the buchholz relay and in doing so it tilts the flap to close the contacts of mercury switch. This completes the trip circuit to open the circuit breaker controlling the transformer. Advantages: 1. 2. It is the simplest form of transformer protection. It detects the slow developing faults at a stage much earlier than other forms of
protection. Disadvantages: 1. It can only be used with oil immersed transformers equipped with conservators. 2. The device can detect only faults below oil levelling the transformer. Therefore separate protection is needed for connecting cable.
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CHAPTER-4 SUBSTATION EARTHING

In substation, earthing system is essential not only to provide the protection of people working or walking in the vicinity of earthed facilities and equipments against the danger of electric shock but also to maintain the proper function of the electrical system. By using proper conductor and electrode side, earthing system may be able to lightning effects. 4.1Earthing system for substation An effective substation earthing system typically consists of earth rods, connecting cables from the buried earthing grid to metallic parts of structures and equipment, connections to earthed system neutrals, and the earth surface insulating covering material. Current flowing into the earthing grid from lightning arrester operation, impulse or switching surge flashover of insulators, and line to ground fault current from the bus or connected transmission lines all cause potential differences between earthed points in the substation. Without a properly designed earthing system, large potential differences can exist between different points within the substation itself. Under normal circumstances, it is the current constitutes the main threat to personal. An effective earthing system has the following objectives 1) Ensure such a degree of human safety that a person working or walking in the
vicinity of earthed facilities is not expressed to the danger of a critical electric shock. The touch and step voltage produced in a fault condition have to be at safe values. A safe value is one that will not produce enough current within a body to cause ventricular fibrillation. 2) Provide means to carry and dissipate electric currents into earth under normal and
fault conditions without exceeding any operation and equipment limits or adversely affecting continuity of services. 3) Provide earthing for lightning impulses and the surges occurring from the
switching of substation equipment, which reduces damage to equipment and cables. 4) Provide a low resistance for the protective relays to see and clear ground faults,
which imp protective equipment performance, particularly at minimum fault.
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CHAPTER-5 STATION BATTERY

5.1 General Details Station battery is a key equipment in the power system and its proper selection, installation, operation and maintenance are vital for the safe and reliable functioning of the system. If any fault occurs in the transmission line or if the power supply is cut off, these charged batteries provides sufficient voltage for the working of equipments in the station The function a storage cell is to convert electrical energy into chemical energy during the process known as charging and reverse of it during discharging. During charging the cell, when current is passed through it, certain chemical changes takes place in the active materials of the cell. Such chemical changes absorb energy during their formation. When those chemical reactions are completed and the electric current produces no further chemical changes, then the cell is said to be fully charged. When the cell is connected to an external electrical circuit, then the active material of the cell revert to their original condition, thereby reversing the changes which occurred during charging. In this process of undergoing the chemical changes, absorbed energy is released in the form of electric current and this process being known as discharging. Battery room in the substation is provided with 55 lead acid cells each with 2V.
Fig 5.1 Station Battery 5.2 Lead Acid Cell The substance of the cell which take active part in chemical combination and hence absorb or produce electricity during charging or discharging, are known as active materials of the cell.
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Active materials for Lead acid cell are Lead peroxide (PbO2) for +ve plate Sponge lead (Pb) for ve plate Dilute Sulphuric acid (H2SO4) as electrolyte Lead Acid Storage Battery Installation Battery room shall be clean and adequately ventilated. As the battery approaches full charge significant amount of hydrogen gas will be released from the cells. When the cell is fully charged, each charging ampere will produce 0.000453 m3 hydrogen per hour from each cell (at temperature 270C). Follow suppliers manual of instructions while installing on the racks. It is utmost important that the positive terminal of the battery set is connected to the positive lead of the battery charger The acid to be used in the battery for initial filling shall be of battery grade sulphuric acid of specific gravity 1.190 0.005 (at 270C) After installation of the cells in the racks, connect the cells together with the cell connectors supplied by the manufacturers. Apply thin film coating of petroleum jelly on the threads and boiling faces. Cool, pure sulphuric acid of 1.1900 sp.gr. shall be carefully poured into the cells, till the level indicator in each cell rises to the maximum recommended level After filling, allow the cells to stand for a period of 8-12 hours. The plates will absorb electrolyte and level will drop. At the end of rest period of 8-12 hours add battery grade electrolyte and adjust the level. The battery is ready for initial charging. Normally the initial charging of the battery will take about 50 Hrs to 90 Hrs, depending on the Ah. capacity. Charging equipment shall be capable of delivering the required charging current specified by the supplier for the battery set supplied. Before charging, ensure connection of cells, their polarity and polarity of the charging leads. Commence charging not later than 24 hours after filling the first cell with the electrolyte. During charging take hourly reading of all cells, for a few hours after filling the cells, the specific gravity may fall even during charging. After some charging, the specific gravity will begin to improve and finally reach a steady value
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When specific gravity reading reaches the maximum and remains steady for three hours, it shall be deemed that the battery is fully charged. The voltage of the battery will also rise to approximately 2.75 V per cell and remain constant. If for 3 hours, the voltage and specific gravity remain steady at the maximum value, charging shall be discontinued. All cells shall be gassing freely at the end of charge. At the end of the first charge, if the specific gravity of electrolyte in any cell exceeds 1.205, withdraw some electrolyte and add distilled water and continue charging for some time.
If at the end of the first charge, if the specific gravity of the electrolyte is below 1.195 after both voltage and specific gravity have remained constant for over 3 consecutive reading, withdraw some electrolyte and add acid of 1.350 to 1.400 specific gravity and continue charging for some time. .
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CHAPTER-6 COMMUNICATION SYSTEM IN SUBSTATION

1. 2. 3. PLCC- Power line carrier communication Microwave communication Optical Fibre communication
In Pallom, they use the first two. 6.1 PLCC Communication Power line communications systems operate by impressing a modulated carrier signal on the wiring system. Different types of power line communications use different frequency bands, depending on the signal transmission characteristics of the power wiring used. Since the power distribution system was originally intended for transmission of AC power at typical frequencies of 50 or 60Hz, power wire circuits have only a limited ability to carry higher frequencies. The propagation problem is a limiting factor for each type of power line communications. Data rates and distance limits vary widely over many power line communication standards. Low-frequency (about 100200 kHz) carriers impressed on high-voltage transmission lines may carry one or two analog voice circuits, or telemetry and control circuits with an equivalent data rate of a few hundred bits per second; however, these circuits may be many miles long. Higher data rates generally imply shorter ranges; a local area network operating at millions of bits per second may only cover one floor of an office building, but eliminates the need for installation of dedicated network cabling.
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CHAPTER-7 MAINTENANCE SHEDULE

Table 7.1 Maintenance schedule
POWER TRANSFORMER Perio d. Items to be inspected. Oil level in transformer Oil level in bushings Relief vent diaphragm De-Hydrating breather Action required if inspection shows unsatisfactory condition. If low top up with dry oil, examine the transformer for leaks. If low bring it to the original level Replace if cracked or broken If silica gel is pink, change by spare charge. The old charge may be reactivated Clean or replace Take suitable action to restore quality of oil. Makeup oil if required.
No
Inspection notes.
1 2 3
Daily ,, ,,
Check against transformer oil temperature _ _
,,
5 6 7
Quarte rly ,, ,,
Bushings Oil in transformer De-Hydrating breather Oil in transformer.
Examine for cracks & dirt deposits. Check the dielectric strength & water content. Check oil level in the oil cup & the air. Check for BDV, acidity, water content & sludge.
Yearly
Filter or replace.
Windings. Oil filled bushings. Gasket joints.
Compare with the Using a 5KV-megger measure values at the time of the IR values of primary & commissioning, process secondary. if require. Test oil. Filter or replace. Tighten the bolt evenly to avoid uneven pressure.
10 11
,, ,,
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12
,,
Oil coolers
Dismantle & Inspect the tubes for chocking, damages, oil leaking etc, Check for over current, abnormal sound & oil leaking. Check local-remote operation, check for leaking & mechanical defect. For water leaking through coolers, valves, pipe joints etc, Check for looseness.
Clean the tubes with suitable brush and repair or replace if necessary. Rectify the problems observed. Rectify circuit problem, replace gland packing & apply fresh bearing grease. Replace the old gasket packing & O-ring Clean, put contact grease &tightened maximum.
13
Yearly Oil pump motors. . ,, Motorized inlet valve of cooling water Cooling system Terminal connections.
14
15
,,
16
,,
SF6 CIRCUIT BREAKERS 1 2 Daily. ,, Porcelain. Air pressure For dust and damage Normal range is14.515.5kg/sq.cm 5.5-6kg/sq.cm at 20deg.c. 5.7-6.3 ,, ,, at 30 ,, ,, 6-6.6 ,, ,, at 40 ,, ,, Check oil level Drain out air cylinder for water. (a)Check grounding pad for looseness. (b)Check foundation bolt. (c)Check the position indicator. (d) Record the No. of operations. Check air leakage for max. drop of 10% in 24hrs. (a)Check the stroke mechanism. Clean and replace Check compressor circuit for not restarting at 14.5Kg/sq.cm pressure. Leak testing using soap water & charge gas to the normal pressure. Top up oil or recharge fresh oil. Clean drainage valve for chocking. Tight if necessary. -DoRectify air leaking.
3 4 5 6
,, Weekly ,, Yearly.
Gas pressure & temp. Compressor oil. Compressor air. Appearance
7 8
Yearly. ,,
Air system. Pneumatic operating mechanism.
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(b)Check the over stroke. (c)Check the nuts for mechanical linkage for looseness. (d)Lubrication of mechanism. 9 ,, Compressor and motor Pressure switches. Check for any abnormality. (a) Check setting of air pressure Switch for alarm, lockout, & compressor governing. (b) Check the setting of gas pressure switch for alarm & trip. (a)Check contacts of auxiliary switches, wiring for looseness , etc. (b)Check the resistance of trip & close coils. (c)Check space heater ISOLATORS AND EARTH SWITCHES Isolator contacts.(on closed position) Porcelain. Operations. Look for less contact area or gap between fixed & moving contacts. For damages. Check close-open operations on lockal & remote and their indication (a)Check motor-mechanism for abnormal sound &over load. (b)Check the porcelain for dust and damages. (c) Check the contacts& terminal connection for looseness and damages.
Tight the nuts Charge oil& Greece to the necessary parts Tight foundation, change oil& V-belt. Adjust if necessary,
10
,,
,,
-doReplace contacts, switches, etc, and rectify loose connections Replace the coils if necessary. Replace if necessary.
11
,,
Control system.
1 2 3
Daily. Daily Quarte rly.
Adjust alignment of moving contact. Replace the supporting porcelain. Rectify the circuit problem if any. Dismantle the mechanism and repair. Replace wheels or bearings and put fresh Grease. Clean or replace. Tight maximum. Repair or replace damaged items. Adjust alignment if necessary.
Yearly .
Overhaul inspection.
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Yearly . 5 ,, Marshalling box.
(d)Check pipe connection of moving contact to the motormechanism for looseness and damages. (a)Check switches, contacts, push buttons ,etc, (b)Check wiring for loose connection. (c)Check for painting.
Tight nut & bolt lubricate hinges and bearings. Replace if necessary. Tight all connections. Paint if necessary.
1 2 3 4
Daily. Yearly . ,, ,,
CT & PTs, AND LIGHTNING ARRESTERS Porcelain. For dust and damages. Clean or replace. Measure IR values and Replace or repair as per Testing. conduct other testing. test result. Terminals. Painting Check for loose connections of both HV&LV terminals and fuses of PTs for blown out. Check metallic body for rust. Tight all connections and change fuses if necessary. Paint if required.
CONTROL DESK, PANAL BOARD, & MARSHALING BOXES 1, 2, 3, Daily. ,, Weekly Control Desk. Relay Panels. MMB Contacts. Check for fused Bulbs. Check Trip circuit indications. Check for overheating and Coil burns. BATTERY 1. 2. 3. Daily ,, Quarter ly Voltage & Specific gravity Electrolyte level Electrodes Complete reading of all cells. Switch off charger 1 hr before Level should be maintained To prevent Buckling of plates, Sulphation ,reduce internal resistance Cell taken out of service-replaced If level drops-distilled water added Battery discharged-10 to 15 hrs Replace. If unhealthy, rectify circuit problem. Clean and repair or replace.
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CHAPTER-8 PERMIT FOR A WORK

