India Glycols seminar report

Summer Training Report
A report on practical training at
India Glycols Limited
Abhinav Singh
VII Semester, B.Tech
MNIT Jaipur

ACKNOWLEDGMENT
I would like to express my special thanks of gratitude to Mr. Sanjeev Khanna, Sr.
Manager (HR & Admin). India Glycols Limited, Gorakhpur and Mr. Mohan Chaubey
Asst. Manager (HR) who gave me the permission to train in IGL, Gorakhpur facility and
utilize their resources unhesitatingly.
I am extremely grateful to Mr. Shailesh Chandra, AGM India Glycols Limited for
providing me proper guidance during the training period. I have been able to
comprehend some bit of the industrial perspective of my stream under his mentorship
and can never thank him enough for the passion that he has tried to vitalize in me and
other fellow trainees of our stream.
I would also like to thank Mr. Kanhaiya Lal Chauhan, Mr. J K Maurya and Mr. Sunil
Yadav for their effort to make me acquainted with the mechanical aspects of power
pla t a d it’s Dist i utio Co t ol “ ste . I a also tha kful to Mr. Rajnikant Pandey,
Electrical Department for giving me insight of heavy industrial equipments in the
domain of electrical field.
At last I would like to thank all employees of Electrical Substation who accompanied us
in most of our visits to different plants and their Control Rooms and eagerly informed us
about various equipments and schemes in the facility.
After being a part of the India’s o l g ee pet o he i al o pa , I a o e hel ed
by their dedication towards safety, coordination and efficiency in work and their
incessant commitment towards innovation and optimized utilization of the electrical
energy and available resources.

Table of contents
1. Co pa p ofile………………………………………………………………………………………… .
IGL usi esses………………………………………………………………………………………….. .
E po ts……………………………………………………………………………………………………… .
Custo e fo us…………………………………………………………………………………………. .
Visio …………………………………………………………………………………………………………. .
Missio ………………………………………………………………………………………………………. .
2. Boile ………………………………………………………………………………………………………….. .
T pes of oile ……………………………………………………………………………………………. .
Fi e tu e oile ………………………………………………………………………………………… . .
Wate tu e oile ……………………………………………………………………………………. . .
Ra ki e le…………………………………………………………………………………………….. .
Four processes in rankine cycle…………………………………………………………………. .
Boile i IGL Go akhpu …………………………………………………………………………….. .
Fluidized bed o ustio te h olog ……………………………………………………….. .
Boile a esso ies………………………………………………………………………………………. .
Boile ou ti gs………………………………………………………………………………………… .
3. Ge e ato …………………………………………………………………………………………………… .
Ope ati g p i iple…………………………………………………………………………………….. .
T o ethods of ge e ati g a po e ………………………………………………………... .
“ ste s used i IGL……………………………………………………………………………………. .
Co po e ts of ge e ato …………………………………………………………………………… .
4. Tu i e……………………………………………………………………………………………………….. .
Principle of operatio ………………………………………………………………………………… .
MW tu i e………………………………………………………………………………………….. .
Tu i e o t ol s ste ……………………………………………………………………………… .
Tu i e t ip poi ts…………………………………………………………………………………….. .
5. “ it hgea ………………………………………………………………………………………………… .1
Basic objectives of system p ote tio ………………………………………………………… .2
6. “ it h a d…………………………………………………………………………………………………. .1
Po e t a sfo e …………………………………………………………………………………….. .2
Instrument transforme ……………………………………………………………………………… .3
T pe of i sulato s………………………………………………………………………………………. .4
Isolators…………………………………………………………………………………………………….. .5

Bus a ………………………………………………………………………………………………………..6.6
Lighti g a este ………………………………………………………………………………………….6.7
Ci uit eake …………………………………………………………………………………………….6.8
Rela s………………………………………………………………………………………………………….6.9
“u ge o ito …………………………………………………………………………………………..6.10
Ea th s it hes…………………………………………………………………………………………..6.11
7. Ope atio a d o t ol s ste ……………………………………………………………………7.1
Scada fu tio al e ui e e ts………………………………………………………………….7.2
“ ada o u i atio e ui e e ts………………………………………………………….7.3
Rela o u i atio e ui e e ts…………………………………………………………..7.4
Co po e ts of s ada s ste ………………………………………………………………….....7.5
PI s ste …………………………………………………………………………………………………….7.6
Be efits of PI s ste …………………………………………………………………………………..7.7
Fu tio s of PI s ste …………………………………………………………………………………7.8
8. “u statio …………………………………………………………………………………………………..8.1
Dist i uted o t ol s ste …………………………………………………………………………8.2
Bus a a a ge e t………………………………………………………………………………….8.3
Po e o t ol e t e………………………………………………………………………………….8.4
Moto o t ol e t e…………………………………………………………………………………..8.5
Auto ati oltage egulato ……………………………………………………………………….8.6
Programmable logic o t ol………………………………………………………………………..8.7
Load dist i utio at IGL………………………………………………………………………………8.8
P ote tio s he es…………………………………………………………………………………….8.9
9. Diesel ge e ato ………………………………………………………………………………………….9.1
10.Othe pla ts at IGL……………………………………………………………………………………. .1
ENA a d R“ pla t………………………………………………………………………………………10.2
DM pla t……………………………………………………………………………………………………10.3
11.Ele t ostati p e ipitato …………………………………………………………………………..11.1

COMPANY PROFILE
India Glycols is a leading company that manufactures green technology based bulk,
specialty and performance chemicals and natural gums, spirits, industrial gases, sugar
and nutraceuticals.
The company was established as a single mono-ethylene glycol plant in 1983. Since
then, IGL has brought together cutting-edge technology, innovation and an unflagging
commitment to quality, to manufacture a wide range of products that have found global
demand.
IGL’s state-of-the-art, integrated facilities manufacture chemicals including glycols,
ethoxylates, glycol ethers and acetates, and various performance chemicals. Its product
range spans the chemicals, spirits, herbal and other phytochemical extracts and guar
gum, industrial gases and realty sectors, and finds application across an increasing
number of industries.
These products are manufactured in compliance with stringent global standards of plant
ope atio s, ualit a d safet . The o pa ’s fa ilities ha e ee app o ed a d
certified by international agencies including Det Norske Veritas (DNV). The operations at
all plants are closely monitored through distributed control systems (DCS), which
facilitate a high degree of control over the quality of products.
The o pa ’s fa ilities ha e ee app o ed a d e tified by international agencies
including Det Norske Veritas (DNV). The operations at all plants are closely monitored
through distributed control systems (DCS), which facilitate a high degree of control over
the quality of product. The company has distinction of producing Electrical Energy from
slop (waste from alcohol production), rice husk and coal. The power produced is used to
run various plants.
IGLBusinesses
IGL’s flagship he i als di isio sta ted out ith a path-breaking green approach to
manufacturing ethylene oxide and derivatives. Using the molasses-ethyl alcohol-
ethylene 'green route', the company is the only one of its kind in the world. With the
emphasis now increasingly shifting to green manufacturing, the chemical division is well
poised to meet the i dust ’s eed fo e i o e tall espo si le p odu ts a d
production techniques. Keeping in mind the critical dependence on agricultural
feedstock, the company has taken up several initiatives including backward integration

into sugar manufacturing to ensure seamless raw material availability. Other
complementary initiatives include co-opting the cane growing community to ensure
cane availability while providing adequate returns to the farmer. Apart from chemicals,
India Glycols has a significant presence in the natural active pharmaceuticals and
nutraceuticals space with Ennature Biopharma; a well-established natural gum division
manufacturing guar gum and a variety of derivatives; a spirits division that manufactures
country and Indian-made foreign liquor adhering to the highest quality standards; and
Shakumbari Sugar – a well-established player in the Indian sugar industry.
Exports
IGL has traditionally looked to leverage the export potential of its products. The
company has therefore initiated the process of aligning to emerging global trends and
has established facilities and operations that are in compliance with global good
manufacturing practices.
Customer_focus
The company strives to achieve excellence through proactively addressing customer
needs and requirements. Integral to this approach is the identification and development
of customised products backed by research and development support. IGL's R&D
function is not only driven by organisational needs, but more importantly by customer
needs. Its R&D centre employs state-of-the-art equipment that empowers IGL scientists
and engineers to consistently deliver customised solutions that meet, and at times, even
exceed customer expectations.
Vision
To be one of the most respected and innovative manufacturers of internationally
sustainable products derived from natural, green or renewable resources, which add
value and continuous growth to all stakeholders and the society at large.
Mission
To manufacture and promote products, with concern for the environment and the
wellness of people across the globe, by deriving them from renewable, natural, agro and
waste feed stock. And to achieve this mission by deploying safe, eco-friendly and cost-
effective processes and technologies.

BOILER
A boiler (or steam generator) is any closed vessel exceeding 22.75 liters capacity, in
which, water under pressure is converted into steam. When water is boiled into steam
its volume increases about 1,600 times, producing a force that is almost as explosive as
gunpowder. This causes the boiler to be extremely dangerous equipment that must be
treated with utmost care. Hence, it is one of the major components of a thermal power
plant. A boiler is always designed to absorb maximum amount of heat released in
process of combustion. This is transferred to the boiler by all the three modes of heat
transfer i.e.
(1) Radiation: It is the transfer of heat from a hot body to a cold body without a
conveying medium
(2) Convection: It is the transfer of heat by a conveying medium, such as air or water
(3) Conduction: it is the transfer of heat by actual physical contact, molecule to
molecule.
Types of Boiler
There are mainly two types of boiler – water tube boiler and fire tube boiler. In fire tube
boiler, there are numbers of tubes through which hot gases are passed and water
surrounds these tubes. Water tube boiler is reverse of the fire tube boiler. In water tube
boiler the water is heated inside tubes and hot gasses surround these tubes. These are
the main two types of boiler but each of the types can be sub divided into many which
we will discuss later.
Fire Tube Boiler
As it indicated from the name, the fire tube boiler consists of numbers of tubes through
which hot gasses are passed. These hot gas tubes are immersed into water, in a closed
vessel. Actually in fire tube boiler one closed vessel or shell contains water, through
which hot tubes are passed. These fire tubes or hot gas tubes heated up the water and
convert the water into steam and the steam remains in same vessel. As the water and
steam both are in same vessel a fire tube boiler cannot produce steam at very high
pressure. Generally it can produce maximum 17.5 kg/cm2
and with a capacity of 9
Metric Ton of steam per hour.

