SlideShare a Scribd company logo
1 of 26
REPORT
ON
IN-PLANT TRAINING
CONDUCTED BY
DURATION OF TRAINING: - 6.7.2015 TO 17.7.2015 (10 DAYS)
SUBMITTED BY:-
BHARGAV KUMAR TRIPATHY
107112014
ELECTRICAL AND ELECTRONICS ENGINNERING
NATIONAL INSTITUTE OF TECHNOLOGY
TIRUCHIRAPPALLI
1 | P a g e
CERTIFICATE
This is to certify Mr. BHARGAV KUMAR TRIPATHY who is presently pursuing B.TECH
in ELECTRICAL AND ELECTRONICS ENGINEERING at NATIONAL INSTITUTE OF
TECHNOLOGY, TIRUCHIRAPPALLI has successfully completed the In-Plant training
conducted at BPCL KOCHI REFINERY and has attended the course regularly and has
submitted the report on the training conducted.
Signature and seal of the guide:
2 | P a g e
INTRODUCTION
The Kochi Refinery (KR) is a public crude oil refinery in the city of Kochi, in the state of Kerala, India.
It has a production capacity of 9.5 million tons per annum. Formerly known as Cochin Refineries
Limited and later renamed as Kochi Refineries Limited, it was acquired by Bharat Petroleum
Corporation Limited in the year 2006.
HISTORY
Kochi Refinery started on 27 April 1963 when Government of India, Phillips Petroleum Company of
USA and Duncan Brothers of Calcutta signed an agreement for the construction of a petroleum
refinery in south India, in Kochi, Kerala. The company was formally registered, as Cochin Refineries
Ltd (CRL), on 6 September 1963 at Ernakulam. Phillips Petroleum International Corporation was the
prime contractors for the construction of the refinery. Construction work started in March 1964 and
the first unit came on stream just after 29 months in September 1966. The Prime Minister of India
Ms.Indira Gandhi inaugurated it on 23 September 1966. In 2006, Kochi Refinery was acquired by the
Bharat Petroleum Corporation Limited.
CAPACITY
The refinery had an original design capacity of 2.5 million metric tons per annum (mmtpa) which was
increased to 3.3 mmtpa in 1973. Production of liquefied petroleum gas (LPG) and aviation turbine
fuel (ATF) commenced after this expansion. Refining capacity was further enhanced to 4.5 mmtpa in
November 1984 when a fluidized catalytic cracking unit (FCCU) of 1 MMTPA capacity was added.
In Dec 1994, refining capacity was increased to 7.5 mmtpa (150,000 bpsd) along with revamp of
FCCU to 1.4 MMTPA. A fuel gas de-sulphurisation unit was installed as part of this project to
minimise sulphur dioxide emission. CRL entered into petrochemical sector in 1989 when aromatic
production facilities with a design capacity of 87,200 tons per annum of benzene and 12,000 tons
per annum of toluene was commissioned. In the year 2000, a 2 MMTPA Diesel Hydro De-
sulphurisation (DHDS) plant was added to reduce the sulphur content in Diesel.
In August 2010, the refining capacity was further increased to 9.5 mmtpa (190,000 bpsd). A captive
power plant of 26.3 MW was commissioned in 1991. An additional captive power plant of 17.8 MW
was commissioned in 1998 thus making the refinery self-sufficient in power. An LPG bottling plant of
capacity 44,000 TPA was commissioned in 2003. A Bitumen Emulsion plant of 10000 TPA capacity
has also been commissioned in 2004. A Biturox Bitumen Oxidation Unit of 378,000 TPA capacity was
successfully commissioned and started-up in 2008.
MERGER WITH BPCL
3 | P a g e
Bharat Petroleum Corporation Limited (BPCL) acquired the Government of India's shares in KRL in
March 2001. Consequent to the merger Order dated 18 August, 2006 issued by Ministry of Company
Affairs, the refinery has been amalgamated with Bharat Petroleum Corporation, hence forth to be
known as BPCL-Kochi Refinery.
COMPETENCY
Today Kochi Refinery is a frontline entity as the unit of the Fortune 500 company, BPCL. With a
turnover of around US$2500 million, the refinery aims to strengthen its presence in refining and
marketing of petroleum products and further grow into the energy and petrochemical sectors.
Kochi Refinery produces all fuel based refinery products viz liquefied petroleum gas, naphtha,
gasoline, kerosene, aviation turbine fuel, gas oil, fuel oil, and bitumen. The foray into direct
marketing began since 1993 through marketing its aromatic products: benzene and toluene.
The company entered the International Petroleum business stream when its first parcel of Fuel Oil
was exported in January 2001. Since then the company has exported around 100 parcels. In the last
financial year the refinery exported products worth over US$280 million.