Permit to work on equipments is issued to the officials concerned on request after switching off and isolating the equipments from the line parts. 8.1 EHT Feeders The permit work on EHT feeders is issued after observing the following conditions. The feeders should be switched OFF. Isolated Earthed at both ends of the EHT feeder portion.
When the EHT Feeder Trips : When the EHT feeder breaker trips accept the alarm and note down the relay indications. Reset the relay. Test charge the relay. If the feeder trips again repeat the process and test charge after about 2 minutes. If the incoming EHT feeder trips at this end confirm whether the feeder tripped at the sending end. If the feeder stood ok then close the breaker at this end after resetting the relays. Procedure for Charging the EHT feeder after Permit to Work a) Remove all caution boards on return of the permit to work. b) Transmit message to the receiving end to remove the earth provided on the feeder. c) After getting confirmation from the substation to which the line is connected, open the earth switch of the isolator and lock the mechanism box. d) Close the line isolator and bus isolator manually and check for proper making of the contacts and close the circuit breaker and inform the matter to the other end.
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TRAVANCORE CEMENTS LIMITED
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White Portland Cement or White Ordinary Portland Cement (WOPC) is similar to ordinary, gray Portland cement in all respects except for its high degree of whiteness. Obtaining this color requires substantial modification to the method of manufacture, and because of this, it is somewhat expensive than the gray product. White Portland cement is used in combination with white aggregates to produce white concrete for prestige construction projects and decorative work. White concrete usually take the form of pre-cast cladding panels, since it is uneconomic to use white cement for structural purposes. White cement is also used in combination with inorganic pigments to produce brightly colored concretes and mortars. With white cement, bright reds, yellows and green can be readily produced. The whiteness of WOPC is measured as the powdered material having a reflectance value ("L value) in excess of 85%. 1.1 Cement Industry in India Cement industry in India has made significant contribution to the countrys economic development. This is obvious because most of the development activities of the country involve construction works using cement. South Indian Industry
Limited installed the first cement industry in Tamil Nadu in 1904 and then onwards number of factories manufacturing cement was started. In our country there are 51 companies and 99 plants having installed capacity of manufacturing 700 million KN of cement and with this installed capacity, the Indian cement industry is the largest in the world after China, Russia, Japan and USA. It accounts of about 4% of the worlds production. Some of the important highlights of Indian cement can be summarized as follows. 1. The energy consumpt ion is substant ially higher than that in efficient
plants abroad. 2. 3. The energy protection act ivit ies require be improving and updat ing. The new technologies i.e. high efficiency separator, roll press, vert ical
roller mill, precalcinators etc, have to be improved. 4. The requirements such as better packaging materials, bulk
containers and ready mix concrete technology deserve immediate attention.
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1.2 History of the Company The Travancore Cement Limited was incorporated in the year 1946. The year of commencement of Grey Cement in the year 1949. The licensed capacity of the plant was 50, 800 Ts of cement per annum. The master-mind behind setting up of this factory was that of late Sir. C.P.Ramaswami Iyer, the then Devan of Travancore, who had realized the vital role of cement in the industrial development of Kerala. The company was promoted by M\s. Essel Limited, Bombay and the Technology tie up made with M\s. F.L.Smith & Co. Denmark. During 1959, the company diversified into the production of White Portland Cement. The installed capacity for the production of White Cement is 30,000 Ts per annum. Till 1974, the company was manufacturing both White Cement and Grey Cement in the same plant, disturbing the production of two over certain period in a year. Since 1974, the company manufacturing white Cement alone, as the demand for white cement went up. During the last 54 years of its existence, TCL has diversified its activities to related areas. Besides Super Shelcem brand Cement paint, the company has added to its products ranges, Sheltex Acrylic Emulsion paint for interiors and exteriors and Shelprime Cement Primer. The Travancore Cements Limited is the only manufactured, perhaps in the whole world, producing White Cement from a raw material other than conventional limestone. The main raw material of TCL is lime shell, which is dredged out of Vembanad Lake, one of the back waters in Kerala. The company has successfully executed a diversification project for manufacture of Grey cement during the year 2000, with a capacity of 66,000 MT per annum.
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CHAPTER-2 PRODUCT PROFILE

The company is producing three types of products. They are,
White Portland Cement under the brand name VEMBANAD. Cement paints under the brand name SUPER SHELCEM in 42 different shades. Wall putty under the brand name VEMBANAD. 2.1 Vembanad White Portland Cement It is having first place in Indian white cement market, by its excellent quality. As compared to other brands it accounts for its superior whiteness and maintain its quality by using lime shells instead of lime stone. The white cement is the best suited for housing and construction of industries. Vembanad White Cement is quick drying, process high strength and superior aesthetic values. Also it is good for floor finish, plaster and ornamental works. The miscellaneous application of white cement are in swimming pools, where it replaces the use of glazed tiles with coloured shades under water, for moulding sculptures and statues, for painting furnitures. It is also used for ready mixed concrete, precast blocks and to fix marbles and glazed tiles. Special Features Lowest magnetic content and hence most durable white cement. Brilliant whiteness. High strength. Super soundness. Super finishing. Excellent properties. Ideal for manufacturing cement paints, mosaic tiles etc.
Applications Pointing brick works. Road marking. Cast stone finish. External rendering. Mosaic tiles.
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Terrazzo flooring. Primary coat for cement paints.
2.2 Super Shelcem Cement Paint In 1977 TCL started manufacturing cement paints under the brand name SHELCEM. It was rebranded as SUPER SHELCEM in 1986. Super Shelcem is a unique technology formulation with the most durable VEMBANAD white cement. It is an intimate mixture of Vembanad white cement, water proofing fungicides, oxide extends, non fading oxide pigments and hardening agents. Cement paint is water biased paint widely used for painting buildings. Unlike other cement paints, Super Shelcem doesnt require water curing after first and second coat. Only initial wetting of the surface is necessary. This makes it ideal for exteriors of multi storied buildings and sky scrapers. Also it is ideal for interiors since, tedious curing after removing furniture can be avoided which means saving of labour. Once a wall is painted with Super Shelcem, it looks and stays good for years unaffected by weather and fungal attack. Super Shelcem carries ISI marks and the approval of Bureau of Indian Standards, is E-1969. It is available in a wide range of colours of total 42 different shades in the market. Special Features Capacity: Any previous deep shade made on the surface can be effectivelyhidden with a single coat of Super Shelcem. The second coat completely covers thedark patches and stains on the wall. Coverage: Super Shelcem covers greater area than any other cement paint. 1Kgcovers 100 sq feet for a single coat or 65 sq feet for two coats. Adhesion: Super Shelcem can be applied on a wide variety of surface likecement plaster, concrete, brick work and plastered surface.
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Drying: Super Shelcem dries very quickly. While other cements paints requires16 to 24 hours waiting time for applying the second coat, Super Shelcem need only3 to 6 hours after the first coat. 2.3 Vembanad Wall Putty Vembanad Wall Putty was introduced in the year 2008. It is dry powder putty with Vembanad White Cement as the base. By the low content of MgO in Vembanad White Cement, the putty when applied on the cement plastered wall and ceiling will ensure durability, extra coverage and smooth finish. Vembanad Wall Putty can be applied on freshly plastered surface also. Like other products of TCL, Vembanad Wall Putty is also excellent in quality. Before applying wall putty, one or two coats of Vembanad White Cement is recommended to be applied on the newly plastered wall. Special Features Quality tested Vembanad White cement is used for making wall putty. Its production process goes through the strictest quality test. It has a unique formulation. It has more coverage than any other wall putty in the market.
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CHAPTER-3 DEPARTMENTAL DETAILS

3.1 Departments of TCL There are many departments in TCL. They are as follows: 1. 2. 3. 4. 5. 6. a. b. c. d. e. f. g. h. i. j. k. Personnel Department Purchase Department Production Department Finance Department Marketing Department Other Departments General Stores Maintenance Department Electrical Department Quality Control Department Transportation Department Packing House Workshop Degrading Department Cement Paint Department Time Office Department Security Department
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CHAPTER-4 PLANT STUDY