Water Tube Boiler
A water tube boiler is such kind of boiler where the water is heated inside tubes and the
hot gasses surround them.
Fig1. Steam boiler
This is the basic definition of water tube boiler. Actually this boiler is just opposite of fire
tube boiler where hot gasses are passed through tubes which are surrounded by water.
RANKINE CYCLE
The Rankine cycle is a model that is used to predict the performance of steam turbine
systems. It is an idealized thermodynamic cycle of a heat engine that converts heat into
mechanical work. The heat is supplied externally to a closed loop, which usually uses
water as the working fluid. It is named after William John Macquorn Rankine, a Scottish
polymath and Glasgow University professor.

Fig2. Rankine cycle
THE FOUR PROCESSES IN THE RANKINE CYCLE
T-s diagram of a typical Rankine cycle, operating between pressures of 0.06 bar and 50
bar. There are four processes in the Rankine cycle. These states are identified by
numbers in the above T-s diagram.
Process 1-2: The working fluid is pumped from low to high pressure. As the fluid is a
liquid at this stage, the pump requires little input energy.
Process 2-3: The high pressure liquid enters a boiler where it is heated at constant
pressure by an external heat source to become a dry saturated vapour. The input energy
required can be easily calculated using mollier diagram or h-s chart or enthalpy-entropy
chart also known as steam tables.
Process 3-4: The dry saturated vapour expands through a turbine, generating power.
This decreases the temperature and pressure of the vapour, and some condensation
may occur. The output in this process can be easily calculated using the Enthalpy-
entropy chart or the steam tables.

Process 4-1: The wet vapour then enters a condenser where it is condensed at a
constant pressure to become a saturated liquid.
1. Slope (60-65%)
BOILER IN IGL GORAKHPUR
India Glycol Limited Gorakhpur has four boilers. Three are manufactured by Cheema
Boilers Limited and one is manufactured by Lippy
Boiler 1( lippy boiler) has the least efficiency and is used for only rice husk as fuel. The
capacity of the boiler is 35 ton.
Boiler 2 (cheema boiler) uses slope, rice husk and coal as the fuel. The capacity of the
boiler is 35 ton.
Boiler3 (cheema boiler) is boiler cum super heater. The capacity of this boiler is 10 ton.
Boiler4 (cheema boiler) is 35 ton boiler. This also uses slope, rice husk and coal as the
fuel.
The boiler used in IGL is FBC (Fluidized Bed Combustion) technology based boiler. It is
used to burn solid fuels.
The power is produced by using three sources. These are:
1. Slope (60-65%)
2. Rice husk (25-30%)
3. Coal ( rest)
Fluidized Bed Combustion technology
In its most basic form, fuel particles are suspended in a hot, bubbling fluidity bed of ash
and other particulate materials (sand, limestone etc.) through which jets of air are
blown to provide the oxygen required for combustion or gasification. The resultant fast
and intimate mixing of gas and solids promotes rapid heat transfer and chemical
reactions within the bed. FBC plants are capable of burning a variety of low-grade solid
fuels, including most types of coal and woody biomass, at high efficiency and without
the necessity for expensive fuel preparation (e.g., pulverising).
The FBC technology has following advantages:

1. High thermal efficiency.
2. Easy ash removal system, to be transferred for made cement .
3. Short commissioning and erection period.
4. Fully automated and thus ensures safe operation, even at extreme temperatures.
5. Efficient operation at temperatures down to 150° C ( i.e. well below the ash
fusion temperature).
6. Reduced coal crushing etc.(pulverised coal is not a necessity here).
7. The system can respond rapidly to changes in load demand, due to quick
establishment of thermal equilibrium between air and fuel particles in the bed.
8. The operation of fluidized bed furnace at lower temperature helps in reducing air
pollution. The low temperature operation also reduces the formation of nitrogen
oxides. By adding either dolomite (a calcium-magnesium carbonate) or lime
stone (calcium carbonate) to the furnace the discharge of sulphur oxides to the
atmosphere can also be reduced if desired.
BOILER ACCESORIES
1. FEEDWATER HEATER: A feedwater heater is a power plant component used to pre-
heat water delivered to a steam generating boiler. Preheating the feedwater reduces
the irreversibilities involved in steam generation and therefore improves the
thermodynamic efficiency of the system. This reduces plant operating costs and also
helps to avoid thermal shock to the boiler metal when the feedwater is introduced back
into the steam cycle. In a steam power plant (usually modelled as a modified Rankine
cycle), feedwater heaters allow the feedwater to be brought up to the saturation
temperature very gradually. This minimizes the inevitable irreversibilities associated
with heat transfer to the working fluid (water).
2. ECONOMIZER: An economizer serves a similar purpose to a feedwater heater, but is
technically different. Instead of using actual cycle steam for heating, it uses the lowest-
temperature flue gas from the furnace (and therefore does not apply to nuclear plants)
to heat the water before it enters the boiler proper. This allows the heat to transfer

between the furnace and the feedwater to occur across a smaller average temperature
gradient (for the steam generator as a whole). System
efficiency is therefore further increased when viewed with respect to actual energy
content of the fuel.
3. SUPER HEATER: A superheater is a device used to convert saturated steam or wet
steam into dry steam used in steam engines or in processes, such as steam reforming.
There are three types of superheaters namely: radiant, convection, and separately
fired. A superheater can vary in size from a few tens of feet to several hundred feet (a
few metres to some hundred metres). A super heater is a device which removes the last
traces of moisture from the saturated steam leaving the boiler tubes and also increases
its temperature above the saturation temperature. The steam is superheated to the
highest economical temperature not only to increase the efficiency but also to have
following advantages:
a. No corrosion and pitting at the turbine blades occur owing to dryness of steam.
b. Superheated steam being dry, turbine blades remain dry so the mechanical resistance
to the flow of steam over them is small resulting in high efficiency.
c. Reduction in requirement of steam quantity for a given output of energy owing to its
high internal energy reduces the turbine size.
4. AIR PREHEATER: An air pre-heater (APH) is a general term used to describe any
device designed to heat air before another process (for example, combustion in a boiler)
with the primary objective of increasing the thermal efficiency of the process. They may
be used alone or to replace a recuperative heat system or to replace a steam coil. The
purpose of the air pre-heater is to recover the heat from the boiler flue gas which
increases the thermal efficiency of the boiler by reducing the useful heat lost in the flue
gas. As a consequence, the flue gases are also conveyed to the flue gas stack (or
chimney) at a lower temperature, allowing simplified design of the conveyance system
and the flue gas stack. It also allows control over the temperature of gases leaving the
stack (to meet emissions regulations, for example).
5. INDUCED DRAFT FAN: In an induced draft system, the fan is at the exit end of the
path of flow, and the system is under negative pressure - that is, the pressure in the flow
area is below atmospheric, because the air is being drawn through the fan. Suck the

gases out of the furnace and throw them into the stack by creating sufficient negative
pressure in the furnace (5-10 mmwc) in the balanced draft units.
Modern technology VFD (Variable Frequency Drive) is used in these boilers.
VFD: A variable-frequency drive (VFD) (also termed adjustable-frequency drive, variable-
speed drive, AC drive, micro drive or inverter drive) is a type of adjustable-speed
drive used in electro-mechanical drive systems to control AC motor speed and torque by
varying motor input frequency and voltage.
225 kW VFD is used to run ID pump induction motor in IGL .
Ratings of ID Fan used in IGL Gorakhpur
ID FAN
Model ID2450
Static pressure 300 mm Hg
Motor power 240 HP
Capacity 134388 m3
/hr
Operating temperature 1800
C
Speed 750 rpm
Serial number 2064711-12
6. FORCED DRAFT FAN: In FD system, the fan is located at air inlet of the boiler. Hence it
pushes high pressure fresh air into the boiler and the pressure decreases through the
accessories upto the chimney.
Although the FD system has quite a number of advantages over the ID system, a
combination of both, known as 'Balanced Draught System' is used to combine the
advantages of both.
In IGL Gorakhpur Fancor Industrial FD fans are used. The static pressure maintained by
these fans is 175 mm Wg and the capacity is 70276 m3
/hr.
7. BOILER FEED WATER PUMP: A boiler is a device for generating steam, which consists
of two principal parts: the furnace, which provides heat, usually by burning a fuel, and
the boiler proper, a device in which the heat changes water into steam.

In IGL Gorakhpur BFW are of ultistage ce trifugal type three BFW pumps are used
and one BFW pump operated by HT motor is used.
HT motors are used for 3.3 kV or above whereas LT motors are used for 415 V or below.
For the same power rating size of HT motor is smaller than that of LT motor. But the
insulation level in HT motor is more straighten than LT motor. The current is very high
in same rating LT motor so the rating of the protection device will be higher than HT
type motor. So generally we have taken HT motor in bigger size like greater than 100
kW.
HT BFW PUMP
Type AMA 450L2ABAI
Phase Three
Duty S1
Connection Star
Insulation class F
Weight 3900 Kg
Output 270 Kw
Voltage 11 Kv
Frequency 50 Hz
Speed 2983 rpm
Current 20 A
Power factor 0.7
Efficiency 91.8%
Ambient temperature 500
C
IS 325 IEC 60034-1
BOILER MOUNTINGS
Boiler mountings are used to ensure safety of equipment and personal in case of
unprecedented faults.