SPECIALTY PRODUCTS
Kochi Refinery makes Specialty products for domestic markets Viz. Benzene, Toluene, White Spirit,
Poly Iso Butane and Sulphur .Kochi Refinery offers supplies of any grade Fuel Oil (both 180 cst and
380 cst) and Low Aromatic Naphthalene (High Paraffinic) to the international market. Kochi Refinery
also produces specialty grade bitumen products like Natural Rubber Modified Bitumen, Bitumen
Emulsion etc .The Fuel Oil has been bench marked in the Singapore and Dubai Fuel Oil markets.
Currently Kochi Refinery is known as BPCL Kochi Refinery (BPCL KR). KR is undergoing a capacity
expansion which will make it a 15MMTPA refinery. This project called Integrated Refinery Expansion
Project will also mark KR's foray into petrochemical business. This is a 20000 cores rupees project.
POWER & UTILITY SECTION (P&U)
In BPCL Kochi refinery the generation and utilization of power utilities is taken care by P&U
Department which is subdivided in electrical section and utilities section. Electrical section takes care
of the electrical maintenance, power generation and distribution. Utilities section takes care of
generation and distribution of various utilities operation. DGM (P&U) heads the P&U department,
Senior Manager in utilities and electrical section assists him.
The power necessity and steam demand have increased considerably since commissioning of
refinery in 1966.A 2.5 MW TG set was commissioned in 1985 along with FCCU and CO boiler. In 1991
a gas turbine cogeneration plant of base load capacity of 21.98 MW and HRSG of steam generation
capacity 50 T/Hr were commissioned. Power and steam demands increased further due to new
projects. Therefore in addition to existing GT and 2.5MW TG anew hp steam boiler UB7 and a
condensing and double extraction type STG of 17.8MW capacity were installed and commissioned in
1997. Along with DHDS plant consisting of 2 boilers UB8 and UB9 of HP steam capacity of 60t/hr
each and nitrogen plant was also commissioned in 2000. To make up the shortfall in steam
4 | P a g e
production from CO Boiler due to FCCU revamp, UB 10 boiler of capacity 80t/hr was commissioned
in 2005.
CAPTIVE POWER PLANT (CPP)
KSEB GRID
Power from the main bus 1 or 2 is stepped down to 33KV using transformers TR1and TR2 which is
received in a 33KV ABB GIS, two 33KV cable feeders bring KSEB power to BPCL and is received as
grid incomer 1 & 2 at 33KV Siemens GIS in GT2 substation.
Power requirement of BPCL-KR is around 55MW under full load operation of all processing
plants.Power is generated and distributed from CPP using two Gas Turbine Generators GTG1 and
GTG2 one steam turbine generator STG (not in use considering the economics and cost). It also
receives power from 220 KV KSEB substation at Ambalamugal via two 33KV feeders -GRID incomer
1&2. Power is then distributed two 11KV/33KV substations from which is distributed to individual
loads. Apart from this there is a 2.5 MW turbo Generator TG whose generation is controlled by
Utilities section. Tie transformers 1, 2, 4 ties 33 KV gas insulated substation GIS to Switch gear SWGR
2101. In secondary distribution system power received at 33KV substation are converted to 6.6,
3.3KV, 415 ac, 230V ac, 110V ac, 110V dc.
The black start transformer is used when bothGT2 and KSEB lines are faulty. The GIS bus will be
charged when using black start transformer. The stationary auxiliary transformer is used by the
auxiliary equipment in the system. The terminal voltage of all the 3 generators are 11KV and GT2 is
connected to 33KV lines after stepping up the voltage using step-up transformer. As GT1 and STG
are both connected to 11KV lines, power transformer is not used. The GIS bus is a 2 bus structure as
shown below. A 2 bus structure is preferred for the continuity of service i.e. even if 1 bus fails other
is able to supply.
WORKING OF GT2 AT A GLANCE
GT2 consists of a diesel engine, turbine, gearbox and compressor. The speed of diesel engine is 2000
rpm. When it attains a speed of 1000 rpm firing is given to the compressor which consists of air and
fuel. When a spark is given to the compressor it ignites the gas used to run the turbine. The diesel
engine is used separately for turbines as it requires high starting power which is obtained from the
diesel engine. Diesel engine, generator and the turbine is connected to the same shaft. Diesel engine
is used for the starting purpose of the turbine, once the turbine attains rated speed (5000rpm) FSNL,
diesel engine is removed. At 60% of the turbine speed, fuel to diesel engine is cut, so its speed
begins to fall while, the turbine remains in the same speed. Turbine and diesel engine is
mechanically connected using a jaw clutch. Once the speed of the diesel engine decreases, the jaw
clutch widens and it falls back from the shaft and thus after starting it disconnects from the shaft.
The maximum speed of the generator is 3000rpm, but the turbine runs at 5000rpm. As they are
connected to the same shaft, a gear box mechanism is used to decrease the speed of the turbine
and feed it to the generator.