The raw materials used for the production of White Cement are Lime Shell, White Clay, White Sand and Gypsum. The production process consists of grinding the raw materials to a fine stage, blending them to a uniform composition and heating them to the point of incipient fusion when the cement compounds are formed. The Portland cement is the product obtained by cooling and grinding the clinker thus formed with gypsum to a tine powder. 4.1 Different Process under Main Stages a) Dredging
b) Unloading c) Clay Washing
d) Shell-Sand grinding (Ball Mill) e) f) Slurry making (Raw Mill) Slurry selection
g) Clinker Making (Kiln) h) i) Clinker grinding (Cement Mills) Packing and Despatching
a) Dredging The main raw material for the production of the Vembanad white cement is lime shell, which is an underwater deposit in the Vembanad Lake. It is dredged and brought to the company by means of power bargers. The company has two dredgers, one hydraulic dredger and one mechanical dredger. The capacities of two dredgers are about 30 Tonnes per hour. The dredger can cut the lime shell around 40 feet maximum, in depth. The dredger works on two powerful engines, a dredger pamper engine and an auxiliary engine.
Fig. 4.1 Dredging
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Dredger Operation The Dredger is placed anywhere in the lake using a spud which is then at lowered position, while the other spud is at the raised position. The cutter is about 10 meters in length. It can cut the shell to a maximum of 30 ft from the water level. For cutting operation one spud is lowered and the other spud is kept in a raised position so that the dredger can swing with the lowered spud as pivot for 1 swinging in the clockwise direction. The star board swing winch is tightened and port swing winch is loosened. For swinging in the anticlockwise direction, the port swing winch is tightened and starboard swing winch is loosened. The cutting action goes deep and deep by due to clockwise and anticlockwise swings, every time lowering the cutter frame in steps by operating the ladder winch. The cutter motor rotates the cutter. The shell thus obtained is sucked and discharged by a centrifugal type dredge pump to the screening plant, affecting the primary washing. After primary washing, the shell is transferred to the barge. b) Unloading Station The shell brought by Barger from lake is unloaded here. Shell in barger is diluted with about 60 percent of water by means of diluting pump for easiness of sucking. A 30HP, 440V, 37A diluting pump is used. A 75 HP, 400 V, 65A sucking pump draws water along with the shell to receiving tank near the rotary grill of screening plant. The shell is then passed through the rotary grill and waste materials are washed out during its rotation. 30HP, 440V, 37A wasing grill motor is being used in the company. Cleaned shell is either passed through the belt conveyors through hoppers or stored out. There are two rubber conveyors (Conveyor 1-short and straight, conveyor 2-long and inclined) for conveying the shell to the ball. Two conveyor belt motors of 15HP and 5HP respectively are used.
Fig. 4.2 Shell Unloading
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c) Wash Mill Before actually used for process, the clay in the solid form is made into slurry form by mixing with water. This is done in a clay wash mill. Clay wash mill is a well like pit of RCC construction. Clay is put to the mill and about 65 % water is also added during the grinding. Because of hammering action of the weights provided in wash mill, clay is made to a slurry form known as clay slurry. The clay slurry is pumped to the storage tank known as silo. From there it is taken for process when required. d) Shell-Sand Grinding (Ball Mill) Slurry preparation is the fourth stage in the production process of white cement. Slurry is a mixture of shell sand and clay with around 40% water. For slurry preparation two grinding mills are used. Roughing mill known as Ball mill. Finishing mill known as Raw mill.
Ball mill is a cylindrical shell of welded metal plates. The shell along with the required amount of white sand and water is fed to the ball mill by a rotating feed table. When the mill rotates the materials are crushed down to small particles while it passes through the balls. The materials coming out of the ball mill is diverted to a hammer screen by means of a slurry elevator. Fine material comes out of the hammer screen and is fed to the raw mill. The course materials return to the ball mill for further grinding. 200HP slip ring induction motor is used in the Ball mill. e) Slurry Making The raw mill is a hollow cylindrical shell, inside of which is lined with flint blocks to avoid the contamination of iron in the slurry. The grinding media used is flint pebbles. The output from the ball mill and the clay from the silo are finely ground in the raw mill and the output of raw mill is transferred to the slurry pit. 550HP squirrel cage induction motor is used in the raw mill. f) Slurry Selection Slurry discharged from the raw mill is stored in silos by means of pumps. The chemical composition of the slurry will be adjusted at this stage. There are three silos for storing the slurry. The slurry from the silos is first collected in the correction pit and is transferred to the slurry basin. The slurry is given air agitation always.
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The slurry basin is an ordinary well type pit provided with mechanical and air agitation facility. From this the slurry is taken to the rotary Kiln through a scoop feeding mechanism. g) Clinker Making (Rotary Kiln) Kiln is a cylindrical steel shell lined with refractory bricks, mounted at an angle of 3 to the base on roller supports, so that it can be rotated. The kiln is having a length of about 285 feet with diameter of 9 feet at the chain zone and 8 feet for the remaining portions and is rotated at about 1 rpm by a DC motor. Slurry is fed to the kiln at the upper end by a scoop feeder. Since the feeder is synchronized with the kiln, it will deliver slurry proportional to the speed of the kiln. In the kiln there are three zones called Drying Zone, Calcining Zone and Burning Zone. The fuel used in the kiln is LSHS or Furnace oil. The fuel is burned in the kiln using a pressure jet burner. The oil is preheated to 110 0 C to 120 C by an electric heater for better atomization. Blower supplies primary air along with fuel. The secondary air is sucked through the coolers provided around the kiln by an ID fan, which drives the flue gas through the chimney. The air inlet to the Kiln is controlled by I the damper provided at the chimney side. The O2 percentage in the flue gas is maintained around 2% to get the maximum fuel efficiency. Kiln n
Fig. 4.3 Rotary Kiln To improve the heat transfer in the drying zone a system of chains are hung inside the shell, which absorbs the heat from the flue gas and transfer to the material to be dried. In the drying zone 99% of the water content in the slurry will be removed. In the calcining zone removal of CO2 takes place. This is represented by the formula given below:
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CaCO3
CaO+CO2
After passing through the calcining zone, the materials enter the burning zone. The clinker is formed in the burning zone by fusing the compounds at about 1400C. At this temperature, the coloured ferric oxide of iron is bleached to light green colour. Ferrous oxide and thus the clinker is of light green colour is formed. The burned clinker is then quenched by spraying water. The steam produced by this water creates a reducing atmosphere in the kiln which speeds the conversion of FeO2 to Fe2O and also it prevents the reverse reaction. The clinker then flows through nine coolers connected on kiln's periphery. h) Clinker Grinding (Cement Mills) The clinker as obtained from rotary kiln is carried by conveyors into the cement mill. There are three cement mills A, B, C with clinker grinding capacity of 60 Tonnes, 50 Tonnes, and 50 Tonnes respectively. The mills B and C are identical in nature. During grinding, small quantity of about3% to4% Gypsum is added. The Gypsum controls the initial setting time of cement. If Gypsum is not added, the cement would set as water is added. The Gypsum acts as retarder and it delays the setting action of cement. It thus permits cement to be mixed with aggregates and to be placed in position. The cement coming out of the mill is conveyed to the classifier by means of bucket elevator. In the separator, coarse particles are separated and they flow to the mill while fine particles flow to the Flaxo pump, which is operated by compressed air. Using Flaxo pump cement is transferred to the cement Silo located at the packing house.
Fig. 4.4 Clinker i) Packing and Despatch The white cement stored in silos is packed in bags in the packinghouse. Compressed air is used for the free flow of cement from the silo and the hopper located
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above the packing machine. Cement is conveyed from the silo to the packing machine hopper through screw conveyors and bucket elevator. The pressure created by the compressed air forces the cement to escape through the opening of the spout where the bag is fitted for packing. When the bag is filled with 50kgs, material discharges from the spout automatically. The spillage during package will return to the elevator through a screw conveyor. The filled bags which fall down from the spout to the wire net conveyor will be transferred to the truck through a fixed point belt conveyor and a movable belt conveyor. A dust blower and a cyclone separator are provided at the packing house for the removal of dust. The white cement is packed in gunny bags.
Fig. 4.5 Cement Bags
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4.2 FLOW OF PROCESS SHELL SILO SAND SILO DREDGING ROTARY FILTER BARGE SHELL CLAY
SAND
BALL MILL
RAW MILL
SLURRY PIT
SLURRY SILO
CORRECTION PIT SLURRY BASIN
SLURRY FEEDER ROTORY KILN
HAMMER CRUSHER CLINKER SILO CEMENT SILO FLUXO PUMP DESPATCH BAGGING
GYPSUM
CEMENT MILL
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CLAY PIT
CLAY SILO
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Fig. 4.6 Flow Diagram of Cement Manufacturing
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CHAPTER-5 ELECTRICAL SECTION