1.SAFETY VALVE: The function of the safety valve is to permit the steam in the boiler to
escape to atmosp0here when pressure in the steam space in the boiler. The safety valve
operates in the principle that a valve is pressed against its seat through some agency
such as sturt, screw or spring by external weight or force, when the steam force due to
boiler pressure acting under the valve exceeds the external force, the valve gets lifted
off its seat and some of the steam rushes out until normal pressure is restored again.
2. CONTROL VALVE: This valve is used to regulate the boiler drum to ensure that there is
always enough feedwater in the boiler to create steam. The boiler feedwater control
valve must have an equal-percentage characteristic to compensate for the difference
between the characteristic of the boiler feedwater pump and the boiler plant.
Fill control valve: This valve fills the boiler drum when the plant is started. Sizable
differential pressure and cavitation must be controlled at this time, subjecting the valve
to high forces and, thus, wear. Often small in design, it is equipped with hard, graduated
valve trim and is positioned parallel to the main boiler feedwater control valve.
GENERATOR
An alternator is an electrical generator that converts mechanical energy to electrical
energy in the form of alternating current. For reasons of cost and simplicity, most
alternators use a rotating magnetic field with a stationary armature. Occasionally, a
linear alternator or a rotating armature with a stationary magnetic field 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. Large 50 or 60 Hz three phase alternators in power plants generate most of
the world's electric power, which is distributed by electric power grids.
OPERATING PRINCIPLE
A conductor moving relative to a magnetic field develops an electromotive force (EMF)
in it, (Faraday's Law). This EMF reverses its polarity when it moves under magnetic poles

of opposite polarity. 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. Since the
currents in the stator windings vary in step with the position of the rotor, an alternator
is a synchronous generator.
The rotor's magnetic field may be produced by permanent magnets, or by a field coil
electromagnet. Automotive alternators use a rotor winding which allows control of the
alternator's generated voltage by varying the current in the rotor field winding.
Permanent magnet machines avoid the loss due to magnetizing current in the rotor, but
are restricted in size, due to the cost of the magnet material. Since the permanent
magnet field is constant, the terminal voltage varies directly with the speed of the
generator.
Alternators used in central power stations also control the field current to regulate
reactive power and to help stabilize the power system against the effects of momentary
faults. 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.
TWO METHODS OF GENERATING A.C. POWER
(a) REVELOVING ARMATURE
The design of revolving armature generators is to have the armature part on a rotor and
the magnetic field part on stator. A basic design, called elementary generator, is to have
a rectangular loop armature to cut the lines of force between the north and south poles.
By cutting lines of force through rotation, it produces electrical current. The current is
sent out of the generator unit through two sets of slip rings and brushes, one of which is
used for each end of the armature. In this two-pole design, as the armature rotates one
revolution, it generates one cycle of single phase alternating current (AC). To generate
an AC output, the armature is rotated at a constant speed having the number of
rotations per second to match the desired frequency (in hertz) of the AC output.

(b) REVOLVING FIELD
The design of revolving field generators is to have the armature part on stator and the
magnetic field part on rotor. A basic design of revolving field single-phase generator is
shown on the right. There are two magnetic poles, north and south, attached to a rotor
and two coils which are connected in series and equally spaced on stator. The windings
of the two coils are in reverse direction to have the current to flow in the same direction
because the two coils always interact with opposing polarities. Since poles and coils are
equally spaced and the locations of the poles match to the locations of the coils, the
magnetic lines of force are cut at the same amount at any degree of the rotor. As a
result, the voltages induced to all windings have the same value at any given time. The
voltages from both coils are "in phase" to each other. Therefore the total output voltage
is two times the voltage induced in each winding. As the rotor turns 180 degrees, the
output voltage is alternated to produce the highest voltage on the other direction. The
frequency of the AC output in this case equals to the number of rotations of the rotor
per second.
SYSTEM USED IN IGL
In IGL, Gorakhpur we have Revolving Field type generator. The advantage of Revolving
Field type are:
1.The arrangement and connection of three phase winding is easy.
2. The insulation of high voltage armature winding is easy.
3. As there is no slip ring , large power can be produced.
4. The structure is mechanically strong.

SPECIFICATIONS
12MW GENERATOR
(Three Phase Synchronous Generator)
Type QFW-12-4
Product STD No IEC60034-1
Rated Frequency 50 Hz
Rated output 12 MW
Rated speed 1500 rpm
Rated stator voltage 11 Kv
Rated stator current 787.3 A
Rated exciting current 379 A
Weight 44085 Kg
Rated power factor 0.8
Connection Star
AC EXCITER
Output 100 KVA
Voltage 245 kV
Exciting voltage 40.1 V
Current 408 A
Exciting current 3.5 A
Frequency 125 Hz
Armature connection Star
Pole 10
COOLER
Type KCWQ450
Air flow 12 m3
/sec

Water consumption 100 m3
/hr
Max. operating water pressure 0.5 MPa
Rated output 450 KW
Rated temp. of cooling water 340
C
Water pressure drop 40000 Pa
Air pressure drop 230 Pa
SPACE HEATER
Output 2.4 KW
Voltage 24 V
Frequency 50 Hz
Phase Single
3.8 MW TURBINE
Serial number 100109
Turbine speed 5500 rpm
Steam inlet pressure 43 ATA
Steam exchange pressure 45 ATA
Steam extraction pressure 10 ATA
Turbine oil SV68
Year of manufacture 1994
Power 3800 MW
Output speed 1500 rpm
Steam inlet temperature 4200
C
Lubricating oil pressure 2 bar
ALTERNATOR
Rated voltage 11 KV
Rated power 5 MVA
Speed 1500 rpm
Power factor 0.8 lag
Stator voltage 11 KV
Stator current 262.4 A
Phase Three

Frequency 50 Hz
Inlet temperature 500
C
C
Exciting voltage 94 V
Exciting current 396 A
GENERATOR COMPONENTS
ROTOR- The electrical rotor is the most difficult part of the generator to design. It
revolves in most modern generators at a speed 3,000 revolutions per minute. The
problem of guaranteeing the dynamic strength and operating stability of such a motor is
complicated by the fact that a massive non-uniform shaft subjected to a multiplicity of
differential stresses must operate in oil lubricated sleeve bearings supported by a
structure mounted in foundations all of which possess complex dynamic be behavior
peculiar to them. It is also an electromagnet and to give it the necessary magnetic
strength the windings generate heat but the temperature must not be allowed to
become so high, otherwise difficulties will be experienced with insulation. To keep the
temperature down, the cross section of the conductor could not be increased but this
would introduce another problems.
LUBE OIL SYSTEM- Lube oil system supplies oil to the compressor, turbine bearings,
gears and couplings. The lube oil is drawn from the reservoir by the pumps and is fed
under pressure through coolers and filters to the bearings. Upon leaving the bearings,
the oil drains back to the reservoir.
BEARING COOLING SYSTEM -Antifriction bearings are used for small alternators but oil
lubricated bearings are more in use for larger ones. Self-contained ring-oiled bearings
are used for horizontal shafts. But for heavy applications and high speeds, ring oiling is
supplemented by recirculation of externally cooled oil. An emergency supply of oil is
also maintained is such systems as a stand by for failure of main supply.
DC EXCITATION SYSTEM- It helps in giving DC supply to the rotor by rectifying the AC
produced by the exciter through rectifiers built on the rotor, which is given to the rotor
of Alternator.
NEUTRAL GROUNDING TRANSFORMER- Neutral grounding transformers in resistance
grounding resistor systems protect power transformers and generators from damaging

fault currents. Low resistance grounding of the neutral limits the ground fault current to
a high level (typically 50 amps or more) in order to operate the protective fault clearing
relays and current transformers. These devices are then able to quickly clear the fault,
usually within a few seconds. 24 hour turn around on neutral grounding transformer.
STEAM TURBINE
Turbine is a machine in which a shaft is rotated steadily by impact or reaction of current
or stream of working substance (steam, air, water, gases etc.) upon blades of a wheel. It
converts the potential or kinetic energy of the working substance into mechanical
power by virtue of dynamic action of working substance. When the working substance is
steam it is called the steam turbine.
PRINCIPLE OF OPERATION- Working of the steam turbine depends wholly upon the
dynamic action of Steam. The steam is made to fall under pressure in a passage of
nozzle, due to this fall in pressure a certain amount of heat energy is converted into
mechanical kinetic energy and the turbine is set moving with a greater velocity. The
rapidly moving particles of steam, enter the moving part of the turbine and here suffer a
change in direction of motion which gives rise in change of momentum and therefore to
a force. This constitutes the driving force of the machine. The process of expansion and
direction change may occur once or a number of times in succession and may be carried
out with difference of detail. The passage of steam through the moving part, commonly
called as blade, may work in such a manner that the pressure at the outlet side of the
blade is equal to that at the inlet inside. Such a turbine is broadly termed as impulse
turbine. On the other hand, when the pressure of the steam at outlet of the moving
blade may be less than that of the inlet side; the drop in pressure suffered by the steam
during its flow causes a further generation of kinetic energy within the blades and adds
to the propelling force which is applied to the turbine rotor. Such a turbine is broadly
termed as impulse reaction turbine. The majority of the steam turbine have, therefore
two important elements, or Set of such elements. These are: The nozzle, in which the
system expands from high pressure end to a state of comparative rest at a lower
pressure end.