EXCITATION SYSTEM IN GT2
5 | P a g e
To avoid sparking due to a flow of high excitation current through brushes, brushless dc excitation
scheme is implemented. It consists of the following components:-
 Rotating diode rectifier
 3 phase main exciter
 3 phase pilot exciter
 Digital Automatic voltage regulator
The permanent magnet generator (PMG) consists of a permanent magnet and a coil, as the magnet
is placed in the shaft, it rotates and an emf is induced. This ac is given to AVR. From there it is given
to the exciter which is a single phase ac generator with stator on the shaft. Again in the exciter ac is
produced which is rectified in a rectifier and is given as the excitation to the rotor of the main
generator.
The AVR is used for:-
 To convert ac to dc
 Regulation of output voltage of the main generator (this should be constant). When it decreases
AVR increases its excitation and thus the terminal voltage increases and vice versa.
SYNCHRONIZATION, CONTROL AND ANNUNCIATION PANEL (SCAP)
This is a panel that is used for centralized monitoring control, status indication and annunciation of
generators and transformers and also 33 or 11 KV breakers. For continuity in service synchronization
or paralleling of generators GT1 or GT2 with the KSEB line is done. For 2 machines to be connected
in parallel, its terminal voltage, frequency and phase sequence should be same. This is achieved
through a synchroscope and synchronization trolley.
SYNCHRONIZATION TROLLEY
This is provided for synchronizing any breaker represented on SCAP. 20 pin synchronous sockets are
provided for each breaker with synchronization provision. Socket may be connected to the
synchronization trolley using connector cables.
 Diesel Engine Battery bank: The starter for diesel engine requires 12 V dc, which is provided
using lead- acid batteries.
UNINTERRUPTED POWER SUPPLY (UPS)
Uninterrupted 110V ac power to meet critical loads can’t withstand a momentary interruption or
other ac mains disturbance in supply voltage. Every UPS shall be provided with separate battery
bank for energy storage, which shall be used during the periods of main power interruption.
Following loads are connected:-
 Critical instrumentation and process control.
 Critical communication equipment.
 Microprocessor based distribution digital control system.
A typical UPS consists of rectifier, inverter bypass supply, battery bank. Rectifier is a thyristor based
circuit used to provide dc voltage to keep battery bank in floating charging. The inverter converters
6 | P a g e
dc to 110v ac using thyristor controlled circuits. A servo based voltage regulator adjusts output
voltage of the bypass supply to 110V ac. Bypass supply may be used during planned maintenance of
UPS or during failure of both UPS.
BATTERY CHARGES
Thyristor controlled battery charges are used to rectify 415V ac supply to a voltage suitable for
charging a battery bank. For Ni-Cd battery banks, the charger feeds DC loads and charges the battery
bank at float voltage in normal condition.
LOAD SHEDDING AND ISLANDING SCHEME
LOAD SHEDDING SCHEME
Generation capacity available at any point of time is sufficient to cater the load requirement. If total
available generation capacity is less than load requirement (due to tripping of generators,
disconnected of power carrying links to bus bar etc.) there is a possibility of generators to trip one by
one on overload resulting to Blackout. To avoid this, frequency based load shedding scheme was
introduced to ensure that loads are shed on its non-critically, until the available generation can cater
more critical loads thereby saving critical plant loads and avoiding a blackout.
ISLANDING SCHEME
When BPCL-KR captive generation is parallel with KSEB any fault outside KR electrical system (faults
in KSEB) will also be fed by KR captive generation. The same happens if there is a failure in KSEB grid
voltage. It is essential to make KR system independent of KSEB grid during times of instability or
faults, thus ensuring that doesn’t disturb KR system. This is done using relays. Relays sense the
voltage of grid 1 & 2 to monitor the voltage, rate of change of voltage, frequency, rate of change of
frequency and the direction of fault current of KSEB grid.
Selectivity of islanding sensitivity is based on availability of captive generators and is implemented in
islanding relays using setting group change logic. Logic enables group A with more sensitivity settings
for islanding relays when all the generators are running in parallel thus islanding relay uses setting
group B with lesser sensitivity settings, which restricts occurrence of islanding only to more severe
faults in KSEB thereby ensuring higher availability of KSEB during a shortage in captive generation.
PROCEESING UNITS
The crude oil processed in the refinery is classified into
1) Indigenous
2) Low sulphur imported crude
3) High sulphur imported crude
BH crude is low in sulphur content and high sulphur crude imported from the Persian gulf region
(PG) is having higher sulphur content as today more than 60 different crude oils have been
processed in the units the important process units and there features are explained below
DIESEL HYDRO DESULPHURIZATION (DHDS) UNIT
High speed diesel (HTS) contains contaminants like organic sulphur nitrogen and metal compounds
7 | P a g e
with contribute to increased level of air pollution, equipment corrosion etc. The diesel hydro
desulphurization (HSD) converts the sulphur in presence of hydrogen to H2S so that sulphur level in
HSD is reduced less than 100ppm. The unit utilizes a fixed bed catalyst process to upgrade the
quality of petroleum distillate fractions by decomposing the contaminants with a negligible effect on
the boiling range of feed.