5.1 Electrical System The 11kVsupply received from KSEB is stepped down to 433 volts in the substation located at the factory premises. The company has installed two distribution transformers having capacity 11kV/433V, 1600kVA each. At present the entire load of company is distributed through a single transformer. In addition a diesel generator having capacity of 1000kVA is installed in the company. The DG set is provided to facilitate supply to some major loads from the LT main panel of the transformer, distribution of load for different units through various load centers and sub-switch board at various locations. 5.2 Power Factor Correction The company is having three numbers of 550HP auto synchronous motors. The system power factor can be maintained around unity by adjusting the field excitation of these motors. For the purpose of power factor correction, leading power factor is maintained in the synchronous motor by adjusting the field excitation to compensate for the lagging power factor caused due to the induction motor used in the plant. The leading power factor at the synchronous motor and lagging power factor at the induction motor leads to increased distribution due to increased line current. The present average system power factor of the company is about 0.94.The average recorded maximum demand of the company for the year 2011-2012 was 1153kVA. The advantages of power factor improvement by capacitor addition are, a. Reactive component of the network is reduced and also the total current in the I2R power losses are reduced in the system because of the reduction in the current. Voltage level at the load end is increased. kVA load on the source generators, transformers and lines upto the capacitors
system from the source end. b. c. d.
reduces giving capacity relief. A high power factor can help in utilizing the full capacity of the electrical system.
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5.3 Transformer Loading and Losses Two numbers of 11kV /433V, 1600kVA transformers are installed in the company to meet the electrical power requirement of the entire company. Normally the entire plant load is fed from any one of the transformers and the other is kept as standby. Switching off transformer for long periods will reduce the insulation resistance of the oil and the switching off period should be kept minimum by operated both transformers alternatively. From the transformer test data it is seen that the maximum efficiency of a1600kVA transformer is about 99.302% at a loading of 35%.For the present average load of 861kVA i.e.; at a percentage load of 53.8%, the efficiency is found to be 99.302%.
Fig. 5.1 Transformer with OLTC arrangement Table 5.1 Rating of Transformer kVA Rating Volts At No Load (HV) Volts At No Load (LV) Amperes (HV) Amperes (LV) Phases (HV & LV) Type Of Cooling Frequency Impedance Voltage At 75C Connection Symbol Make 1600 11000 V 433 V 83.98 A 2133.40 A 3 ONAN 50 6.93% Dyn11 KEL
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5.3.1 Parallel Operation of Transformers The design of power control center (PCC) and motor control center (MCC) of any new plant should have the provision of operating two or more transformers in parallel. Additional switch gears and bus couplers are provided at the design stage. Whenever two transformers are operating in parallel, both should be technically identical in all aspects and more importantly should have the same impedance level. This will minimize the circulating current between the transformers. Whenever the load is fluctuating in nature, it is preferable to have more than one transformer running in parallel, so that the load can be optimized by sharing the load between the transformers. The transformers can be operated close to the maximum efficiency range by this operation. At present in TCL, entire plant load is fed from any one of the transformers and the other is kept as standby. In this condition the total loss of the transformer is found to be about 6.05kW for an average load of 861kVA.By distributing the entire load through two transformers, the loading of each transformer becomes 430kVA and the corresponding loss will be 2.86kW and total loss will be 5.72kW. 5.3.2 Tapchanger A tap changer is a connection point selection mechanism along a
power transformer winding that allows a variable number of turns to be selected in discrete steps. A transformer with a variable turns ratio is produced, enabling stepped voltage regulation of the output. The tap selection may be made via an automatic or manual tap changer mechanism. If only one tap changer is required, manually operated tap points are usually made on the high voltage (primary) or lower current winding of the transformer, to minimize the current handling requirements of the contacts. However, a transformer may include a tap changer on each winding if there are advantages to do so. For example, in power distribution networks, a large step-down transformer may have an off-load tap changer on the primary winding and an on-load automatic tap changer on the secondary winding or windings. The high voltage tap is set to match long term system profile on the high voltage network (typically supply voltage averages) and is rarely changed. The low voltage tap may be requested to change positions multiple times each day, without
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interrupting the power delivery, to follow loading conditions on the low-voltage (secondary winding) network. There are 14 tap changers in TCL. There are mainly four types of tap changing. They are mechanical, automatic, manual and remote. Table 4.2 Rating of On load Gears Rated Through Current Rated Step Voltage Rated Insulation Level No: Of Service Tapping Positions Control Voltage Motor Voltage 5.4 Alternator An alternator is an electromechanical device that converts mechanical energy to electrical energy in the form of alternating current. Most alternators use a rotating magnetic field with a stationary armature but occasionally, a rotating armature is used with a stationary magnetic field; or a linear alternator is used. In principle, any AC electrical generator can be called an alternator, but usually the term refers to small rotating machines driven by automotive and other internal combustion engines. An alternator that uses a permanent magnet for its magnetic field is called a magneto. Alternators in power stations driven by steam turbines are called turbo-alternators. Alternators generate electricity using the same principle as DC generators, namely, when the magnetic field around a conductor changes, a current is induced in the conductor. Typically, a rotating magnet, called the rotor turns within a stationary set of conductors wound in coils on an iron core, called the stator. The field cuts across the conductors, generating an induced EMF (electromotive force), as the mechanical input causes the rotor to turn. A brushless alternator is composed of two alternators built end-to-end on one shaft. Smaller brushless alternators may look like one unit but the two parts are readily identifiable on the large versions. The larger of the two sections is the main alternator and the smaller one is the exciter. The exciter has stationary field coils and a rotating 60.6 A 275 V 75 kVp 11 110 V, 50Hz 415 V, 50Hz
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armature (power coils). The main alternator uses the opposite configuration with a rotating field and stationary armature. A bridge rectifier, called the rotating rectifier assembly, is mounted on a plate attached to the rotor. Neither brushes nor slip rings are used, which reduces the number of wearing parts. The main alternator has a rotating field as described above and a stationary armature (power generation windings). Varying the amount of current through the stationary exciter field coils varies the 3-phase output from the exciter. This output is rectified by a rotating rectifier assembly, mounted on the rotor, and the resultant DC supplies the rotating field of the main alternator and hence alternator output. The result of all this is that a small DC exciter current indirectly controls the output of the main alternator.
Fig. 5.2 Alternator 5.5 Exciter An electric generator or electric motor that uses field coils rather than permanent magnets requires a current to be present in the field coils for the device to be able to work. If the field coils are not powered, the rotor in a generator can spin without producing any usable electrical energy, while the rotor of a motor may not spin at all. Smaller generators are sometimes self-excited, which means the field coils are powered by the current produced by the generator itself. The field coils are connected in series or parallel with the armature winding. When the generator first starts to turn, the small amount of remanent magnetism present in the iron core provides a magnetic field to get it started, generating a small current in the armature. This flows through the field coils, creating a larger magnetic field which generates a larger armature current. This "bootstrap" process continues until the magnetic field in the core levels off due to saturation and the generator reaches a steady state power output.
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Very large power station generators often utilize a separate smaller generator to excite the field coils of the larger. In the event of a severe widespread power outage where islanding of power stations has occurred, the stations may need to perform a black start to excite the fields of their largest generators, in order to restore customer power service. 5.6 Diesel Generator A diesel generator is the combination of a diesel engine with an electrical generator (often an alternator) to generate electrical energy. Diesel generating sets are used in places without connection to the power grid, as emergency power-supply if the grid fails, as well as for more complex applications such as peak-lopping, grid support and export to the power grid. Sizing of diesel generators is critical to avoid low-load or a shortage of power and is complicated by modern electronics, specifically non-linear loads. The packaged combination of a diesel engine, a generator and various ancillary devices (such as base, canopy, sound attenuation, control systems, circuit breakers, jacket water heaters and starting system) is referred to as a "generating set" or a "genset" for short.
Fig. 5.3 DG Set A diesel/generator set having capacity of 1000kVA is installed in the company of self excitation during supply interruption and power cuts. A brush less AC generator is used for this purpose. Table 5.3 Rating of Diesel Generator Make KIRLOSKAR ELECTRIC CO LTD
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kVA Rating Speed Volts Amps Excitation Voltage Excitation Current Frequency Phases
1000 1500 rpm 11 kV 52.5 A 86 V 2.65 A 50 Hz 3
Grounding is provided through Neutral Grounding Resistor. The purpose of this method is to limit the current for greater safety. There are 3 types1.Earthing through reactance. 2.Earthing through ARC - Suppression coil. 3.Earthing through resistor. These parameters are needed to specify the earthing resistor: U: Rated voltage 11/3 kV I: Rated current 52.5 A T: Rated time 10 Sec R: Resistance value - 120.96 ohm A diesel generator set of capacity 160 kVA is used for lighting and other auxiliary supplies.
Fig. 5.4 160 kVA DG Set
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Table 5.4 Rating of 160kVA DG Set kVA Rating Rpm Volts Amps Excitation Voltage Excitation Current Phase Frequency 5.7 Circuit Breakers a) b) c) Air Blast Circuit Breakers (ABC) Vaccum Circuit Breakers (VCB) Oil Circuit Breakers (OCB) 160 1500 415 V 222.5 A 240 V 6.5 A 3 50 Hz
Most of the circuit breakers used in TCL are ABC and VCB. 5.7.1 Air Blast Circuit Breakers
Fig. 5.5 Air Blast Circuit Breaker
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It is used in several mills such as A, B, C etc for protecting circuits from faults. These types of breakers employ air blast as the quenchin g medium. The contacts are opened by air blast produced by the opening of blast valve. The air blast cools the arc and sweeps away the arcing products to the atmosphere. This rapidly increases the dielectric strength of the medium between contacts and prevents from re-establishing the arc. Consequently the arc is extinguished and the flow of current is interrupted. 5.7.2 Vacuum Circuit Breakers VCB is used in alternator circuits in TCL. In a vacuum circuit breaker, two electrical contacts are enclosed in a vacuum. One of the contacts is fixed and one is movable. When the circuit breaker detects a dangerous situation, the movable contact pulls away from the fixed contact, interrupting the current. Because the contacts are in a vacuum, arcing between the contacts is suppressed, ensuring that the circuit remains open. As long as the circuit is open, it will not be energized. Table 5.5 Rating of VCB Voltage Circuit Current Busbar Current Frequency 12 kV 630 A 800 A 50 Hz
Fig. 5.6 Vacuum Circuit Breaker
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5.7.3 Oil Circuit Breakers A high-voltage AC electrical switch whose main contacts are located in a space filled with mineral (transformer) oil. Upon interruption of the electric circuit, an electric arc forms between the contacts of the circuit breaker. Because of the high temperature of the arc the oil is evaporated rapidly and oil vapours are partially decomposed, liberating ethylene, methane, and other gases. A gas bubble is formed in the arcing zone; the pressure in the bubble may be as high as several dozen mega Newtons per sq m. The arc is then extinguished, both because of its elongation upon parting of contacts and because of intensive cooling by the gases and oil vapour. In an oil circuit breaker with simple interruption under oil, the duration of arcing is 0.02-0.05 sec. To extinguish the arc more efficiently, arc-quenching chambers are used. In a longitudinal blast chamber the vapours and gases evolved travel upward along the arc, thus cooling it. In addition, the arc is in contact with the cold oil that fills the annular slots of the chamber, which also accelerates cooling of the arc. In a transverse blast chamber a drastic pressure increase within the gas bubble causes a stream of oil and gases to flow across the arc, thus accelerating the cooling process.
Fig. 5.7 Oil Circuit Breaker 5.8 Synchronous Motor This motor is used in B mill, C mill, and raw mill. 550 HP motors are used in the first 3 mills. A synchronous electric motor is an AC motor in which, at steady state, the rotation of the shaft is synchronized with the frequency of the supply current; the rotation period is exactly equal to an integral number of AC cycles. Synchronous motors contain electromagnets on the stator of the motor that create a magnetic field which rotates in time with the oscillations of the line current. The rotor turns in step with this
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field, at the same rate. The motor does not rely on "slip" under usual operating conditions, and as a result produces torque at synchronous speed. Synchronous motors can be contrasted with induction motors, which must slip in order to produce the rotor magnetic field and to provide torque. The speed of the synchronous motor is determined by the number of magnetic poles and the line frequency.
Fig. 5.8 Synchronous Motor Table 5.5 Rating of Synchronous Motor Phase B.H.P Power factor Speed Frequency Field Amps Stator Amps Volt Phase Volt Make 3 550 0.9 760 rpm 50Hz 635 A 300 A 440 V 1340 V Crompton Parkinson
Synchronous motors are available in sub-fractional self-excited sizes to highhorsepower industrial sizes. In the fractional horsepower range, most synchronous motors are used where precise constant speed is required. In high-horsepower industrial sizes, the synchronous motor provides two important functions. First, it is a highly efficient means of converting AC energy to work. Second, it can operate at leading or unity power
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factor and thereby provide power-factor correction. These machines are commonly used in analog electric clocks, timers and other devices where correct time is required. The principal components of a synchronous motor are the stator and the rotor. The stator of synchronous motor and stator of induction motor are similar in construction. The stator frame contains wrapper plate. Circumferential ribs and keybars are attached to the wrapper plate. To carry the weight of the machine, frame mounts and footings are required. When the field winding is excited by DC excitation, brushes and slip rings are required to connect to the excitation supply. The field winding can also be excited by a brushless exciter. Cylindrical, round rotors, (also known as non salient pole rotor) are used for up to six poles. In some machines or when a large number of poles are needed, a salient pole rotor is used. The construction of synchronous motor is similar to that of a synchronous alternator. 5.8 Slip Ring Induction Motor These motors are used in A mill and Ball mill 250 HP and 200 HP are used irrespectively for the motors. A wound-rotor motor is a type of induction motor where the rotor windings are connected through slip rings to external resistances. Adjusting the resistance allows control of the speed/torque characteristic of the motor. Wound-rotor motors can be started with low inrush current, by inserting high resistance into the rotor circuit; as the motor accelerates, the resistance can be decreased. Compared to a
squirrel-cage rotor, the rotor of the slip ring motor has more winding turns; the induced voltage is then higher, and the current lower, than for a squirrel-cage rotor. During the start-up a typical rotor has 3 poles connected to the slip ring. Each pole is wired in series with a variable power resistor. When the motor reaches full speed the rotor poles are switched to short circuit. During start-up the resistors reduce the field strength in the stator. As a result the inrush current is reduced. Another important advantage over squirrel-cage motors is higher start-up torque. A wound-rotor motor can be used in several forms of adjustable-speed drive. Certain types of variable-speed drives recover slip-frequency power from the rotor circuit and feed it back to the supply, allowing wide speed range with high energy efficiency. Doubly fed electric machines use the slip rings to supply external power to the
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rotor circuit, allowing wide-range speed control. Today speed control by use of slip ring motor is mostly superseded by induction motors with variable-frequency drives. A slip ring is an electromechanical device that allows the transmission of power and electrical signals from a stationary to a rotating structure. A slip ring can be used in any electromechanical system that requires unrestrained, intermittent or continuous rotation while transmitting power and / or data. It can improve mechanical performance, simplify system operation and eliminate damage-prone wires dangling from movable joints. 5.9 DC Shunt Motor DC shunt motors are used in kiln. 45KW and 1.1 KW motors are used. 45 kW motor used for kiln drive and 1.1 kW motor used for slurry feeder. The shunt motor is different from the series motor in that the field winding is connected in parallel with the armature instead of in series. Since the field winding is placed in parallel with the armature, it is called a shunt winding and the motor is called a shunt motor. The shunt winding is made of small-gauge wire with many turns on the coil. Since the wire is so small, the coil can have thousands of turns and still fit in the slots. The small-gauge wire cannot handle as much current as the heavy-gauge wire in the series field, but since this coil has many more turns of wire, it can still produce a very strong magnetic field. A shunt motor has slightly different operating characteristics than a series motor. Since the shunt field coil is made of fine wire, it cannot produce the large current for starting like the series field. This means that the shunt motor has very low starting torque, which requires that the shaft load be rather small. When voltage is applied to the motor, the high resistance of the shunt coil keeps the overall current flow low. The armature for the shunt motor is similar to the series motor and it will draw current to produce a magnetic field strong enough to cause the armature shaft and load to start turning. Like the series motor, when the armature begins to turn, it will produce back EMF. The back EMF will cause the current in the armature to begin to diminish to a very small level. The amount of current the armature will draw is directly related to the size of the load when the motor reaches full speed. Since the load is generally small, the armature current will be small. When the motor reaches full rpm, its speed will remain fairly constant . The DC shunt motor used in kiln for drive the kiln in on
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load and constant speed. It helps to control the speed of the kiln. It has considerable starting torque. Thyristor control method is used for synchronizing the kiln motor and slurry feeder motor. 5.10 Tacho Generator Tacho generators are AC or DC generators that output a voltage in proportion to the rotational speed of a shaft on a rotating electrical machine (electric motor), and thus are used to measure the speed and direction of rotation. Most commonly found in
fractional horsepower (FHP) applications they are often referred to as 'sensors', most electric motor manufacturers offer a tacho generator on DC commutated
(brushed/permanent magnet) motor types. 5.11 Automatic Power Factor Corrector An automatic power factor correction unit consists of a number of capacitors that are switched by means of contactors. These contactors are controlled by a regulator that measures power factor in an electrical network. Depending on the load and power factor of the network, the power factor controller will switch the necessary blocks of capacitors in steps to make sure the power factor stays above a selected value. 100 KVAR APFC is used in TCL.
Fig. 5.9 100KVAR APFC Panel 5.12 TOD Meters Nowadays power cuts are happening in the peak usage timing such as from 6:00 PM to 10:00 PM. This is happening because the power requirement in these times is very high as compare to other off-peak timings. Unnecessary usage must be avoided to eliminate this problem. In many countries electricity providers are implemented TOD
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based energy meter to reduce the usage of electricity by increasing rates in Peak hours and reducing rates is Off-peak hours .Time of Day metering (TOD), also known as Time of Usage (TOU) or Seasonal Time of Day (STOD), metering involves dividing the day, month and year into tariff slots and with higher rates at peak load periods and low tariff rates at off-peak load periods. While this can be used to automatically control usage on the part of the customer (resulting in automatic load control), it is often simply the customers responsibility to control his own usage, or pay accordingly (voluntary load control). This also allows the utilities to plan their transmission infrastructure appropriately. 5.13 EOT (Electrically Operated Over Head Travel) Crane Electrical Overhead Travelling (EOT) cranes are simplest type of cranes used in industries for maintenance purpose (mostly). The capacity can go up to 50tons. In TCL it is used to transfer the lime stones, white sand, gypsum, waste etc.
Fig. 5.10 EOT Crane
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COCHIN SHIPYARD LIMITED
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Cochin Shipyard was incorporated in the year 1972 as a fully owned Government of India company. In the last three decades the company has emerged as a forerunner in the Indian Shipbuilding & Ship repair industry. This yard can build and repair the largest vessels in India. It can build ships upto 1,10,000 DWT and repair ships upto 1,25,000 DWT. The yard has delivered two of Indias largest double hull Aframax tankers each of 95,000 DWT. CSL has secured shipbuilding orders from internationally renowned companies from Europe & Middle East and is nominated to build the countrys first indigenous Air Defences Ship. The major sections are ship repair and ship building. Ship building Facilities includes ship building docks, Steel Stock Yard, Hull Shop, Assembly Shop and Quays. Hull shop is provided with EOT cranes (50 T) for along the bay movements and gantry crane (20 T) and trailers for across the bay transfer of materials. Assembly shop has telescopic sliding roof with gantry cranes of 300 T and 150 T which spans over it and building dock. Hull blocks up to 450 T can be jumboized here and erected in the building dock using the gantry crane. In addition, two 20 T capacity EOT cranes are there in the shop. CSL has totally three Quays having almost a length of 1 KM. Ship repair Facilities includes ship repairing docks, engine and machine shop etc. The training has been done at U&M (Utility & Maintenance) department, ship repair department and ship building department. I had done my training in 5 sections. They are MRS, EM-2, EM-3, electronics and electric shop. MRS receives electric power from KSEB. It distributes power to various location of shipyard. There are 21 unmanned substations. The installed sub-station is of 66kV. There are two incoming feeders of 66kV each. The incoming 66kV is step down to 11kV and distributed to local substations. The details about machineries and work in different sections have been explained further in the report.
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CHAPTER-2 PROFILE OF COMPANY