The blade or deflector, in which the steam particles changes its directions and hence its
momentum too. The blades are attached to the rotating element which itself is attached
to the stationary part of the turbine, usually termed the stator, casing or cylinder
Two turbines are used for power generation at IGL, specification of those are given
below. One is 3.8 MW Back-Pressure Cum Extraction turbine and the other is 12 MW
Extraction cum Condensation Turbine.
Back Pressure cum Extraction turbines can either be single stage or multi-stage which
are often used in industrial plants, the turbine serves as a reducing station between
boiler and the process steam header.
These turbines can either be used for drive application (Sugar mill drives, Sugar fibrizor /
Shredder drive, Pump drives and so on) or power generation application in which case
the turbine drives the generator. These turbines are straight-back pressure type and find
application where back pressure steam is fully utilized to meet process demands. The
power generation is incidental to the process steam demand.
The back pressure turbine may also have bleed points (uncontrolled extractions) to
satisfy steam demands at intermediate pressures. This provision is applicable when the
bleed (medium pressure) steam volume demand is low and pressure variations can be
tolerated. These turbines are of bleed cum back pressure type.
The back pressure turbine with one controlled extraction point is possible, this
extraction steam is also used to meet process steam demand at intermediate pressure
when volume demand is high and pressure variations cannot be tolerated. These
turbines are of extraction cum back pressure type.
12 MW SKODA–JINMA Extraction cum Condensation Turbine
The SKODA steam turbine is impulse condensing type, with one controlled extraction,
without reheating. It is used for generating along with the boiler, generator and the
other auxiliary facility. The extracted steam can be used for industrial usage, such as the
process of iron works, chemical factory, sugar factory etc. It can not only supply the
electric power, but also improve the economics of the heating supply system. Turbine is
single casing, located on common frame with the gear box. Admission steam is leaded
into turbine inlet through stop valve, which is mounted directly on side of the control
valve chamber. The control valve chamber is connected by flange with upper part of

turbine casing. The turbine has four control valves over-hanged on the cross beam. The
lift of this cross beam (that is also the opening of the control valves) is controlled by the
control valve servomotor, which located on the cover of the front bearing pedestal.
Steam pass through the opening of the control valves, and then the nozzle, and then
flows into the first governing stage of turbine. After the first pressure stage, one part of
steam will be extracted for industry, another part of steam will be extracted for
deaeration after the 5th pressure stage. The extraction after the 7th pressure stage is an
uncontrolled one for the low pressure heater. The flow part consists of two control
stages and ten pressure stages. All rotating blades of the first governing stage are
equipped by double shrouds (the inner riveted, the outer is integrated), and the moving
blades are mounted by means of forked root. The moving blades of other stages use
"T"-root, the last locking blade is inserted in a special lock and secured by pin. The
moving blades of the last stage uses the four-forked root. Except for the last four stages,
circumferential packing is formed by rotating edge on shrouds, packing against the
insertion piece, which is caulked into diaphragm. And the last four stages are equipped
by twisted blades without shrouds. All diaphragms use weld structure. Blades of each
stage are welded into a piece of grid, and then welded into the disc of diaphragm. The
extractions are both adopt control valve to control the steam extraction. On rotor in
place under nozzle chambers, there is by gradation of diameter made compensatory
steam-piston, which compensates part of axial force. Rotor is integrally forged and is
connected with the gear-box and then the generator separately by the membrane
couplings of the high-speed shaft and the low-speed shaft. Rotor is supported by two
radial bearings. The front bearing is made as combination with axial bearing, and it is
fixed on the front bearing pedestal. The equipment of hydraulic control system and the
protection system are also mounted in the pedestal. The front bearing pedestal is
located on the common base frame, and adjusted to the center of the turbine by the
guide key which make it can expand free on the frame. The front part of the casing is
hanged on the front bearing pedestal and the frame separately by means of the carrying
footer. And the keys in the horizontal joint make turbine free expand along the traverse
direction. The guide key between the front bearing pedestal and the base frame make
turbine can expand free in the axial direction. The connecting piece between the lower
part of the front casing and the front bearing pedestal is located the casing and make
turbine can expand free in the vertical direction. The rear-bearing is fixed on the rear
bearing pedestal which is connected with the rear casing by the semicircle flange. Rear
casing is supported on the frame by bracket each side. The intersection of the central

line of the keys (which is located between the brackets and the frame) and the axial line
of the pin (which is located between the rear casing surface and the frame) form the
dead point of the turbine. The front casing of turbine is integrally casting, and the rear
casing use weld structure. Turbine casing is divided into two parts (lower and upper) in
horizontal interface. The lower and upper part of casing is connected by bolts. The front
nozzle chamber which assembled with control valve and stop valve is located in the
front of the upper casing. The two extraction nozzle chambers are welded into two parts
with nozzles and located on the lower casing. The gland extraction flange and the
leakage flange are located in the front of the lower casing. And one extraction are
located after the 1st pressure stage. The extract steam parameter can be regulated by
the extraction control valves. The levers of extraction control valves are connected with
the extraction control valve servomotor. By the control system, auto regulating the
opening of the extraction valve to ensure the extract steam parameter stably at
deferent loading. Two reheated extraction flange are located after the 5th and 7th
pressure stage of the lower casing. The exhaust steam flows into the rear casing, and
then exhaust to the condenser finally. The turning gear located between the rear
bearing and the coupling. It is used for turning rotor before turbine start-up and after
turbine shut-down, to avoid deflection of rotor until the temperature of outer surface of
casing less than 100℃. The turning gear is driven by a 3-phase motor. Keep the speed of
the turning gear rotor 9 r/min by means of a pair of worm wheel and a pair of gears.
When the turbine start up, the turbine rotor speed ups more than the turning gear
speed, the turning gear can trip automatically. When the turbine shut down, the turning
gear is allowed to put into use after the rotor stop completely.

3.8 MW TURBINE
12MW TURBINE SPECIFICATION
Turbine control system
Turbine control system is electric-hydraulic. The speed is controlled by WOODWARD
505E which provide a communication series and Modbus to connect with the control
center. Turbine use ProTech 203 over-speed protection system. The steam input the
turbine by main stop valve which is connected to the control valve chamber and

operated by a hydraulic actuator. The admission steam volume at the turbine inlet is
controlled by four control-valves. Spindles of valves are leisurely over-hanged on the
cross beam. Lift of this cross beam is controlled by the control valve servomotor which
located on the cover of the front bearing pedestal. The control valve chamber is
connected by flange with upper part of turbine casing. The nozzle blocks are located in
the upper casing also. The opening of the control valves are given by the secondary oil
pressure, which is generated by the distributing oil in the electric-hydraulic converter
CPC. The opening of the stop valve is given by quick-closing oil, which is generated by
the distributing oil in the main relay after its engagement into working position. The
main relay will act to cut down the quick-closing oil just as it gets the trip pulse from the
protect equipment or the over-speed protection system acts. Then the stop valve will be
closed to make the turbine shut down. The opening of the extraction control valves are
given by the secondary oil pressure, which is generated by the distributing oil in another
electric-hydraulic converter CPC.
Description of individual parts of the control system
Main Relay- The main relay is a component which can receives the pulses for turbine
shut-down from each protection systems and cut down the quick-closing oil. When the
main relay is engaged , the operation oil flow into top chamber of main relay, the piston
conquer the spring force by the means of oil pressure and move into working position,
close the drain of the quick-closing oil , build the quick-closing oil pressure. Then the
main stop valve opened by means of the quick-closing oil. The main relay will disengage
from the working position when the operation oil lose its pressure, then the quick-
closing oil lose its pressure, and main stop valve is closed and the turbine shut down.
Electro accelerator- When the switch for paralleling exterior electric network skips,
turbine control valve will be close 2-3 seconds to avoid turbine over-speed. In normal
situatio , the ele t o ag et of ele t o a ele ato does ’t o k. Whe the s it h fo
paralleling skips, the electromagnet will be electrified 2-3 seconds to release the
secondary oil, then the control valve close. After 2-3 seconds, the trip relay lose
electricity, the secondary oil will be controlled by speed controller again. When the
quick-closing oil pressure loss, the electro accelerator will also release the secondary oil,
then close the control valve.
Turbine protection system- The ProTech 203 over-speed protection system is a digital
over-speed trip device, that senses the turbine speed through three magnetic pick-

ups(MPUs). It consists of three identical independent speed sensing units, which are
continuously monitoring the turbine speed and activate the electro-hydraulic trip device
(saddle valves) in case when they are detected the over speed conditions. The three
channels of the ProTech 203 system are evaluated by voting two of three signals, what
considerably increases the protection reliability. The unit functions include the ability to
display the actual speed measured by each separate pick up, they display the highest
speed during the actual trip and during the over-speed testing. The modular design
allows to replace a defected unit during the normal operation. Light Emitting Diodes
LEDs a d digital displa o the u it’s f o t pa el i di ate the function status.
Stop valve- It is located at the turbine steam inlet and controlled by its actuator. The
piston of actuator is operated by spring force on one side and by quick-closing oil on the
other side. The quick-closing oil is brought to the oil cylinder via a slide valve orifice. This
will cause the piston move upward against the spring force and the valve open. In case
of the quick-closing oil pressure loss, the slide valve move downward and cut off the
quick-closing oil then the main stop valve closed. There is a test device on the stop
valve. It can make the piston move downward a few millimeters in order to check the
valve rod get stuck or not.
Control valve- The control valve controls the amount of steam coming into turbine. All
four valves are hanged on the cross beam. Its lift is controlled by the control valve
servomotor, and is corresponding to the pressure of secondary oil. The control valve
closed quickly by the action of spring discs when the high pressure oil loses pressure.
The opening of valve opening is also given by secondary oil pressure.
Extraction control valve- The extraction control valve can controls the extraction steam
flow. All four valves are hanged on the crossbeam. Its lift is controlled by its servomotor,
and is corresponding to the pressure of tertiary oil. The control valve closed quickly by
the action of spring discs when the high-pressure oil loses pressure.
Extraction non-return stop valve- It is located at the extraction outlet. When the
pressure of bled steam tapping point is equal to or higher than the pressure of
extraction piping, turbine will begin to extract steam. When failures in the piping appear
or the load of turbine drops suddenly, causes the extraction pressure lower than the
piping pressure, the non-return stop valve will close automatically to avoid the steam