The hydrogen required for the purpose is obtained by steam naphtha reforming as feedstock. The
raw feedstock utilized to generate hydrogen is first desulphurised in the final desulphurization unit
(FDS) to sulphur level of less than 0.05ppm. The sweet feed (free of sulphur) is then performed to
convert higher hydrocarbon to methane. The methane rich feed is then reformed. The hydrogen
obtained by reforming is around 70% pure. The pressure swing adsorption (PSA) unit further
enhances the purity of hydrogen to 99.99% volume. H2S gas from DHDS is treated with amine to
enrich it and then the H2S rich gas is treated in sulphur recovery unit SRU to obtain sulphur as a
byproduct. The sulphur is obtained by clauses process. The acid gas from the clauses reactor is
treated in maximum clauses recovery concept unit to recover sulphur to maximum possible extend.
HTLC STARTER
The HTLC (High Torque Low Current) Starter is Converteam’s patented motor starting method for
high inertia loads using a low voltage with input and output transformers to control motor torque
and limit current when starting a medium/high voltage motor.
The HTLC is a solution to motor starting problems where Direct on Line (DOL) starting is not feasible
due to high inrush current, causing problems on the distribution system or where a reduced voltage
starter cannot provide enough torque to achieve breakaway and accelerate the motor to full speed.
The conventional starting method for medium voltage induction motor is to start them DOL. This
typically results in 600% inrush current while motor is accelerating. The breakaway or locked rotor
torque for a motor is around 80%.
At remote sites with long power line feeds, the utility will not permit the use of high current DOL
starter’s .The unusual approach is to use a reduced voltage soft starter. The net result of this
reduced starting torque is that the motor would not be able to break the “stiction” therefore limiting
acceleration or simply stalling.
The Converteam HTLC overcomes both of these problems. In excess of 60% torque is available at
breakaway requiring less than 10% current at starting , increasing to approximately 30% at full load
speed. The HTLC starter can be used to start most unloaded compressors with MV/HV motors up to
around 20000HP as a practical limit.
The HTLC is equipped with an input isolation transformer to change the medium voltage supply to a
low voltage level, typically 690V. The VFD i chosen to deliver the current needed to start the motor
and connected load. The auto transformer use three resistors connected in series with the windings
at low frequencies to add impedance to the circuit and limit the transformer saturation current. As
the frequency increases, the resistors are removed from the circuit and the transformers then
operates normally.
8 | P a g e
The VFD operator at its own variable frequency and will not be in synchronism with the grid when
the motor reaches the full speed. In order to match the grid frequency the inverter will typically run
at a frequency slightly above the grid so that the VFD and the grid will match the phase rotation and
can accommodate any variations in the supply frequency. The HTLC contains a synchronizing relay
that determines when the two are frequency and phase matched. When the match is detected a
signal is sent to close the bypass circuit breaker or contactor in the Medium Voltage Switchgear.
Once the breaker closes the inverter load will increase as it is still running at a frequency slightly
higher than the suppy but still in parallel with it. At this point the HTLC output circuit breaker will
open, the drive will shut off and the motor is then operated solely from the utility supply. The HTLC
input power can be removed at this point as the starter is no longer required.
HTLC Features
1) Reduces starting inrush current from 600% to 10%.
2) Over 60% Breakaway torque available
3) Multiple motors started from a single HTLC starter.
4) Up to 12 starts per hour permitted.
5) Bump less transfer to line at 50 or 60 Hz.
6) Significantly less costly than fully rated VFD.
SYNCHRONOUS MOTOR STARTING
The standard synchronous motor, those designed for line supply and fixed speed, have brushless
dc excitation and use built in induction motor features for starting. For the soft or weak line
condition (allowed current <100%) the >400% Direct on line current will be unacceptable. Reducing
the voltage will reduce the starting torque in proportion to the voltage squared, so there may not be
enough torque.
The HTLC system utilizes a VFD to ramp up the voltage and frequency from start to 100% speed. For
a typical induction motor this allows a very effective motor utilization achieving near 1 per unit
torque/current at all speeds. The relatively poor induction motor characteristics prevent the
synchronous motor from achieving good torque efficiency. For a given motor the ratio of
Torque/Stator current is maximum of 0.4 at 90% speeds (10% slip). Even with the benefit of a VFD
providing the maximum torque efficiency at all speeds the value of 0.4 wold mean we need >100%
stator current for 44% breakaway torque.
The great benefit of the asynchronous motor is that torque is proportional to the product of the
stator and excitation flux. If excitation can be 100% the required stator current for 44% torque
reduces to 44% or less. This solution requires an AC exciter
CRUDE DISTILLATION UNIT (CDU)
The crude oil distillation unit (CDU) is the first processing unit in virtually all petroleum refineries.