Shipyard commenced ship repair operations in the year 1982 and has undertaken repairs of all types of ships including upgradation of ships of oil exploration industry as well as periodical layup repairs and life extension of ships of Navy, UTL, Coast Guard, Fisheries and Port Trust besides merchant ships of SCI & ONGC. The yard has, over the years, developed adequate capabilities to handle complex and sophisticated repair jobs. Of the services provided by the shipyard are building platform supply vessels and doublehulled oil tankers". Presently it is building the first indigenous aircraft carrier for the Indian Navy. 2.1 History 1. Cochin Shipyard was conceived in the year 1969 when a team surveyed various locations in India before selecting Cochin for the launch of the first Greenfield Ship building Yard in the country. 2. The yard facilities in the first phase were completed by 1982. The yard was designed and constructed under technical collaboration with M/s Mitsubishi Heavy Industries (M.H.I), Japan. The company was legally incorporated in the year 1972. 3. The yard commenced the shipbuilding operations in 1978, shiprepair in 1981, Marine Engineering Training in 1993 and Offshore Upgradation in 1999. 4. Cochin Shipyards recent success in securing export orders have been achieved through consistent improvement in productivity and also aggressive marketing undertaken in the last few years . 5. The yard could reduce the average time of construction of large ships in the last decade through augmentation of facilities, upgradation of ship design department with installation of Tribon and CAD/CAM software and adoption of Integrated Hull Outfitting and Painting system (IHOP) system of construction. 6. The shipyard commenced ship repair operations in the year 1982 and has undertaken repairs of all types of vessels including upgradation of ships of oil exploration industry as well as periodical layup repairs and life extension of ships of Navy, UTL, Coast Guard, Fisheries and Port Trust besides merchant fleet. The yard has, over the years, developed adequate capabilities to handle complex and sophisticated repair jobs.
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7. CSL has established tie-ups with select specialist firms from near-east, far-east, Southeast, Europe and USA for technology transfer & material packages for shipbuilding, ship repair, platforms, rigs and upgradation of yard facilities 2.2 Credentials Shipbuilding Only Shipyard in India which can build upto 1,10,000 DWT Has built various types of vessels including Tankers, Bulk Carriers, Port Crafts, Passenger Vessels etc Reputed international clientele Currently building Platform Supply Vessels for exports and Aircraft Carrier for the Indian Navy. Shiprepair Only Shipyard in India which can repair ships upto 1,25,000 DWT The only yard which can repair an Air Defence Ship. Can undertake complex and sophisticated repairs to Oil Rigs; & ships of Navy, Coast Guard & Merchant Navy Secured three major projects from ONGC for repairs of Mobile Offshore Drilling Unit (MODU) Sagar Vijay, Mobile Offshore Drilling Unit (MODU) Sagar Bhushan and Jack Up Rig (JUR) Sagar Kiran in 2005-06. Offshore Has undertaken a variety of complex and sophisticated offshore Upgradation contracts
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CHAPTER-3 UTILITY AND MAINTENANCE DEPARTMENT