flow back into the casing. When turbine shutdown, the high-pressure oil will be released
to close the non-return stop valve.
Electro-hydraulic converter- Adjustive process of electro-hydraulic converter is as
follow : Input speed, electric power or extraction pressure signal of turbine to
electronic controller by sensor. After the electronic controller compare the input signal,
then output the signals to control the opening of control valve and extraction control
valve. The signals convert to the pressure of control oil corresponding by electro-
hydraulic converter.
Gland steam system
Turbine adopt front and rear gland system in order to avoid steam leak out from the
front part of casing and air seep in from the rear part of casing. A contact less labyrinth
glands seal the clearance between the rotor and casing. The glands are designed with
sealing edges that are caulked into the rotor, while the gland body adopts flanged type
and seated in the turbine casing. Front glands are divided into three compartments,
while the rear glands have two compartments. The high pressure gland steam from
front gland leads into the 2nd bled steam tapping point directly as part of the extraction
steam for deaeration. The middle part of gland steam from front gland leads into the
front part of the rear gland as sealing steam. During start-up, one part of main steam is
treated to fall the temperature and pressure, and then as the sealing steam. The sealing
steam is controlled by two control valves, and its pressure will be controlled in stable
range. When its pressure falls down, it will be filled up by main steam; while its pressure
raises, one part of it will flow into condenser after control valve, and the other part will
flow into the gland condenser. The leakage steam from rear gland and the low pressure
part of front gland, lead into leakage steam condenser directly. The high pressure
leakage steam from the main stop valve and the control valve is leaded into the middle
part of front gland, while the low pressure leakage steam is leaded into the low pressure
part of front gland.
Measurement of turbine
The measurement system of the turbine provides enough reliable information for
turbine starting up and nominal operating. Turbine must have security system and alarm
system which can indicate the abnormal operation or send out pulse signal to close the
main stop valve, shut down the turbine. The main information can be shown on the

control room. The measuring box which equipped with some pressure gauges, speed
tachometer etc. are located in the front of the turbine.
Turbine trip points

SWITCHGEAR
The apparatus used for switching, controlling and protecting the electrical circuits and
equipment is known as switchgear.
The switchgear equipment is essentially concerned with switching and interrupting
currents either under normal or abnormal operating conditions. The tumbler switch
with ordinary fuse is the simplest form of switchgear and is used to control and protect
lights and other equipment in homes, office etc. for higher rating, a high-rupturing
capacity(H.R.C.)fuse in conjunction with a switch may serve the purpose of controlling
and protecting the circuit. However, such a switchgear cannot be used profitably on
high voltage system(3.3 kV) for two reasons. Firstly, when a fuse blows, it takes some
time to replace it and consequently there is interruption of service to the customers.
Secondly, the fuse cannot successfully interrupt large fault currents that result from the
faults on high voltage system. With the advancement of power system, lines and other
equipments operate at high voltages and carry large currents. When a short circuit
occurs on the system, heavy current flowing through the equipment may cause
considerable damage. In order to interrupt such heavy fault currents, automatic circuit
breakers (or simply circuit breakers) are use. A circuit breaker is a switchgear which
where a fuse is inadequate, as regards to breaking capacity, a circuit breaker may be
preferable. It is because a circuit breaker can close circuits, as well as break them
without replacement and thus has wider range of use altogether than fuse. Essential
Features of Switchgear
1. Complete reliability
2. Absolutely certain discrimination
3. Quick operation
4. Provision for manual control
5. Provision for instruments

BASIC OBJECTIVES OF SYSTEM PROTECTION
The fundamental objective of system protection is to provide isolation of a problem
area in the power system quickly, so that the shock to the rest of the system is
minimized and as much as possible is left intact. Within this context, there are five basic
facts of protective relay application. The five basic facts are:
1. Reliability: assurance that the protection will perform correctly.
2. Selectivity: maximum continuity of service with minimum system disconnection.
3. Speed of operation: minimum fault duration and consequent equipment damage and
system instability.
4. Simplicity: minimum protective equipment and associated circuitry to achieve the
protection objectives.
5. Economics: maximum protection at minimal total cost.

SWITCHYARD
Switchyard plays a very important role as a buffer between the generation and
transmission. It is a junction, which carries the generated power to its destination (i.e.
consumers). Switchyard is basically a yard or an open area where many different
kinds of equipments are located
Switchyards can be of400KV &132KV.
The switchyard at IGL Gorakhpur is 132 KV.

The substation is an assembly of the following major electrical equipments:
Power Transformer:
A static electrical machine used for transforming power from one circuit to another
circuit without changing frequency is termed as Power transformer. The transformers
are generally used to step down or step up the voltage levels of a system for
transmission and generation purpose. These transformers are classified into different
types based on their design, utilization purpose, installation methods, and so on.
Power rating 12.5 MVA
Voltage rating 132/11 kV
Current (HV) 54.67A
Current (LV) 656.08A
Phase Three
Frequency 50 Hz
Auxiliaries of power transformer:
Bushing: bushing allows an electrical conductor to pass safely through a grounded
conducting barrier such as the case of a transformer or circuit breaker.
Oil temperature meter: This meter indicates the temperature of transformer oil. If
temperature crosses a certain level then it makes an alarm.
Winding temperature meter: this meter indicated the temperature of transformer
winding.
Silica gel: Air draft is used for cooling the winding of the transformer. Silica gel absorbs
the moisture from the air inducted in the transformer. When it is fresh it is blue in color,
after absorbing moisture it becomes pink in color.
Radiator: This is used to radiate the heat of a transformer when transformer is heated up
at a certain level.

Bucholz relay: The Buchholz protection is a mechanical fault detector for electrical
faults in oil-immersed transformers. The Buchholz (gas) relay is placed in the piping
between the transformer main tank and the oil conservator. The conservator pipe must be
inclined slightly for reliable operation.
Often there is a bypass pipe that makes it possible to take the Buchholz relay out of
service.
Pressure Relief Valve: Pressure relief devices are specially designed to release pressure
inside the transformer to reduce the risk of explosion of the transformer itself.
In case of sudden and uncontrolled increase in pressure inside the transformer, the
pressure relief device allows the discharge of insulating fluid in milliseconds time
facilitating the decrease of the pressure.
Instrument Transformers:
The current and voltage transformers are together called as the Instrument transformers.

Current Transformer
Current transformer is used for the measurement of the alternating current by taking
samples of the higher currents of the system. These reduced samples are in accurate
proportions with the actual high currents of the system. These are used for installation
and maintenance of the current relays in substations for protection purpose which are
normally have low-current ratings for their operation.
Potential Transformer
Potential transformer is quite similar to the current transformer, but it is used for taking
samples of high voltages of a system for providing low-voltage to the relays of protection
system and also to the low-rating meters for voltage measurement. From this low-voltage
measurement, the actual system’s high voltage can be calculated without measuring high
voltages directly to avoid the cost of the measurement system.
Conductors
Conductors
The material or object that obeys the electrical property conductance (mostly made of
metals such as aluminum and copper) and that allows the flow of electric charge is
called conductor. Conductors permit free movement of the flow of electrons through
them. These are used for the transmission of power or electrical energy from one place
(generating station) to another place (consumer point where power is consumed by the
loads) through substations. Conductors are of different types and mostly aluminum
conductors are preferred in practical power systems.

ALUMINIUM CONDUCTOR STEEL REINFORCED (ACSR) is the most commonly
used conductor.
APPLICATIONS: Used as bare overhead transmission conductor and as primary and
secondary distribution conductor and messenger support. ACSR offers optimal strength
for line design. Variable steel core stranding enables desired strength to be achieved
without sacrificing ampacity.
CONSTRUCTION
-H19 wires, concentrically stranded about a steel core. Standard core
wire for ACSR is class A galvanized.
-5% aluminium - mischmetal alloy
coating.
orrosion protection is available through the application of grease to the
core or infusion of the complete cable with grease.
-specular.
In IGL Gorakhpur PANTHER 30/7 ACSR conductors are used.

Insulators
Insulators
The metal which does not allow free movement of electrons or electric charge is called
as an insulator. Hence, insulators resist electricity with their high resisting property.
There are different types of insulators such as suspension type, strain type, stray type,
shackle, pin type and so on. A few types of insulators are shown in the above figure.
Insulators are used for insulation purpose while erecting electric poles with conductors
to avoid short circuit and for other insulation requirements.
TYPES OF INSULATORS
These are the common classes of insulator:
PIN TYPE INSULATORS – As the name suggests, the pin type insulator is mounted
on a pin on the cross-arm on the pole. There is a groove on the upper end of the
insulator.he conductor passes through this groove and is tied to the insulator with
annealed wire of the same material as the conductor. Pin type insulators are used for
transmission and distribution of electric power at voltages up to 33 kV. Beyond operating
voltage of 33 kV, the pin type insulators become too bulky and hence uneconomical.