The CDU distills the incoming crude oil into various fractions of different boiling ranges, each of
which are then processed further in the other refinery processing units. The CDU is often referred to
as the atmospheric distillation unit because it operates at slightly above atmospheric pressure. The
9 | P a g e
incoming crude oil is preheated by exchanging heat with some of the hot, distilled fractions and
other streams. It is then desalted to remove inorganic salts (primarily sodium chloride). Following
the desalter, the crude oil is further heated by exchanging heat with some of the hot, distilled
fractions and other streams. It is then heated in a fuel-fired furnace to a temperature of about 398
°C and routed into the bottom of the distillation unit. The cooling and condensing of the distillation
tower overhead is provided partially by exchanging heat with the incoming crude oil and partially by
either an air-cooled or water-cooled condenser. Additional heat is removed from the distillation
column by a pump around system. The residue from an atmospheric distillation tower can be sent to
a vacuum distillation tower, which recovers additional liquid at 4.8 to 10.3 kPa. The vacuum, which is
created by a vacuum pump or steam ejector, is pulled from the top of the tower. Relative to
atmospheric columns, vacuum columns have larger diameters and their internals are simpler. Often,
instead of trays, random packing and demister pads are used. The overhead stream – light vacuum
gas oil – can be used as a lube base stock, heavy fuel oil, or as feed to a conversion unit. Heavy
vacuum gas oil is pulled from a side draw. The vacuum residue can be used to make asphalt, or it can
be sent to a coker or visbreaker unit for further processing. Some of the products obtained are
Naptha, Heavy Naptha, Kerosene diesel and reduced crude oil.
BPCL-KR has two distillation units with capacities 4.5MMTPA and 5.0MMPTA adding to a total of
installed capacity of 9.5MMPTA.
SPM
The SPM facility at offshore Kochi. An offshore crude oil receipt facility consisting of an offshore
single point mooring (SPM) facility and an associated shore tank farm (situated in Vypin). This was
commissioned on December 2007. The refinery is equipped to receive crude oil in Very Large Crude
Carriers (VLCCs).
PROCESS
Kochi Refinery presently has a crude oil processing capacity of 9.5 MMTPA (Million Tons per Annum)
in its two Crude Distillation units (CDU-1 and CDU-2). The refinery currently processes about 30% of
Indigenous and 70% Imported crude oils. Crude oil is transported in ships from the point of origin to
Kochi and is received through a Single Point Mooring (SPM) facility. Kochi SPM, located
approximately 20 km off the shore of Puthuvypeen, is capable of handling Very large Crude Carriers
(VLCC) with crude oil carrying capacities up to 3.0 Lakh Tons. Crude oil from SPM is received in
offshore tanks in Puthuvypeen and is then pumped to the refinery.
SINGLE POINT MOORING
A Single buoy mooring (SBM) (also known as single-point mooring or SPM) is a loading buoy
anchored offshore, that serves as a mooring point and interconnect for tankers loading or offloading
gas or liquid products. SPMs are the link between geostatic subsea manifold connections and
weathervaning tankers. They are capable of handling any size ship, even very large crude carriers
(VLCC) where no alternative facility is available.
PARTS
There are four parts in the total buoying system: the body of the buoy, mooring and anchoring
elements, product transfer system and other components.
10 | P a g e
BUOY BODY
The buoy body usually is supported on static legs attached to the seabed, with a rotating part above
water level connected to the (off) loading tanker. The two sections are linked by a roller bearing,
referred to as the "main bearing". The moored tanker can freely weather vane around the buoy and
find a stable position due to this arrangement.
MOORING AND ANCHORING PARTS
Moorings fix the buoy to the seabed. Buoy design must account for the behavior of the buoy given
applicable wind, wave and current conditions and tanker sizes. This determines the optimum
mooring arrangement and size of the various mooring leg components. Anchoring points are greatly
dependent on local soil condition.
TRANSFORMER
A transformer is an electrical device that transfers electrical energy between two or more circuits
through electromagnetic induction. Commonly, transformers are used to increase or decrease the
voltages of alternating current in electric power applications. A varying current in the transformer's
primary winding creates a varying magnetic flux in the transformer core and a varying magnetic field
impinging on the transformer's secondary winding. This varying magnetic field at the secondary
winding induces a varying electromotive force (EMF) or voltage in the secondary winding.
Operation of a transformer at its designed voltage but at a higher frequency than intended will lead
to reduced magnetizing current. At a lower frequency, the magnetizing current will increase.
Operation of a transformer at other than its design frequency may require assessment of voltages,
losses, and cooling to establish if safe operation is practical. For example, transformers may need to
be equipped with 'volts per hertz' over-excitation relays to protect the transformer from overvoltage
at higher than rated frequency.