3.1. Main Receiving Station (MRS) 3.1.1 66 kV EHT Yard At CSL Main Receving Station receives electric power from KSEB. It distributes power to various location of shipyard. For these purpose 21 unmanned substations has set up. One is from Marine Drive and the other one from Vytilla. The installed sub-station is of 66kV. There are two incoming feeders of 66kV each. Always only one feeder is energized according to KSEBs instruction. Both these supply are taken from KSEB through XLPE (Cross Linked Polyethylene) Al cable of size 3x1x100sq.mm. Also there exist spare cables. All the components except lightning arrester and transformer are designed for 110kV for the further enhancement of capacity of sub-station. The incoming 66kV is step down to 11kV and distributed to local substations. The secondary is taken to the new 11 kV switch board in the ground floor of MRS building. An operating room is also provided on the first floor of MRS building. The circuit breakers, isolators, capacitor banks etc. can be controlled either by
REMOTE/LOCAL/PLC. Operating room incomer panel 1 and 2 consists of metering instruments like ammeter, voltmeter, wattmeter, power factor meter, frequency meter, electro trivector meter and protective relays. There are two automatic power factor controllers and a KVA meter. 3.1.2 Substation In General A substation is a part of an electrical generation, transmission and distribution systems. Substations transform voltage from high to low or the reverse or perform any of several other important functions. Substations may be owned and operated by an
electrical utility or may be owned by large industrial or commercial customer. Generally substations are unattended, relying on SCADA for remote supervision and control. Elements Of A Substation (a) Lightning Arrester A lightning arrester is a device used on electrical power systems
and telecommunications systems to protect the insulation and conductors of the system
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from the damaging effects of lightning. The typical lightning arrester has a high-voltage terminal and a ground terminal. When a lightning surge (or switching surge, which is very similar) travels along the power line to the arrester, the current from the surge is diverted through the arrestor, in most cases to earth. Surge arresters are generally connected between phase conductor and ground. In a Substation surge arrester is located at the starting of the substation as seen from incoming transmission lines and is the first equipment of the substation. Surge arresters are also provided near the transformer terminals phase to ground. Two types of surge arresters are available 1) Gapped Arresters 2) Gapless Zinc Oxide arresters. Specification: ZnO, 60kV, 10kA
Fig. 3.1 Lightning Arrester (b) Isolator Switches In Sub-Station, it is often desired to disconnect a part of the system for general maintenance and repairs. This is accomplished by an isolating switch or isolator. An isolator is essentially a kniff Switch and is design to often open a circuit under no load, in other words, isolator Switches are operate only when the line is which they are connected carry no load. For example, consider that the isolator are connected on both side of a cut breaker, if the isolators are to be opened, the C.B. must be opened first. Voltage Current Phase 123 kV 1600A 3 Table 3.1 Rating of Isolator
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It is used to separate KSEB section from EHT section of shipyard. The isolator used is of off-load type. It can be operated either by 3 ac motor of 1HP or by mechanically rotating a lever. An Earth Switch (ES) is also provided for protection purpose during maintenance. The ES is mechanically interlocked with the isolator.
Fig. 3.2 Isolator (c) Instrument Transformer The lines in Sub-Station operate at high voltage and carry current of thousands of amperes. The measuring instrument and protective devices are designed for low voltage (generally 110V) and current (about 5A). Therefore, they will not work satisfactory if mounted directly on the power lines. This difficulty is overcome by installing Instrument transformer, on the power lines. There are two types o f instrument transformer. Current Transformer A current transformer is essentially a step-down transformer which steps-down the current in a known ratio, the primary of this transformer consist of one or more turn of thick wire connected in series with the line, the secondary consist of thick wire connected in series with line having large number of turn of fine wire and provides for measuring instrument, and relay a current which is a constant fraction of the current in the line. Current transformers are basically used to take the readings of the currents entering the substation. This transformer steps down the current from 800 amps to1amp.This is done because we have no instrument for measuring of such a large current.
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Table 3.2 Rating of Current Transformer Nominal system voltage Highest system voltage 1min.AC withstand voltage Lightning impulse withstand voltage Insulation class 110kV 123kV 230kV 550kVp A
Fig.3.3. Current Transformer Potential Transformer It is essentially a step down transformer and step down the voltage in known ratio. The primary of these transformer consist of a large number of turn of fine wire connected across the line. The secondary way consist of a few turns and provides for measuring instruments and relay a voltage which is known fraction of the line voltage.
Fig. 3.4 Potential Transformer Table 3.3 Rating of Potential Transformer Voltage Highest system voltage 1 min. AC withstand voltage 110kV/66kV 123kV 230kV
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Lightning impulse withstand voltage Insulation class (d) Circuit Breaker
550kVp A
Circuit Breaker is used for Switching during normal and abnormal operating conditions. It is used to interrupt the short circuit currents. It is used to interrupt short circuit currents. Circuit Breaker operations include closing, opening and auto reclosing. Circuit Breaker is located near every switching point and also located at the both ends of every protection zone. Depending on the voltage level circuit breakers are used. For Extra High Tension, SF6 circuit breakers are used. For High Tension, SF6 and Vaccum Circuit Breakers are used. For Low Tension, Air Circuit Breakers and Oil Circuit Breakers are used. Table 3.4 Rating of SF6 Circuit Breaker Rated voltage Frequency Ambient temparature range Rated normal current Rated short circuit breaking current Rated short circuit making current Rated line charging breaking current 145kV 50Hz -300C to 500C 3150A 40kA 100kAp 50A
SF6 circuit breaker is used. It can be operated on-load or off-load. Interlocking is provided between circuit breaker and isolator. To close the circuit breaker the isolator should be kept closed. 110V dc series motor is used for driving circuit breaker.
Fig. 3.5 SF6 Circuit Breaker
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(e)
Power Transformers Power Transformers are used to step up or step-down a.c. voltages and to transfer
electrical power from one voltage level to another. Tap changers are used for voltage control. Transformer protection: Transformers are totally enclosed static devices and generally oil immersed. Therefore chances of fault occurring on them are very easy rare, however the consequences of even a rare fault may be very serious unless the transformer is quickly disconnected from the system. This provides adequate automatic protection for transformers against possible faults. Conservator and Breather: When the oil expands or contacts by the change in the temperature, the oil level goes either up or down in main tank. A conservator is used to maintain the oil level up to predetermined value in the transformer main tank by placing it above the level of the top of the tank. Breather is connected to conservator tank for the purpose of extracting moisture as it spoils the insulating properties of the oil. During the contraction and expansion of oil air is drawn in or out through breather silica gel crystals impregnated with cobalt chloride. Silica gel is checked regularly and dried and replaced when necessary. Specification: 66/11kV, 10MVA, OLTC Two transformers of 66/11kV, 10MVA capacity are installed. Either one of these two or both can be energised at a time. Feeder 1 can energise both transformers using bus coupler. Same is the case for feeder 2. Both transformers are on-load tap changing type. Various protective measures like Buchholz relay, explosion vent etc. are provided. 17 tap positions are there for OLTC and are of Remote Tap Change Control (RTCC) type. On load tap changer (850L) It consists of double set of switches where by any tap can be connected to either of two busbars which are joined by a resistor or reactance with a middle terminal connected to the supply. During the process of tap changing, the supply is temporarily connected to taps through the limiting resistance or reactance. On load tap changer is
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often contained in the main tank and immersed in the transformer oil and its operation may be controlled by AVR.
Fig. 3.6 Power Transformer 3.1.3 Station Earthing System Station Earthing System includes Earth Mat and Earth electrodes placed below ground level. These Earth Mat and Earth electrode is connected to the equipment structures, neutral points for the purpose of Equipment earthing and neutral point earthing. Function earthing system is to provide low resistance earthing for Discharging currents from the surge arresters, overhead shielding, earthing switches. For equipment body earthing. For safe touch potential and step potential in substation. 3.1.4 Metering, Control And Relay Panels To house various measuring Instruments, control Instruments, Protective relays. They are located in air-conditioned building. Control Cables are laid between Switchyard equipment and these panels.
Fig. 3.7 Control and Relay Panel
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3.1.5 New HT Panel Incomer 1 from transformer1 supplies existing 11kV, PC sub-station, capacitor bank1. Incomer 2 from transforme2 supplies existing 11kV, PB sub-station, capacitor bank2. Undervoltage (UV) and Overvoltage (OV) relays are provided for both these incomers. Interlocking is provided between incomer1, incomer2 and bus coupler. The capacitor bank connected is of 11kV, 630 kVAr capacity. 3.1.6 Existing 11kV Panel Existing 11kV panel supplies 16 sub-stations. Incomer1 supplies 8 substations and incomer 2 supplies 8 sub-stations. Interlocking is provided between incomer1, incomer 2 and bus coupler. Both these incomers have 2 capacitor banks each. Automatic Power Factor Controller (APFC) is also used in this panel. Capacitor Bank Four capacitor banks (C1, C2, C3, C4) each of capacity 11kV, 1060kVAR are installed. Each bank contains 12 capacitors (88.34kVAR). 4 numbers are connected in parallel to form each leg of the star connected capacitor bank. A reactor (60 kVA) is connected in series with each capacitor bank to limit surge current and limit harmonics. A potential transformer is also connected to the capacitor bank. Neutral Displacement Relay (NDR) is provided which detects any unbalance in voltage in the capacitor bank. When unbalance occurs a neutral voltage develops and when it reaches 5V NDR acts trips the circuit. APFC (Automatic Power Factor Controller) It is a state of art microcontroller based system which reads the instantaneous power factor values from online power factor monitor and decides on the required status of compensating capacitor after reading the current status of capacitor bank. The controller has 8 dedicated input lines through which it can continuously monitor the current status of all 4 capacitor banks (250kVAR*4).There is another set of 8 lines through which the controller initiates the switch on or off of each of the capacitors. Table 3.4 Automatic power factor controller in substations SUBSTATIONS 1Q HF kVAR 500 kVAR 300 kVAR
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HC HA FA PC FS PB Battery Bank
300 kVAR 300 kVAR 500 kVAR 500 kVAR 500 kVAR 500 kVAR
It consists of 55 cells of 2V capacity. Control voltage of 110V is provided with a battery bank. 3.1.7 Captive Power Plant (CPP) In case of power failure and excess demand CPP supplies the required power. CPP consists of two Diesel Generators (DG) sets of 1250kVA each. For parallel operation of DGs frequency, phase sequence and terminal voltage should match. This is done automatically by a synchroscope. Generator neutrals are independently earthed through Neutral Isolator Switch (NIS). In the case of parallel operation only one neutral should be earthed. Table 3.5 Rating of Alternator Make Output Speed Voltage Frequency Insulation class Phases Poles Type of cooling Excitation AVR Power factor Current Rating Kirloskar Electric CO. 1000kW at rated rpm 1500 rpm 11kV 50Hz F 3 4 Air cooled Brushless Static 0.8 66A 1250kVA
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Reverse power protection Generator indended to operate in parallel must have Reverse power protection. A reverse power relay monitors the direction of power flowing between the generator and switch board. If the speed of one of the generator goes down with respect to the other generator a motoring action occurs and this action will act as a load on the next generator. The relay senses this and gives signal to trip the breaker of generator. AVR (Automatic Voltage Regulator) Sudden load current surges on generator causes a corresponding changes in its output voltage. This is due to IR drop in the generator ac windings and the effect is usually called voltage dip.An AVR will control the generator output to +/ -2.5%. AN AVR senses the output voltage and acts to alter the field current to maintain the voltage at its set value. AVR consists of transformer rectifier, zener diodes, transistors and thyristors. The voltage sensing unit transforms, rectifies and smoothens the generator output voltage. This produces a low voltage dc signal that is proportional to the actual generator output voltage. This actual dc signal is compared with a set dc value. An error signal from comparator is then amplified and made suitable for driving the control circuit thyristors. Additional circuit components are often included in the AVR to ensure 1. Fair current sharing when the generators are running in parallel. 2. Quick voltage builds up during generator run-up. 3. Over voltage, under voltage alarm / trip protection. 3.1.8 Ring Main Incomer 1 & 2 of HT section supplies PB and PC sub-stations. Both PB and PC supply power to FS sub-station. These three sub-stations form a ring main unit. Two feeders give power to three sub-stations. If any one of the feeder fails to supply the other feeder can. These 3 are Unitised Sub Station (USS). Unitised Sub Station The Unitised sub-station is a compact arrangements, which simplifies conventional sub-station arrangement consists of AB switch, transformer, lightning arresters are mounted on a pole structure. The compact sub-station panel is divided into three compartments. HV compartment which houses VCB or LBS. The transformer
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compartment which houses Resin cast/ Resin impregnated/Oil cooled transformers and the LV compartment which houses ACB, MCCB, SFU etc. Its main advantages are: 1. Reduced Electrical Losses as USS can be provided near the load centre. 2. Cost effective and space saving 3. A High degree of safety and operational reliability is achieved by HT and LT Switchgear with protective relays. 4. Reduction in logistics costs as the USS is delivered as a single unit 5. Due to the enclosed Construction, it avoids bird hit, Human / Animal contacts which may lead to fatal accidents, disruption of power supply and power losses in the case of Open execution. Electrical Interlock USS panel consists of in-built safety interlocks such as door limit switches for transformer doors/ LT panel Doors. If anybody try to open the transformer / LT panel doors accidentally when the sub-station is in energized condition, then the HV Switchgear automatically trips and power supply will be cut-off. Mechanical Interlock Mechanical Interlocks will be provided between the HV switchgear and transformer door by means of castle-key arrangement, in such a way that the transformer doors can be opened only when the HV switchgear is switched off and vice-versa. 3.2 Electronics 150 Tonne Gantry Crane Power Supply AC 3.3KV 440V It consists of 1. PLC input/output module 2. Hoist 1 3. Hoist 2 4. Hoist 3&4 5. Upper Crab 6. Lower Crab 7. Fixed Leg master and slave motors
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8. Moving leg master and slave motors Working Loads Maximum working load on crane 150T 1. Upper crab 150T 2. Lower crab Main Hoist 80T 3. Lower crab Auxiliary Hoist 10T Method of speed control: Siemens Thyristor converter control 150T DC Drive It includes three phase armature converter, single phase field converter, Main contactor, protective semiconductor fuses, control power transformer and power or control terminals. Basic drive panels are fully digital, compact which supply the armature and field of variable speed dc drives with rated armature currents from 15A-1680A.The motor field circuit can be supplied with dc currents of up to 85A. On single quadrant converters a fully controlled three phase bridge supplies the armature. On 4 quadrant converters, 2 fully controlled three phase bridges are connected in inverse parallel connection to allow both positive and negative armature current. For the field converter a single phase half controlled 2 pulse bridge supplies the motor shunt field. The armature and field converters can operate with ac line frequency from 45 to 65HZ.the armature converter three phase ac supply is phase insensitive. However on base drives rated 1180, 1660, 1680A, the three phase cooling fan must be connected to get the proper direction of rotation. The power section cooling system is monitored by means of temperature sensors. The power section of armature and field is constructed of isolated thyristor modules (15A-850A at 460V ac line voltage). On converters rated 1180, 1660 and 1680A at 460V ac, the power section for the armature circuit is constructed using disk thyristors and the heat sinks are at line voltage potential. All open loop and closed loop drive control and communication functions are performed by 2 powerful microprocessors. Drive control functions are implemented in the software as program modules that can be wired up and changed by parameters.
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Converter module Configuration It includes a main circuit and control equipment. The control equipment is common to all converter modules while the main circuit differs with current rating. It consists of three circuit boards, 1) processor board, 2) memory module and input output board. It consists of thyristors bridges, cooling fan, fuses and auxiliary power supply for control equipment. The power components are designed to supply voltage up to 500V or 660V respectively. Thyristor bridge built up as a three phase fully controlled 6 pulse coupling. It is available as single or double converter. In double converters, the thyristors are anti-parallel coupled with common fusing and RC circuits. Thyristor blocks with 2 thyristors in each are used in converters .phase fuses, RC circuits and phase inductors are used as protection for these blocks. Converters with large current ratings are provided with puck thyristors. These are protected with the help of semiconductor fuses in the branches. The trigger pulses are conducted via ribbon cable from the converter control equipment to a pulse transformer board. After galvanic isolation in a pulse transformer, the gate pulses are conducted to the different thyristors. The trigger pulses can be measured via test terminals on the pulse transformer board. The test terminals are located on the primary side of the transformer. The dc current is measured on the ac voltage side of the thyristors units with the help of 2 current transformers. The output signal is rectified in a diode bridge and is adapted with load resistor. It consists of a diode field exciter and a digitally controlled field exciter. It consists of 2 pulse two way bridge and current sensitivity relay. Minimum field current is supervised by means of current sensitivity relay. By using controlled field exciter, the field current is kept constant in accordance with a reference value independent of line voltage and field winding resistance. It consists of phase inductor for limitation of rate of change of current during commutation, a semiconductor bridge and a varistor for limitation of voltage transients from field winding. Single field exciters have a non uniform thyristors bridge with two diodes and two thyristors. The current can only pass in one direction and the voltage cannot change
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sign. This bridge can be used in field weakening systems with moderate acceleration requirement. When shorter acceleration time with negative forcing voltage is required, the double field exciter must be used. The principal use of double field exciter is in systems with field reversal. The double field exciter has 2 anti-parallel thyristors with uniform connection bridges which can give positive and negative output voltage and current in both directions. 300T Crane Working load: Hoist 1 and 2: 180T, hoist 3: 120T and Auxiliary hoist: 10T AC Drive is used here. The method of braking is dynamic braking. Dynamic Braking of Induction Motors It slows down a machine by converting kinetic energy stored in the rotating mass to heat energy in the rotor and/or stator windings. Also switches the motor from the line to a braking circuit that causes the motor to behave as a generator with a connected load. There is no holding torque at the end of the braking period and need a mechanical brake to hold the shaft.
Fig. 3.8 Dynamic Braking Here we are disconnecting the motor from the line and supply a DC source to any two terminals of the stator through a current-limiting resistance. The DC voltage sets up a stationary magnetic field that generates a voltage in the rotor windings, dissipating energy as I2R losses, slowing the motor.
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3.3 Electrical Maintenance 2 3.3.1 Different Types Of Cranes Gantry A gantry crane has a hoist in a fixed machinery house or on a trolley that runs horizontally along rails, usually fitted on a single beam (mono-girder) or two beams (twin-girder). The crane frame is supported on a gantry system with equalized beams and wheels that run on the gantry rail, usually perpendicular to the trolley travel direction. These cranes come in all sizes, and some can move very heavy loads, particularly the extremely large examples used in shipyards or industrial installations.
Fig. 3.9 Gantry Electric Overhead Travelling (EOT) The most adaptable and the most widely used type of power driven crane for indoor service is undoubtedly the three motion EOT crane. It serves a larger area of floor space within its own travelling restrictions than any other permanent type hoisting arrangement. As the name implies, this type of crane is provided with movement above the floor level. Hence it occupies no floor space and this can never interface with any movement of the work being carried out at the floor of the building. The three motions of such crane are the hoisting motion and the cross travel motion. Each of the motions is provided by electric motors.
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Fig. 3.10 Electric Overhead Travelling (EOT) Crane Semi Gantry A gantry crane with one end of the bridge supported by one or more legs that run on a fixed rail or runway. The other end of the bridge is supported by a truck running on an elevated rail or runway.
Fig. 3.11 Semi-Gantry Crane Level Luffing Travelling Tower (LLTT) Normally a crane with a hinged jib will tend to have its hook also move up and down as the jib moves (or luffs). A level luffing crane is a crane of this common design, but with an extra mechanism to keep the hook level when luffing.
Fig. 3.12 Level Luffing Travelling Tower (LLTT)
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Tower Crane The tower crane is a modern form of a balance crane. When fixed to the ground, tower cranes will often give the best combination of height and lifting capacity and are also used when constructing tall buildings.
Fig. 3.13 Tower Crane 3.3.2 50T Crane LLTT Operation And Handling Crane is operated from an operators crab installed on the crane by use of several controllers. Each controller is of indirect control type, by which the change over operation of primary and secondary circuit of motor is effectively through EM contactor. On lowering the notches from 1 through 4 involving the main hoist and the auxiliary hoist are under speed control by means of DC dynamic brake (automatic braking).Throughout this notch range, speed reduction by 15% to 70% is attainable. Notch no 5 is ac controlled and serves for full speeding. On luffing, notches 1 through 3 are under speed control by means of KS brake. Throughout this notch range, speed reduction by 10% to 50% is possible. Avoid using these notches for long hours because KS brake will overheated and used only for time being after starting and before stopping the crane.Emergency stop during the slewing movement is possible by making reverse turn, but it would cause extra burden on crane structure. When moving the controller handle over the notches, go step by step precisely, dont move it too fast, avoid staying on anyone of the low notches for a long time, otherwise the resistor would be over heated.
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Operating Modes (a) Hoisting: A hoist is a device used for lifting or lowering a load by means of a drum or liftwheel around which rope or chain wraps. It may be manually operated, electrically or pneumatically driven and may use chain, fiber or wire rope as its lifting medium. The load is attached to the hoist by means of a lifting hook. 1) The operator turns the controller handle in the direction of his choice, whereby hoisting starts. When he turns the handle back on off notch, the hoisting movement stops. 2) On the hoisting devices are two limit switches provided to control the upper and lower hoisting limits. When the hoisting movement comes up or down in touch with limit switch the motor stops running automatically. Table 3.6 Rating of Hoist Motor Capacity Voltage Frequency Speed (b) Luffing: A level-luffing crane is a crane mechanism where the hook remains at the same level whilst luffing; moving the jib up and down, so as to move the hook inwards and outwards relative to the base. Some types of crane are inherently level-luffing: those with a fixed horizontal jib, such as gantry, hammerhead or the fixed-jib tower cranes commonly used in 45 kW 415 V 50 Hz 1484 rpm
construction. Usually though, the description is only applied to those with a luffing jib that have some additional mechanism applied to keep the hook level when luffing. Level-luffing is most important when careful movement of a load near ground level is required, such as in construction or shipbuilding. This partially explains the popularity of fixed horizontal jibs in these fields. Table 3.7 Rating of Luffing Motor Voltage Frequency 240 V 50 Hz
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Current Capacity Speed (c) Slewing:
89 A 30 kW 1500 rpm
The slewing drive is a gearbox that can safely hold radial and axial loads, as well as transmit a torque for rotating. The rotation can be in a single axis, or in multiple axes together. Slewing drives are made by manufacturing gearing, bearings, seals,
housing, motor and other auxiliary components and assembling them into a finished gearbox. Table 3.8 Rating of Slew Motor Capacity Power Factor Voltage Current Speed 3.3.3 Braking Methods Thrust Brake It develops braking torque by means of spring and release it by thrusting up force of thruster. BRAKING: Thruster cannot develop thrusting up force when it is not supplied with power. Brake shoes hold brake drum, developing braking torque by friction between periphery of brake drum and brake lining; simultaneously with this pushing rod is thrusted down. RELEASING: When power is fed to thruster, pushing up force is generated hydraulically in the thyristor where by pushing rod is forced to go up countering the pushing down force of the brake spring. Brake linings get apart from brake drum releasing the braking force. Magnetic Brake Brake is normally applied and is released when the oil is excited. 30 kW 0.83 415 V 55 A 1475 rpm
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BRAKING: When electromagnet is unexcited, the force of the braking spring bends the left brake shoe to the right and right brake shoe to the left, therefore both brake linings apply a braking force to the brake wheel. RELEASING: When the electromagnet is excited, electromagnet and movable disk are mutually attracted and when the force of braking spring is overcome right brake shoe opens to the right and left brake shoe opens to the left, therefore the brake linings are separated from the brake wheel and brake is released. 3.3.4 Maintenance The useful life of equipment and consequently the extend of productive capacity depends on how well the unit is maintained. Maintenance means the efforts directed towards the up keeping of that machine. There are 2 types of maintenance. 1. Breakdown maintenance. 2. Preventive maintenance. Breakdown maintenance This is done after the breakdown has occurred and can be due to unpredictable failure of components or due to wear and tear of parts. Here the defects are detected only when the machine cannot perform its function any longer. It disrupts the whole
production and is expensive due to over time for the maintenance staff for emergency repair. Preventive maintenance This is the scheduled maintenance to keep the machine in operational condition. The aim is to locate the sources of trouble and to avoid them before the breakdown occurs. It is done to set the maximum availability of the machine in operational condition, to minimize the wear and tear, to ensure the safety of workers and to increase the production efficiency. The advantages of preventive maintenance are: 1. Reduction in production down time. 2. Lesser to pay for maintenance staff. 3. Lesser number of standby equipment is needed. 4. Lesser expenditure on repair 5. Greater safety to workers. 6. Lesser spare parts are required to be kept in stores as it is a scheduled affair.
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3.3.5 Compressor House It houses four compressors. These compressors are used for painting. Compressor 1, 2 & 3 Specification: Motor: Squirrel cage induction motor 370kW, 3.3kV, 590rpm Reciprocating, Double acting two stage Discharge: 68.7m3/min at 7kg/cm2 Autotransformer starting Type of cooling: ON kW: 535, kV/HSV: 3.3, 3.6 LV taps: 50, 60, and 80 Phase - 3
Amp HV =17, Amp LV = 275 Compressor 4 The largest motor in shipyard is used for compressor 4. Specification: Motor: 850kW, 3.3kV, 174A, 50Hz, 2 pole, 2978 rpm, 0.89 pf Star connection, ABB made, Class F Horizontal mounting, centrifugal compressor Soft starting (Neutral FCMA) 3.3.6 Methods of Starting Three Phase Induction Motors Once a supply is connected to a three phase induction motor a rotating magnetic field will be set up in the stator, this will link and cut the rotor bars which in turn will induce rotor currents and create a rotor field which will interact with the stator field and produce rotation. This means that the three phase induction motor is entirely capable of self starting. The need for a starter therefore is not, conversely enough, to provide starting but to reduce heavy starting currents and provide overload and no-voltage protection. There are a number of different types of starter including The Direct On-line Starter, The Star- Delta Starter, and Auto-Transformer and Rotor resistance.
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(a)Direct-on-Line Starter (DOL) The DOL starter switches the supply directly on to the contacts of the motor. As the starting current of an induction motor can be 6-8 times the running current the DOL starter is typically only used for motors with a rating of less than 5kW. (b) Star Delta starter This is the most common form of starter used for three phase induction motors. It achieves an effective reduction of starting current by initially connecting the stator windings in star configuration which effectively places any two phases in series across the supply. Starting in star not only has the effect of reducing the motors start current but also the starting torque. Once up to a particular running speed a double throw switch changes the winding arrangements from star to delta whereupon full running torque is achieved. Such an arrangement means that the ends of all stator windings must be brought to terminations outside the casing of the motor.
Fig. 3.14 Star-Delta Starter (c) Auto-Transformer Starting This method of starting reduces the start current by reducing the voltage at start up. It can give lower start up currents than star-delta arrangements but with an associated loss of torque. It is not as commonly utilized as other starting methods but does have the advantage that only three connection conductors are required between starter and motor.
Fig. 3.15 Auto-Transformer Starter
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(d) Rotor Resistance Starter If it is necessary to start a three phase induction motor on load then a wound rotor machine will normally be selected. Such a machine allows an external resistance to be connected to the rotor of the machine through slip rings and brushes. At start-up the rotor resistance is set at maximum but is reduced as speed increases until eventually it is reduced to zero and the machine runs as if it is a cage rotor machine.
Fig. 3.16 Rotor Resistance Starter (e) FCMA soft starters for induction motor The harmonic free, rugged magnetic soft starter for motor starting. FCMA is an acronym for flux compensated magnetic amplifier which is basically a modulated inductive impedance. When connected in series with the motor the FCMA reduces the starting current to a low value. The impedance of FCMA decreases with increasing motor speed by flux compensation thus incrementing the motor voltage sleeplessly to keep the current constant till motor reaches 90% speed (pullout torque). The motor current now drops to its normal value depending upon the load demand. The motor voltage increment is typically from 50% at start to 95% at full speed steplessly. Ideally suited for centrifugal loads The FCMA is further bypassed by a suitable contactor so that the motor runs at line voltage. The starting current and voltages are purely sinusoidal without harmonics as the flux compensation technology operates the FCMA core always in the linear unsaturated zone. The starting current value is the minimum theoretical value as governed by the motor torque margin and load torque demand. Accelerating torque is always maintained larger than 10% throughout the speed range to avoid critical speed resonance.
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3.4 Electrical Maintenance 3 3.4.1 Pump House It houses various pumps used in the ship repair and building dock. For maintenance of ship it has to be brought to the repair dock and after ship building or maintenance it has to be taken to sea. For both these the docks have to be filled with sea water. Valves are provided on the gates. By opening the inlet valve (butterfly valve) the water gets in. When the dock water level and sea water level becomes equal, the gates are opened using winch motors and the ship is taken to the sea from the dock or taken to the dock from the sea. Four different types of pumps are used. 1. Main Discharge Pump (MDP) 2. Ballast Pump 3. Mud Pump 4. Bilge Pump Main discharge Pump (MDP) It is used for discharging water from the dock. They are of vertical type. 3 MDPs of 650 kW each are available in repair dock and 3 MDPs of 130kW each are available in building dock. The slip ring induction motor used for pump is of resistance type starting. It takes 31/2 hours to dewater the dock. Ballast Pump When the ship is in the dock, the necessary sea water for the work in ship like cleaning, cooling etc. is pumped using ballast pump. This pipe line is throughout around the dock. It is of 75kW, 415 V capacity. Make: L & T. Mud Pump There is a pit below dock level, into which the dirty water from ship is drained. This water is pumped out using mud pump. It is of submersible type. A float switch is provided which switches on the motor automatically. Starting method for the motor is reactor starting.
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Bilge Pump Leaked water from main discharge pipe may get filled in the space where MDP is kept and may damage it. To pump out this water automatically, bilge pump with float switch is used. Gate Winch Motor These motors are used for opening the inlet valve of the dock and water enters the dock. There are two gate winch motors of 7.5 kW each. The filling rate of two valve full open is 30, 000 m3/hr. The length, depth and breadth of repair dock is 270m, 12m, and 45m respectively. Cooling Water Pump 10Hp, 3.3kV motors are used for cooling purposes in the pump room of Cochin Shipyard. Pump Repair Dock (PRD) Substation Transformer Table 3.9 Rating of Transformer Rating No load voltage Current Phases Frequency Cooling Insulation class Max. ambient temparature Max.temp rise winding Impedance voltage Protective class Type of installation 3000kVA Primary: 11kV Secondary: 3.3kV Primary: 157.46A Secondary: 524.86A 3 50Hz Air natural F 400C 900C 6.44% IP 23 Indoor
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Basic insulation level
Impulse voltage(kVpeak) Primary:75 Secondary:40 P.F voltage(kVrms) Primary:28 Secondary:10 Dyn11
Vector group
Circuit Breaker In the PRD Substation Vaccum Circuit Breaker is used. Table 3.10 Rating of VCB Rated Voltage Rated Normal Current Frequency Breaking Symmetrical Current Breaking Unsymmetrical Current Making Current Short Time Current Time Basic Insulation Level 1min. ac withstand 3.6 kV 800 A 50 Hz 18.4 kA 47 kA peak 47 kAp 18.4 kA 3sec 30 kVp 12 kV
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CHAPTER 4 SHIP REPAIR