SUSPENSION INSULATORS– For voltages greater than 33 kV, it is a usual practice
to use suspension type insulators shown in Figure. Consist of a number of porcelain discs
connected in series by metal links in the form of a string. The conductor is suspended at
the bottom end of this string while the other end of the string is secured to the cross-arm
of the tower. The number of disc units used depends on the voltage.
STRAIN INSULATORS– A dead end or anchor pole or tower is used where a
straight section of line ends, or angles off in another direction. These poles must
withstand the lateral (horizontal) tension of the long straight section of wire. In order to
support this lateral load, strain insulators are used. For low voltage lines (less than 11
kV), shackle insulators are used as strain insulators. However, for high voltage
transmission lines, strings of cap-and-pin (disc) insulators are used, attached to the cross
arm in a horizontal direction. When the tension load in lines is exceedingly high, such as
at long river spans, two or more strings are used in parallel.
SHACKLE INSULATORS– In early days, the shackle insulators were used as strain
insulators. But now a day, they are frequently used for low voltage distribution lines.
Such insulators can be used either in a horizontal position or in a vertical position. They
can be directly fixed to the pole with a bolt or to the cross arm.
ISOLATORS
In electrical engineering isolator switch is used to ensure that an electrical circuit is
completely de-energised for service or maintenance. Such switches are often found in
electrical distribution and industrial applications, where machinery must have its source
of driving power removed for adjustment or repair. High-voltage isolation switches are
used in electrical substations to allow isolation of apparatus such as circuit breakers,
transformers, and transmission lines, for maintenance. The isolator is usually not
intended for normal control of the circuit, but only for safety isolation. Isolator can be
operated either manually or automatically (motorized isolator). Unlike load break
switches and circuit breakers, isolators lack a mechanism for suppression of electric arc,
which occurs when conductors carrying high currents are electrically interrupted. Thus,
they are off-load devices, 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 isolator while it supplies a circuit. Standards in some countries
for safety may require either local motor isolators or lockable overloads (which can be
padlocked). Isolators have provisions for a padlock so that inadvertent operation is not
possible (lockout-tagout). In high-voltage or complex systems, these padlocks may be
part of a trapped-key interlock system to ensure proper sequence of operation. In some
designs, the isolator switch has the additional ability to earth the isolated circuit thereby
providing additional safety. Such an arrangement would apply to circuits which inter-
connect power distribution systems where both ends of the circuit need to be isolated.
Bus Bars
Bus bars
The conductor carrying current and having multiple numbers of incoming and outgoing
line connections can be called as bus bar, which is commonly used in substations. These
are classified into different types like single bus, double bus and ring bus.
Lightening Arresters

Lightening Arresters
Surge arresters are devices that help prevent damage to apparatus due to high voltages.
The arrester provides a low-impedance path to ground for the current from a lightning
strike or transient voltage and then restores to a normal operating conditions.
When a high voltage (greater than the normal line voltage) exists on the line, the
arrester immediately furnishes a path to ground and thus limits and drains off the
excess voltage. The arrester must provide this relief and then prevent any further flow
of current to ground. The arrester has two functions; it must provide a point in the
circuit at which an over-voltage pulse can pass to ground and second, to prevent any
follow-up current from flowing to ground. It is connected in parallel and it is equipped
with a surge counter which counts that how many times it is operated. LA is generally
connected at the starting/end of the line in parallel. Fig below shows the basic form of a
surge diverter. It consists of a spark gap in series with a non-linear resistor. One end of
the diverter is connected to the high voltage terminal and the other end is effectively
grounded. The length of the gap is so set that normal voltage is not enough to cause an
arc but a dangerously high voltage will break down the air insulation and form an arc.
The property of the non-linear resistance is that its resistance increases as the voltage
(or current) increases and vice-versa. This is clear from the volt/amp characteristic of
the resistor shown in Figure above. The action of the lightning arrester or surge diverter
is as under:
1. Under normal operation, the lightning arrester is off the line i.e. it conducts no
current to earth or the gap is non-conducting
2. On the occurrence of over voltage, the air insulation across the gap breaks down and
an arc is formed providing a low resistance path for the surge to the ground. In this way,

the excess charge on the line due to the surge is harmlessly conducted through the
arrester to the ground instead of being sent back over the line.
Circuit Breakers
For the protection of substation and its components from the over currents or over load
due to short circuit or any other fault the faulty section is disconnected from the healthy
section either manually or automatically. If once the fault is rectified, then again the
original circuit can be rebuilt by manually or automatically. Different types of circuit
breakers are designed based on different criteria and usage. But in general mostly used
circuit breakers are Oil circuit breaker, Air circuit breaker, SF6 circuit breaker, Vacuum
Circuit Breaker, and so on.
SF6 Circuit Breaker: A circuit breaker in which the current carrying contacts operate in
sulphur hexafluoride or SF6 gas is known as an SF6 circuit breaker. SF6 has excellent
insulating property. SF6 has high electro-negativity. That means it has high affinity of
absorbing free electron. Whenever a free electron collides with the SF6 gas molecule, it
is absorbed by that gas molecule and forms a negative ion. The attachment of electron
with SF6 gas molecules may occur in two different ways,

These negative ions obviously much heavier than a free electron and therefore over all
mobility of the charged particle in the SF6 gas is much less as compared other common
gases. We know that mobility of charged particle is majorly responsible for conducting
current through a gas. Hence, for heavier and less mobile charged particles in SF6 gas, it
acquires very high dielectric strength.
Not only the gas has a good dielectric strength but also it has the unique property of fast
recombination after the source energizing the spark is removed. The gas has also very
good heat transfer property. Due to its low gaseous viscosity (because of less molecular
mobility) SF6 gas can efficiently transfer heat by convection. So due to its high dielectric
strength and high cooling effect SF6 gas is approximately 100 times more effective arc
quenching media than air. Due to these unique properties of this gas SF6 circuit breaker
is used in complete range of medium voltage and high voltage electrical power system.
These circuit breakers are available for the voltage ranges from 33KV to 800 KV and
even more.
RELAYS
Relays
Relays are used for disconnecting the circuits by manual or automatic operation. Relay
consists of the coil which is excited or energized and such that making the contacts of
relay closed activates the relay to break or make the circuit connection. There
are different types of relays such as over current relays, definite time over current
relays, voltage relays, auxiliary relays, reclosing relays, solid state relays, directional

relays,inverse time over current relays, microcontroller relays, etc. The above figure
shows some basic relays and their operation.
SURGE MONITOR
It permits recording of the number of discharges seen by the arrester as well as their
amplitude with time-stamp, together with measurement of the total leakage current
and resistive current through the arrester. The data permits diagnostic analysis of the
surge arrester's performance and state of health over time as part of a Smart Grid
approach to system reliability. Model SM-T2B-3R surge monitor is used in the
switchyard.
EARTH SWITCHES
It is used to ground sections required for maintenance. It is interlocked with breakers
and isolators. It is operated locally only.

OPERATION AND CONTROL SYSTEM
SCADA
As the demand for reliable power became greater and as labor became a more
significant part of the cost of providing electric power, technologies known as
supe iso o t ol a d data a uisitio , o “CADA fo sho t , were developed that
would allow remote monitoring and even control of key system parameters. SCADA
systems began to reduce and even eliminate the need for personal to be on the handed
at substation.
HISTORICAL PERSPECTIVE
d remote indication an control of substation parameter
using technology borrowed from automatic telephone switching system.
- o t ol p odu ts ased o its
su essful li e of “t o ge telepho e s it hing apparatus.
-type electromechanical rely at both ends
of o e tio al t isted-pai telepho e i uit slo data ate a d late of data as
very poor – 10bit/s - so only the limited amount of data could be transfered using this
technology).
remote terminal unit (RTUs).
While the microprocessor offered the potential for greatly increased functionality at
lower cost, the industry also demanded very high reliability. By the late 1970s and early
1980s, integrated microprocessor –based devices were introduced, which came to be
k o as i tellige t ele t o i de i es o IED.
SCADA FUNCTIONAL REQUIREMENTS
Functional requirements capture intended behaviour of the system. This behavior may
be expressed as services , tasks, or functions the system is reqiured to perform. In the
case of SCADA,
 It will contain such information as system status points to be monitored, desired
control points, and analog quantities to be monitored.

 It will also include identification of acceptable delays between when an event
happens and when it is reported, required precision for analog quantities, and
acceptable reliability levels.
 It will also include a determination of the number of remote points to be
monitored and controlled.
 It will also include a formal recognition of the physical, electrical,
communications, and security environment in which the communication is
expected to operate.
SCADA COMMUNICATION REQUIREMENTS
Communication requirements include those elements that must be included in order to
meet the function requirements
 Identification of communication traffic flows --- source / destination / quantity.
 Overall system topology --- for example star, mesh
 Identification of end system locations
 Device/processor capabilities
 Device/processor capabilities
 Timing issues
 Device addressing scheme
 Application data formats
 Qualification of electromagnetic interfernce withstand requirement
 Application data formats.
RELAY COMMUNICATION REQUIREMENTS
Communication system are a vital component of wide area power system relaying. They
provide the information links needed for the relay and control systems to operate. Relay
system perform vital functions to isolate local failures in generation, transmission, and
distribution systems so that they will not spread to other of the interconnected power
system. Because of potential loss of comunnication, relay systems must be designed to
detect and tolerate failures in the communication system. Several communication
systems, which can be used for relay or SCADA communications. It should be noted that