TIE transformers in BPCL-KR are connected between GIS and HT-101/SWGR-2101 switchgear. The
scheme is as shown. The transformers are situated at GT-2 substation and 11kV cables are led from
HT-101 switchgear to live isolation breaker (LIB) situated at GT-2 substation. From LIB, transformers
feed and the neutral isolation breakers (NIB) is given on both sides of the transformer.
11 | P a g e
Fig: TIE transformer
ENERGY LOSSES
Real transformer energy losses are dominated by winding resistance joule and core losses.
Transformers' efficiency tends to improve with increasing transformer capacity. The efficiency of
typical distribution transformers is between about 98 and 99 percent.
As transformer losses vary with load, it is often useful to express these losses in terms of no-load
loss, full-load loss, half-load loss, and so on. Hysteresis and eddy current losses are constant at all
load levels and dominate overwhelmingly without load, while variable winding joule losses
dominating increasingly as load increases. The no-load loss can be significant, so that even an idle
transformer constitutes a drain on the electrical supply. Designing energy efficient transformers for
lower loss requires a larger core, good-quality silicon steel, or even amorphous steel for the core and
thicker wire, increasing initial cost. The choice of construction represents a trade-off between initial
cost and operating cost.
Transformer losses arise from:
1) Winding joule losses
2) Core losses
3) Hysteresis losses
4) Eddy current losses
5) Stray losses
TIE TRANSFORMER SPECIFICATION:
12 | P a g e
MAKE BHEL
MVA 37.5
VOLTAGE (HT/LT) 33/11 kV
CURRENT (HT/LT) 656.8/1968.24 A
COOLING ONAN
OTL BHEL MAKE
VECTOR GROUP YNyn0
PARTS OF TRANSFORMER
1) WINDINGS
Windings are usually arranged concentrically to minimize flux leakage. The conducting material used
for the windings depends upon the application, but in all cases the individual turns must be
electrically insulated from each other to ensure that the current travels throughout every turn. For
small power and signal transformers, in which currents are low and the potential difference between
adjacent turns is small, the coils are often wound from enameled magnet wire, such as Formvar
wire. Larger power transformers operating at high voltages may be wound with copper rectangular
strip conductors insulated by oil-impregnated paper and blocks of pressboard.
The windings of signal transformers minimize leakage inductance and stray capacitance to improve
high-frequency response. Coils are split into sections, and those sections interleaved between the
sections of the other winding.
Power-frequency transformers may have taps at intermediate points on the winding, usually on the
higher voltage winding side, for voltage adjustment. Taps may be manually reconnected, or a
manual or automatic switch may be provided for changing taps. Automatic on-load tap changers are
used in electric power transmission or distribution, on equipment such as arc furnace transformers,
or for automatic voltage regulators for sensitive loads. Audio-frequency transformers, used for the
distribution of audio to public address loudspeakers, have taps to allow adjustment of impedance to
each speaker. A center-tapped transformer is often used in the output stage of an audio power
amplifier in a push-pull circuit. Modulation transformers in AM transmitters are very similar.
2) COOLING
Cutaway view of liquid-immersed construction transformer. The conservator (reservoir) at top
13 | P a g e
provides liquid-to-atmosphere isolation as coolant level and temperature changes. The walls and fins
provide required heat dissipation balance.
To place the cooling problem in perspective, the accepted rule of thumb is that the life expectancy of
insulation in all electric machines including all transformers is halved for about every 7 °C to 10 °C
increase in operating temperature, this life expectancy halving rule holding more narrowly when the
increase is between about 7 °C to 8 °C in the case of transformer winding cellulose insulation.
3) INSULATION DRYING
Construction of oil-filled transformers requires that the insulation covering the windings be
thoroughly dried of residual moisture before the oil is introduced. Drying is carried out at the
factory, and may also be required as a field service. Drying may be done by circulating hot air around
the core, or by vapor-phase drying (VPD) where an evaporated solvent transfers heat by
condensation on the coil and core.
3) BUSHINGS
Larger transformers are provided with high-voltage insulated bushings made of polymers or
porcelain. A large bushing can be a complex structure since it must provide careful control of the
electric field gradient without letting the transformer leak oil.
4) BUCHHOLZ RELAY
It is a very sensitive gas and oil operated instrument which safely detect the formation of gas or
sudden pressure inside the oil transformer.
5) CONSERVATOR
It is used to provide adequate space for the expansion of oil when transformer is loaded or when
ambient temperature changes.
6) SILICA GEL BREATHER
It sucks the moisture from the air which is taken by transformer so that dry air is taken by
transformer.
7) DOUBLE DIAPHRAGM EXPLOSION VENT
It is used to discharge excess pressure in the atmosphere when excess pressure is developed inside
the transformer during loading.
8) OIL LEVEL INDICATOR
It is used to show the oil level in the transformer.
9) WINDING TEMPRATURE INDICATOR
Used to show the temperature of transformer winding.
10) RADIATORS
14 | P a g e
These are used for cooling of the transformer oil.