4.1 Electric Shop 4.1.1 Electrical Nautical Equipments used in ships 1. Gyro Compass-ships position finder 2. Auto pilot-ship auto piloting 3. Echo sounder (Doplar sonar)-Depth measurement 4. Anemometer-wind direction finder 5. Radar true motion, anti collision 6. VHF-communication 7. Radio direction finder 8. Decca navigator 9. Radio transmitter and receiver 10. ARPA- Automative Radar Plotting Aid 11. EPRIB-Emergency Positioning Radar Indicating Beckon 12. GMDSS-global maritime distress safety system 4.1.2 Lighting Transformer Three phase lighting transformer composed of 3 separate single phase units interconnected to form a three phase arrangement. If a fault develops in one phase of such arrangements the faulty unit can be disconnected and a three phase supply still is available although at a reduced power rating. 4.1.3 Brushless Alternator A brushless alternator is composed of two alternators built end-to-end on one shaft. Smaller brushless alternators may look like one unit but the two parts are readily identifiable on the large versions. The larger of the two sections is the main alternator and the smaller one is the exciter. The exciter has stationary field coils and a rotating armature (power coils). The main alternator uses the opposite configuration with a rotating field and stationary armature. The exciter field coils are on the stator and its armature ison the rotor. The AC output from the exciter armature is fed through a set of diodes that are also mounted on the rotor to produce a DC voltage. This is fed directly to the field coils of the main
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alternator, which are also located on the rotor. With this arrangement, brushes and slip rings are not required to feed current to the rotating field coils. This can be contrasted with a simple automotive alternator where brushes and slip rings are used to supply current to the rotating field. The main alternator has a rotating field as described above and a stationary armature (power generation windings). With the armature in the stationary portion of the alternator, the high current output does not have to go through brushes and slip rings. Although the electrical design is more complex, it results in a very reliable alternator because the only parts subject to wear are the bearings.
Fig. 4.1 Brushless Alternator Varying the amount of current through the stationary exciter field coils controls the strength of the magnetic field in the exciter. This in turn controls the output from the exciter. The exciter output is fed into the rotating field of the main alternator to supply the magnetic field for it. The strength of the magnetic field in the main alternator then controls its output. The result of all this is that a small current, in the field of the exciter indirectly controls the output of the main alternator and none of it has to go through brushes and slip-rings. 4.2 Dock No. 1 The repair dock of 270 x 45 x 12 M can accommodate ships up to 1,25,000 DWT. The dock has high capacity discharge pumps to drain it in less than three hours. It is served by three LLTT cranes, one of 40 T and two 10T capacity.
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4.3 Quays There are three quays of 280 M length with 15 T cranage, 208 M length with 10 T & 5 T cranage and 460 M length with 20 T cranage. The quays have adequate service lines of oxygen, acetylene, compressed air and power connections. 4.4 Engine And Machine Shop This shop is equipped with modern machine tools like Plano miller (up to 30 T) Bar Boring equipment (up to 300 mm dia), Inside Grinding machine (up to 300 mm dia), Heavy Duty Lathes (up to 12M length), Horizontal Drilling machine ( up to 100 mm boring & 600 mm drilling), Shrinkage equipment (up to 6 M x 900 mm O.D), Cylindrical Grinding machine (630 mm dia x 2 T), Horizontal Boring machine (up to 560 mm dia), Dynamic Balancing machine (up to 3 T) etc. 4.5 Other Facilities Hauling Carriage for safe docking and un-docking of ships. High Pressure Water Jet for hull cleaning. Blasting and Painting of conventional, epoxy and SPC systems. Facility for Boiler re-tubing. Facility for Tank Coating. Electric shop for overhauling of motors and testing. Electric power at 50 Hz & 60 Hz. Pipeline supply of compressed air, oxygen and acetylene.
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CHAPTER 5 SHIP BUILDING