frequently relay applications have more stringent requirements for speed, latency, and
jitter than do SCADA applications. Electric utilities use a combination of analog and
digital communication systems for their operations consisting of following:
COMPONENTS OF SCADA SYSTEM
SCADA systems employ a computerized SCADA master in which the remote information
is eithe displa ed o a ope ato ’s o pute te i al o ade a aila le to a la ge
e e g a age e t s ste th ough et o ked o e tio s. The su statio RTU is
either hardwired to digital, analog, and control points or frequently acts as a
su aste o data o e t ato i hi h o e tio s to i telllige t de i es i side
the substation are made using communication link. With the introduction of
networkable communication protocols, typified by the IEC 61850 series of standard of
standards, it is now possible to simultaneously support communication with multi
clients located at multiple remote locations.
There are many parts of a working SCADA system. A SCADA system includes signal
hardware (input and output), controllers, networks, user interface (HMI),
communications equipment and software. All together, the term SCADA refers to the
entire central system.
The central system monitors data from various sensors that are either in close proximity
or off site (sometimes miles away). For the most part, the brains of a SCADA system are
performed by the Remote Terminal Units (sometimes referred to as the RTU). The
Remote Terminal Units consists of a programmable logic controller. The RTU are set to
specific requirements, however, most RTU allow human intervention, for instance, in a
factory setting, the RTU might control the setting of a conveyer belt, and the speed can be
changed or overridden at any time by human intervention. In addition, any changes or

errors are automatically logged for and/or displayed. Most often, a SCADA system will
monitor and make slight changes to function optimally;
SCADA systems are considered closed loop systems and run with relatively little human
intervention. One of key processes of SCADA is the ability to monitor an entire system in
real time. This is facilitated by data acquisitions including meter reading, checking
statuses of sensors, etc that are communicated at regular intervals depending on the
system. Besides the data being used by the RTU, it is also displayed to a human that is
able to interface with the system to override settings or make changes when necessary.
SCADA can be seen as a system with many data elements called points. Each point is a
monitor or sensor. Points can be either hard or soft. A hard data point can be an actual
monitor; a soft point can be seen as an application or software calculation. Data
elements from hard and soft points are always recorded and logged to create a time
stamp or history.
Fig3. Scada system
THE PLANT INFORMATION (PI) SYSTEM
Operating a process manufacturing plant is complex. Companies are constantly
challenged to operate at an acceptable profit in the face of changing business conditions

and increasing global competition. Engineering and operations management make
critical operating decisions on a daily basis that affects profitability, plant efficiency and
safety. These decisions include scheduling, product mix to match pricing and demand,
configuring equipment for highest productivity, scheduling equipment outages, planning
equipment replacements or upgrades, and conforming to environmental and safety
standards. A key competitive advantage in making these decisions is to have a clear
knowledge of plant operations at the fingertips of plant personnel. This enables the
operations of the entire plant to be optimized relative to the equipment capabilities and
chemistry of the processes. A complete history of all plant variables is a valuable asset in
achieving optimum performance in a manufacturing operation. Since it is difficult to
know in advance which plant measurements will be needed for future analysis, storing
everything is the best method to safeguard against not having the required information.
With knowledge of the current and historical state of operations, many potential
problems can be diagnosed and corrected before they have a negative effect on plant
operations. People can use the information as a road map to process improvements,
reduced raw materials consumption, increased production and better safety. A plant
information infrastructure is needed that serves the plant process data up to the
Microsoft desktop for operations, engineering and management. This infrastructure
must also serve data to software applications that require high-resolution real time and
historical plant process data to analyze plant performance.
PI SYSTEM AS AN INFORMATION SYSTEM DESIGNED FOR THE MANUFACTURING
ENVIRONMENT

The Plant Information (PI) System is a set of software modules designed for plant-wide
monitoring and analysis. The PI System Data Archive is the foundation of this system. It
handles the collection, storage, and retrieval of numerical and string data. It also acts as
a data server for Microsoft Windows-based client applications. Operators, engineers,
managers, and other plant personnel use these client applications to view the plant data
stored in the PI System Data Archive.
The PI data archive accommodates very large real-time and historical databases typically
sized so that every recorded process point (called a "Tag") is stored on-line near its
original resolution for years. The Microsoft-based PI client applications enable personnel
to easily access this high-resolution data to view a plant's current condition while
providing a very clear and accurate picture of past operations. Data access to and from
the PI Data Archive is extremely fast. Users can retrieve the information they need
within a few seconds regardless of the number of tags or the size of the archive. PI data
can be used for plant and corporate initiatives such as process improvement, total
quality control, and predictive maintenance. The unified plant data repository ensures
that all individuals view and analyze the same data. Software applications such as
maintenance management, expert systems, LIMS (Laboratory information management
system), and optimization/modeling programs can use PI to gain access to real time
data. The PI System can link real time control systems to production planning systems
and enterprise resource planning systems to bridge the gap between business and real-
time production environments. OSI (Open system interconnection) has put a premium
on functionality, reliability, performance, and maintainability in the development of the
PI System products. The PI System is designed to be easy to install, maintain and use.
Inexpensive migration paths that preserve the existing plant historical data are provided
to update legacy PI systems to the Windows NT based technology. New features are
extensively tested for compatibility with older versions.
BENEFITS OF THE P.I. SYSTEM
Lower Production Costs: The PI System's data analysis and graphical tools permit
problems to be resolved faster, and often prevent small conditions from becoming
major upsets. Many companies report that the data stored in PI allow them to improve
their preventative maintenance programs, increasing equipment life. These uses result
in increased production and lower operation costs. In addition, the PI System
contributes to yield improvements and less waste. When the lab system sends massages

to operation via the PI System, for example, the time required to change grades
decreases, increasing production and minimizing waste. Increased Productivity and
Improved Process Knowledge: Less time is wasted trying to obtain data and information
relating to a problem, so more time is available for solving it. Everyone throughout the
facility uses a common set of data, eliminating discussions of whose data set is "right",
again contributing to a more productive use of everyone's time. Also, application
developed internally with the PI System, such as performance monitoring and efficiency
calculations may be shared between sites, reducing development time.
FUNCTIONS OF P.I. SYSTEM
INTERFACES TO HIGHLY COMPLEX MANUFACTURING ENVIRONMENTS
PI provides data pipes from hundreds of different manufacturing automation devices to
bring all of the plant operating data into a common data format in a time series
database. Real-time and historical data is available from this database to the entire
corporation via the Microsoft desktop.
PI PROVIDES REAL TIME AND HISTORICAL DATA ACCESS
At the heart of the PI System is the PI Data Archive, a real-time database optimized for
storing and retrieving time series data. This is where the plant process information, i.e.
pressures, flows, temperatures, setpoints, on/offs, etc. are stored. The major design
features of PI Data Archive are listed below. Captures all data related to operations or
production. By capturing all process data in a single repository, PI can create an
accurate picture of current and past plant operations. All users can access the same
information but with different views and perspectives. A process engineer can quickly
analyze current process performance. A maintenance engineer can view historical data
looking for degradation in equipment performance. Stores data on-line long-term.
Several years worth of process data can be available within a few seconds of the request
by the user or application. Users can pick up seasonal variations in the process, analyze
equipment run times, and view cycles of production. PI utilities are available to archive
off-line any old data that is no longer routinely used. Stores data only once. Because the
PI system stores data in its fundamental form, the data can be used for different
purposes without any data discrepancy. Users can query and view current, historical, or
statistical data with PI client software. Users and applications can request the data to be
calculated and delivered in many formats including summarized or "aggregate" data.

This eliminates the need to decide ahead of time how to summarize the information for
reports or for data analysis. Stores data efficiently. Traditionally companies heavily
summarized data to reduce the amount of disk storage required. The PI Data Archive
uses the "Swinging Door" compression algorithm to store information for thousands of
points to their original time resolution, without requiring vast amounts of disk storage.
Stores data to its original resolution. The PI Data Archive is designed to store process
and event information without loss of time resolution. Data is collected and stored as a
function of its fundamental accuracy and time resolution. For example, if a process
variable is capable of moving very quickly, data for that point is stored at a high time
resolution. The "Swinging Door" compression algorithm ensures that data retrieved
from the Data Archive is always represented within the accuracy specified for each
point.
PROVIDES A DEVELOPMENT ENVIRONMENT FOR INTEGRATING ERP WITH THE PLANT
FLOOR
Many major corporations have implemented ERP systems for integrated financial,
manufacturing, sales, distribution and human resource support. To get the maximum
benefit from ERP, they need to close the loop between the operating decisions made
using ERP and the plant floor operations. The PI System with it's extensive library of
gateways to plant floor automation is the ideal middle tier software to integrate the
factory floor to major ERP vendors such as SAP, Baan, J.D Edwards and PeopleSoft.
SUBSTATION
DISTRIBUTED CONTROL SYSTEM
A distributed control system (DCS) refers to a control system usually of a manufacturing
system, process or any kind of dynamic system, in which the controller elements are not
central but are distributed throughout the system with each component sub-system
controlled by one or more controllers. The entire system of controllers is connected by
networks for communication and monitoring. The basic concept of DCS is to distribute
the control system both functionally and geographically.
A DCS typically uses custom designed processors as controllers and uses both
proprietary interconnections and communications protocol for communication. Input
and output modules form component parts of the DCS. The processor receives

information from input modules and sends information to output modules. The input
modules receive information from input instruments in the process (or field) and
transmit instructions to the output instruments in the field. Computer buses or electrical
buses connect the processor and modules through multiplexer or de-multiplexers. Buses
also connect the distributed controllers with the central controller and finally to the
Human–machine interface (HMI) or control consoles.
APPLICATION
A typical DCS consists of functionally and/or geographically distributed digital controllers
capable of executing from 1 to 256 or more regulatory control loops in one control box.
The input/output devices (I/O) can be integral with the controller or located remotely
ia a field et o k. Toda ’s o t olle s ha e e tensive computational capabilities and, in
addition to proportional, integral, and derivative (PID) control, can generally perform
logic and sequential control. Modern DCSs also support neural networks and fuzzy
application. DCSs may employ one or more workstations and can be configured at the
workstation or by an off-line personal computer. Local communication is handled by a
control network with transmission over twisted pair, coaxial, or fiber optic cable. A
server and/or applications processor may be included in the system for extra
computational, data collection, and reporting capability.
BUSBAR ARRANGEMENT
SINGLE BUS-BAR SYSTEM WITH SECTIONALISATION: In large generating stations where
several units are installed, it is a common practice to sectionalise the bus so that fault on
any section of the bus-bar will not cause complete shutdown. The bus-bar divided into
two sections connected by a circuit breaker and isolators. Three principle advantages
are claimed for this arrangement. Firstly, if a fault occurs on any section of the bus-bar,
that section can be isolated without affecting the supply to other sections. Secondly, if a
fault occurs on any feeder, the fault current is much lower than with unsectionalised
bus-bar. This permits the use of circuit breakers of lower capacity in the feeders. Thirdly,
repairs and maintenance of any section of the bus-bar can be carried out by de-
energising that section only, eliminating the possibility of complete shut-down. It is
worthwhile to keep in mind that a circuit breaker should be used as the sectionalising
switch so that uncoupling of the bus-bar may be carried out safely during load transfer.
Moreover, the circuit breaker itself should be provided with isolators on both sides so
that its maintenance can be done while the bus-bar are alive.