PROTECTION FOR TRANSFORMERS
1. Faults generating production of gases, mainly:
• Micro arcs resulting from incipient faults in the winding insulation
• Slow degradation of insulation materials
• Inter turns short circuit
2. Faults generating internal over pressures with simultaneously high level of line over
currents:
• Phase to earth short circuit
• Phase to Phase short circuit.
These faults may be the consequence of external lightning or switching over voltage. Depending on
the type of the transformer, there are two kinds of devices able to detect internal faults affecting an
oil filled transformer.
3. Buchholz Relay
The Buchholz dedicated to the transformers equipped with an air breathing conservator. The
Buchholz is installed on the pipe connecting the tank of the transformer to the conservator. It traps
the slow emissions of gasses and detect the flow back of oil due to the internal over pressures
4. Backup Protection
• Differential protection
• Restricted earth fault protection
15 | P a g e
• Circuit breaker fail to trip
• Oil temperature trip
• Winding temperature trip
• Inter trip
• Buchholz trip
GAS INSULATED SUBSTATION (GIS)
The 33kV switchgear at GT-2 substation is of Siemens make. It is a Gas Insulated Switchgear in which
the current carrying conductors is placed inside a gas chamber. This will reduce the spacing
requirement and thus reducing the size of switchgear. The gas used is SF6 and the breakers are
vacuum interrupts.
The substation facility comprises 3 compartments sealed with a 1.35 kg/cm2 rated pressure SF6 gas
and a control circuit compartment with control devices mechanism and a gas pressure monitoring
device. The main circuit live section is divided into a bus bar compartment in which the bus running
through all the cubicles. A load side device compartment consist of a vacuum circuit breaker and
isolator. The bus bar compartment and the load-side device compartments are gas-sectionalized
from each other. CTs are mounted in cable compartment and VTs are top mounted.
The gas-tight compartments and the gas seals ensure long service life. A gas density monitor which is
temperature compensated provides accurate readings on the internal gas condition of the
switchgear.
The rated current is 2500A and has a fault current capacity of 40kA, there are 22 panel consisting of
the following
1. 2 generator incomer feeders
2. 2 grid (KSEB) incomer feeders
3. 2 feeders for SAT
4. 6 outgoing feeders
5. 2 spare outgoing feeders
6. 2 bus couplers
7. 2 bus sectionalizer
8. 4 TIE transformer feeders
• CIRCUIT BREAKER OPERATION
1. Manual operation:
Refer to the Breaker Installation Manual and the caution plate of the operating device for the
16 | P a g e
operation of the breaker.
2. Electrical operation:
Turn the local breaker control switch (TNC) handle on the front door panel to OFF or ON or remotely
switch the breaker. The status of the device can be checked with the indicators located at the front
door.
• EARTHING OF BUS AND SWITCHES
1. An interlock allows the bus to be earthed when all the feeder switches are disconnected
from the bus (Dead Bus Check).
2. This is to ensure the respective bus is dead before earthing. This applies to both single and
double bus design.
3. Motorised version of the earth switch is provided as standard package.
4. Unless specified, only a manual earth switch is allocated. Any special interlocks for earthing
operations will be shown in the technical project drawings.
• SAFETY INTERLOCKS IN GIS SWITCHGEARS
Following Interlocks are provided in GIS switchgear for safety purpose during operation &
maintenance:-
1. Mechanical & Electrical interlocks prevent the operation of disconnector switch, when the breaker
is ON.
2. Disconnector switch can be operated only when VCB is off.
3. Closure of VCB is not possible when the disconnector switch is in operation.
4. At a time, Disconnector switch can be operated either electrically or mechanically but not
simultaneously.
5. Closure of VCB is not possible unless the spring is fully charged.
• VACCUM BREAKER
The mechanism and drive is bolted out side of the circuit breaker tank and the three pole assemblies
are bolted inside SF6 tank. They are connected via contact wipe springs and coupling rods through
gas tight sealing bushes to the insulators to the vacuum interrupter moving terminals. The sealing
ring is mounted in the brass hub on the tank.
The mechanism is of the stored energy, motor wound or manually charged spring operated type. It is
suitable for auto reclosing duties. Basically it comprises a closing spring charging system and a spring
charged latch, a closing cam, the close / trip latch which is displaced to trip the closed circuit
breaker, and the drive to the poles in the form of the secondary shaft. In addition there are the
spring release solenoid, the trip solenoid, the auxiliary switches and manual operation On-Off push
buttons.
When the closing spring is CHARGED and the circuit breaker indicates Open, the circuit breaker can
be closed by either the electrical release of the closing spring or by the manual close pushbutton.
17 | P a g e
This causes the main shaft and thus the drive cam to rotate driving the secondary shaft anti-
clockwise via the roller. When the circuit breaker is fully closed, the close/trip latch locates behind
the roller holding the circuit breaker closed and indicating Close.