Cochin Shipyard with its proven expertise is perfectly positioned to offer a flexible range of products such as Tankers Product Carriers Bulk Carriers Passenger Vessels High Bollard Pull Tugs Air Defence Ship 5.1 Dock No 2 The Dock No.2 of 255 x 43 x 9 M is available for building ships up to 1,10,000 DWT. This dock and the grand assembly area are served by two Gantry crane (300 T and 150 T) and two LLTT cranes (50 T). 5.2 Steel Stock Yard The steel stockyard has an area of 13,000 sq.m. aided with two gantry cranes of 25T each and one semi-gantry crane of 25 T. It is directly linked to the rail lines as well as to the waterfront, in addition to road connections. This enables steel to be brought in through wagons, barges or trucks. 5.3 Hull Shop The Hull Shop is self-contained with infrastructure required for fabrication of hull blocks up to 50 T. The shop is provided with EOT cranes (50 T) for along the bay movements and gantry crane (20 T) and trailers for across the bay transfer of materials. The fabrication of the ship is done in the Hull Shop. It has three parts: Preparation, and Assembly. In the preparation stage, the input is provided by the design department. Here the steel is mangled (straightening), blasting and painting is done. A plate mangling roller is used during the mangling process of the steel. A three phase induction motor is used in the plate mangling machine. The operating speed of the roller is 6000 mm/min and there are 5 rollers.
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Table 5.1 Rating of 3phase IM Capacity Frequency Rating Voltage Current Speed Pole Marine Coating Shop There are four Blast / Paint Shops of size 20 x 20 x 11 m are equipped for blasting and painting of fabricated units in controlled and favourable ambient conditions. Blasting using graded copper slag and Painting using modern air-less spray painting machines are carried out to provide the most effective coatings on steel structures. The entire methodology, process and finished surface are checked and vetted by well qualified and experienced personnel from CSL and the paint manufacturer. Next is the blasting process. Here surface of the material is smoothened before painting in a blast chamber. The blasting speed is 3 to 4 m/min. the plate is then painted to prevent from rusting. The paint is dried in a drying chamber. 5.4 Other Major Equipments/Facilities C.N.C. Cutting Machine Plasma Cutting Machine Shot Blasting Machine Automatic Painting Machine 1200 T Hydraulic Press Line Heating Techniques for curved shell formation. F.C.B. One side welding for large panels. Semi-automatic CO2, Gravity welding machines. Electro Slag welding. Electro Gas welding (in the Building Dock). 150mm Pipe Bending Machine. 1.5 kW 50 Hz Continous 415 V 3.1 A 1440 rpm 4
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Pipe Coaster (1.2 m dia capacity) 150 tonne transporter. 5.5 Plasma Cutting It is a process that is used to cut steel and other metals using a plasma torch. I n this process an inert gas is blown at high speed out of a nozzle; at the same time an electrical arc is formed through that gas from the nozzle to the surface being cut, turning some of that gas to plasma. The plasma is sufficiently hot to melt the metal being cut and moves sufficiently fast to blow molten metal away from the cut. Plasma can also be used for plasma arc welding. 5.6 Pipe and Sheet Metal Shop The pipe shop is provided with all the necessary equipment for bending, cutting, welding and pickling of pipes. The sheet metal shop handles all the light steel fabrications, trunking etc 5.7 Assembly Shop This shop has telescopic sliding roof with gantry cranes of 300 T and 150 T which spans over it and building dock. Hull blocks up to 450 T can be jumboized here and erected in the building dock using the gantry crane. In addition, two 20 T capacity EOT cranes are there in the shop. .
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CHAPTER-6 CONCLUSION
Industrial training is an integral part of engineering post graduation curriculum. I was very fortunate to undergo trainings in some of the best stations under KSEB, Lower Periyar Generating Station, Brahmapuram Diesel Power Plant and some of the finest industries, Travancore Cements Limited, Cochin Shipyard Limited. It was a wonderful experience to undergo training where we could explore more ideas about generation, transmission, distribution system. The Industrial Training component can add value to all degree programmes; specifically, it improves graduates work skills and prepares them to face the challenges of the working world. Thus, the Industrial Training programme should be taken seriously to ensure that maximum benefit is obtained by the student in order to increase the marketability and employability of Post graduates. In Lower Periyar Generating Station generators and different electrical machineries used in power house were studied. Starting and shutdown procedures of generators were also studied. BDPP is an efficient power plant under Kerala State Electricity Board. BDPP has also a sewage water treatment plant and pollution control systems. The unit offers vast employment opportunities for skilled labourers in the locality and has been the so ever since it started. Poovanthuruthu 220 kV Substation is a place where we could explore more ideas about generation, transmission and distribution system. In Travancore Cements Limited familiarization of different machines was done. Also became more aware about substation, electrical maintenance of various machines like cranes, pumps etc. Learned about aspects such as dredging, working of various mills, rotary kiln, various electrical machineries etc In Cochin Shipyard Limited there is a 66kV substation from which power is distributed to different local substations. The local substations provide supply for different sections in the yard. There are three Unitised Sub Stations. The control and monitoring is done through PLC. Remote and manual operation is also possible here. The protection schemes for different equipments were studied.
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REFERENCES
[1] Principles of Power System-V. K. Mehta, Rohit Mehta [2] Operating Manual of Lower Periyar Power house [3]Technical Handbook for Power Engineers, KSEB Officers Association [4] Operating Manual of BDPP [5] Introduction to Telemechanique model 40 PLCs [6] Switchgear Protection and Power System-Sunil S Rao, Khanna Publishers [7] Electrical Power-Dr. S L Uppal, Khanna Publishers [8] Manuals and prospectus of TCL [9] Cochin Shipyard Brochure and Prospectus. [10] www.travcement.com [11] www.cochinshipyard.com [12] www.wikipedia.com
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Industrial Training

LOWER PERIYAR POWER STATION

Department of Electrical & Electronics Engg.

Department of Electrical & Electronics Engg.

1.1 Hydro-Electric Projects in Kerala Table 1.1 Hydro-electric Projects in Kerala

Pallivasal Kuttiyadi Panniar Neriamangalam Poringalkuthu Sengulam Kakkad

37.5 225 30 77.65 48 48 50

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CHAPTER-2 HYDEL POWER PLANTS

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Francis Turbines Kaplan Turbines

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CHAPTER-3 SALIENT FEATURES OF LOWER PERIYAR GENERATING STATION

Bhrahmapuram which is directly tied with Kayamkulam Thermal station.

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CHAPTER-4 HYDRAULIC SYSTEM OF LOWER PERIYAR

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Fig 4.1 Profile of the Water Conductor System

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Fig 5.2 Guide Vanes

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Arrangement of Distributing valve controlling a Servomotor.

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CHAPTER-7 VALVE GALLERY

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Guide Bearing Thrust Bearing

Fig 9.1 Generator Bearing

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Lower Guide Bearing.

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CHAPTER-10 STATIC EXCITATION

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Fig 10.2 Block Diagram Static Excitation

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CHAPTER-11 STATION AUXILIARIES

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CHAPTER-13 MAIN CIRCUIT BREAKERS AND POWER TRNSFORMERS

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CHAPTER-14 PROTECTION SYSTEM

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networks, The operation of all distance relays is based

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CHAPTER-16 OPERATION OF DIFFERENT EQUIPMENTS

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