POWER CONTROL CENTER (PCC)
PCC shall mean a continuous line-up of breaker panels, used to feed motors and control
operation of valves. PMCC have duplicate incomers and single bus coupler scheme with
both incomer breakers are closed and bus coupler breaker is open under normal
operating condition. Incomers and all outgoing feeders of a PCC shall be breaker
controlled. Distribution of outgoing feeders shall be such as to ensure uniform loading
on each section of the PCC.
MOTOR CONTROL CENTER (MCC)
MCC shall mean a continuous line-up of free standing vertical sections housing breaker
panels, MCCB modules, MCB modules and contactor operated modules. MCC shall be
fed from upstream PMCC and shall generally have duplicate incomers and a bus-coupler
(normally open). Emergency MCC shall have four (4) incomers – Two (2) from 415V Unit
PMCC#1A & 415V Unit PMCC#1B respectively, one (1) from unitized DG PCC and the
other from Standby DG PCC. Incomers and bus-coupler shall be either breaker or MCCB
controlled depending upon the rating. Based on the rating and application, outgoing
feeders may be breaker controlled, MCCB controlled, MCB controlled, or contactor
operated. Distribution of outgoing feeders shall be such as to ensure uniform loading on
each section of the MCC.
AUTOMATIC VOLTAGE REGULATOR
Basically the AVR or Automatic Voltage Regulators function for generator is to ensure
voltage generated from power generator running smooth to maintain the stable voltage
in specified limit. It can stabilize the voltage value when suddenly change of load
for power supply demand. If the generator running in parallel condition, the AVR can
control the voltage that it produce to ensure of equal value for reactive load sharing.
The AVR maintains the voltage from turbine at 11 Kv. In IGL Gorakhpur AVR made by
AMTECH is used.

Programmable logic control panel
A Programmable Logic Controller, PLC or Programmable Controller is a digital
computer used for automation of electromechanical processes, such as control of
machinery on factory assembly lines and control of Electric supply to various electrical
loads.
At IGL Gorakhpur PLC panels used are of Sofcon systems.
Load distribution of IGL Gorakhpur
Date 06/05/16
Time 11:00AM
Total Home Load-4300kW
1.PCC-1(1200 kW)
FCT5-A 40kW
Distillation 0 kW
Molasses 90 kW
New compressor 0 kW
DCT4A 730 kW
2.PCC-2 (1000 kW)
FCT(5B) 215kW

Utility 120 kW
DCT(4B) 556 kW
Distillation(2B) 0 kW
Fermentation 23 kW
3.PCC-3(1200 kW)
10-A 590 kW
Coal handling 103 kW
DM plant 94 kW
10B 455 kW
4.PCC-4 (1500 kW)
SCV I/C-1 750 kW
New decanter 0 kW
Evaporator 336 kW
Fermentation 65 kW
ENA 475 kW
5.PCC-5 (1250 kW)
New CBL 10A 265 kW
New CBL 10B 7275 kW
R/H MCC 190 kW

12 MCC 97 kW
Lippi boiler 156 kW
CT fan-1 97 kW
CT fan-2 103 kW
PROTECTION SCHEMES
Protection Systems have a significant role in maintaining the stability and reliability of
the electric power grid. Their optimal performance plays a vital role and becomes more
critical when the power system is operating near its limits. Protection Systems are used
to detect and isolate faults or to arrest adverse conditions that occur on the grid.
Subsequently, misoperation of these systems must be kept to a minimum. A primary
objective of all power systems is to maintain a very high level of continuity of service,
and when intolerable conditions occur, to minimize the extent and time of the outage.
Loss of power, voltage dips, and overvoltage will occur, however, because it is
impossible, as well as impractical, to avoid the consequences of natural events, physical
accidents, equipment failure, or misoperation owing to human error. Many of these
result in faults: inadvertent, accidental connections and flashovers between the phase
wires or from the phase wires to ground.
Circuit breakers used in IGL substation:
A. Circuit Breaker (supplying power to Distillation MCC, fermentation cooling
tower,1250 KW DG, distillation cooling tower MCC)
In 2000 A
Ue 415 V-50/60 Hz
ICU 55VA
ICS 55 KA

ICW 55 KA for 1 sec
Utilization category B
B. Circuit Breaker(supplying power to molasses MCC, 12 MW MCC, DM plant,
ENA plant and utility MCC)
In 800 A
Ue 415 V-50/60 Hz
ICU 50VA
ICS 50 KA
ICW 50 KA for 1 sec
C. Circuit Breaker(supplying power to DG incomer)
In 3200 A
Ue 415 V-50/60 Hz
ICU 100VA
ICS 100 KA
ICW 100 KA for 1 sec
D. Circuit Breaker(supplying power to pet bottle plant MCC, PCC-1 and PCC-2)
In 4000 A
Ue 415 V-50/60 Hz
ICU 70VA
ICS 70 KA
ICW 70 KA for 1 sec
TECHNIQUES AND EQUIPMENTS FOR PROTECTION
Basic protection scheme used in industries:
1. Transformer protection
a. Bucholz relay

Buchholz relay in transformer is an oil container housed the connecting pipe
from main tank to conservator tank. It has mainly two elements. The upper
element consists of a float. The float is attached to a hinge in such a way that
it can move up and down depending upon the oil level in the Buchholz relay
Container. One mercury switch is fixed on the float. The alignment of mercury
switch hence depends upon the position of the float. The lower element
consists of a baffle plate and mercury switch. This plate is fitted on a hinge
just in front of the inlet (main tank side) of Buchholz relay in transformer in
such a way that when oil enters in the relay from that inlet in high pressure
the alignment of the baffle plate along with the mercury switch attached to it,
will change.
In addition to these main elements a Buchholz relay has gas release pockets
on top. The electrical leads from both mercury switches are taken out through
a molded terminal block.
b. OTI/WTI
OTI device is used to measure the top oil temperature. An oil temperature
indicator or OTI is also used for protection of transformer.
WTI device measures the LV and HV winding temperature. A winding
temperature indicator or WTI is also used as protection of transformer.
c. Pressure Relief Valve
Pressure relief devices are specially designed to release pressure inside the
transformer to reduce the risk of explosion of the transformer itself.
2. Distance protection
a. Overvoltage relay
b. Under voltage relay
3. Differential protection

Current differential relaying is applied to protect many elements of a power
system. The simplest example of a current differential relaying scheme is shown
in figure. Current differential relaying is applied to protect many elements of a
power system.
Apart from the above mentioned protection schemes IGL Gorakhpur has Micom Relay
(designed by Schneider Electric) which is microcontroller based relay and provides
complete protection scheme.
Diesel Generator
DG1
Power 1250 KVA
Voltage 415 V
Excitation volts 85 V
Current 21 A
Speed 1500 rpm
C
Insulation class F
Phase Three
Frequency 50 Hz
Enclosure IP21
Stator connection Star
A diesel generator is the combination of a diesel engine with an electric
generator (often an alternator) to generate electrical energy. This is a specific case
of engine-generator. In IGL diesel generator is used as a backup supply to power the
necessary process plants in case if grid fails. The maximum load connected and the
maximum voltage drop allowed determines the size of diesel generator. The rating does
not determine the size of the diesel generator. The fuel consumption is 150 l/hr if run at
full load.
Two diesel generators are used here. One has power rating of 1250 KVA and other has
power rating of 625 KVA.
The 625 KVA DG has 2 fuel filters. Fuel filters are required to filter the contaminants
from entering the fuel line.

Air starting is provided to produce power to start the diesel generator. When starting
the engine, compressed air is admitted to whichever cylinder has a piston just over top
dead center, forcing it downward.[1]
As the engine starts to turn, the air-start valve on
the next cylinder in line opens to continue the rotation. After several rotations, fuel is
injected into the cylinders, the engine starts running and the air is cut off.
1250 KVA diesel generator at IGL
PLANTS AT IGL Gorakhpur
ENA and RS plant
The two important spirits made here are extra neutral alcohol and rectified spirit. These
are made from molasses.
The Extra Neutral alcohol or ENA is a high distillated alcohol without any impurities and
others destinated to be used in the high cosmetic industry, perfumeries as well as for
the production of alcoholic beverages such as whisky, vodka, gin, cane, liqueurs and
alcoholic fruit beverages and aperitifs.
As a consumer product, it is almost always mixed with other beverages to create such
drinks as punch. It is also used to make homemade liqueurs, such as limoncello, and in
cooking because its high concentration of alcohol acts as a solvent to extract flavors.
Rectified spirits are also used for medicinal tinctures, and as a household solvent.

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