GAS TURBINE
The gas turbines are of BHEL make GT-1 is of frame 6 having an ISO rating of 42.3MW. The generator
of GT-2 is of BHEL make having an ISO rating of 34.5MW at 0.8pf load. It is also having Brusheless
Excitation Scheme (BLE). GT-2 is provided with neutral grounding. The designed open cycle efficiency
is 32% compared to 28.5% of frame 5 GT-1. It is designed for 3 types of fuel LCO, Naptha and KERO-
2. The expected fuel consumption at rated load is 10T/hr. GT-2 is hooked to the 33kV GIS through a
step up transformer .The cooling is done by air which in turn is cooled by water.
GT-2 Specification:-
MAKE BHEL
MVA 43.12
MW 34.5
STATOR (kV) 11kV
ROTOR 207V
EXCITATION BRUSHLESS
MODEL TRAI 80024P
POWER FACTOR 0.8
Electrical Power Generation
In electricity generating applications the turbine is used to drive a synchronous generator which
provides the electrical power output but because the turbine normally operates at very high
rotational speeds of 12,000 r.p.m or more it must be connected to the generator through a high
ratio reduction gear since the generators run at speeds of 1,000 or 1,200 r.p.m. depending on the AC
frequency of the electricity grid. In a practical gas turbine, mechanical energy is irreversibly
transformed into heat when gases are compressed (in either a centrifugal or axial compressor), due
to internal friction and turbulence.
GT-1 Specification:-
MAKE BHEL
MVA 27.5
MW 22
EXCITATION BRUSHLESS
SPEED 3000rpm
POWER FACTOR 0.8
18 | P a g e
Turbine Configurations
Gas turbine power generators are used in two basic configurations
Simple Systems consisting of the gas turbine driving an electrical power generator.
RELAY PROTECTION
In electrical engineering, a protective relay is a device designed to trip a circuit breaker when a fault
is detected. The first protective relays were electromagnetic devices, relying on coils operating on
moving parts to provide detection of abnormal operating conditions such as over-current, over-
voltage, reverse power flow, over- and under- frequency. Microprocessor-based digital protection
relays now emulate the original devices, as well as providing types of protection and supervision
impractical with electromechanical relays. Electromechanical protective relays at a hydroelectric
generating plant. The relays are in round glass cases. The rectangular devices are test connection
blocks, used for testing and isolation of instrument transformer circuits.
The theory and application of these protective devices is an important part of the education of an
electrical engineer who specializes in power systems. The need to act quickly to protect circuits and
equipment as well as the general public often requires protective relays to respond and trip a
breaker within a few thousandths of a second. In these cases it is critical that the protective relays
are properly maintained and regularly tested.
OPERATION PRINCIPLES
Electromechanical protective relays operate by either magnetic attraction, or magnetic induction.
Unlike switching type electromechanical relays with fixed and usually ill-defined operating voltage
thresholds and operating times, protective relays have well-established, selectable and adjustable
time/current (or other operating parameter) operating characteristics. Protection relays may use
arrays of induction disks, shaded-pole magnets, operating and restraint coils, solenoid-type
operators, telephone-relay contacts, and phase-shifting networks.
Protective relays can also be classified by the type of measurement they make. A protective relay
may respond to the magnitude of a quantity such as voltage or current. Induction types of relay can
respond to the product of two quantities in two field coils, which could for example represent the
power in a circuit. Although an electromechanical relay calculating the ratio of two quantities is not
practical, the same effect can be obtained by a balance between two operating coils, which can be
arranged to effectively give the same result.
By use of a permanent magnet in the magnetic circuit, a relay can be made to respond to current in
19 | P a g e
one direction differently from in another. Such polarized relays are used on direct-current circuits to
detect, for example, reverse current into a generator. These relays can be made bistable,
maintaining a contact closed with no coil current and requiring reverse current to reset. For AC
circuits, the principle is extended with a polarizing winding connected to a reference voltage source.
Light weight contacts make for sensitive relays that operate quickly, but small contacts can't carry or
break heavy currents. Often the measuring relay will trigger auxiliary telephone-type armature
relays.
In a large installation of electromechanical relays, it would be difficult to determine which device
originated the signal that tripped the circuit. This information is useful to operating personnel to
determine the likely cause of the fault and to prevent its re-occurrence. Relays may be fitted with a
"target" or "flag" unit, which is released when the relay operates, to display a distinctive colored
signal when the relay has tripped.
TYPES ACCORDING TO CONSTRUCTION
1) ELECTROMECHANICAL
Electromechanical relays can be classified into several different types as follows:
a) Attracted armature
b) Moving coil
c) Induction
d) Motor operated
e) Mechanical
f) Thermal
"Armature"-type relays have a pivoted lever supported on a hinge or knife-edge pivot, which carries
a moving contact. These relays may work on either alternating or direct current, but for alternating
current, a shading coil on the pole is used to maintain contact force throughout the alternating
current cycle. Because the air gap between the fixed coil and the moving armature becomes much
smaller when the relay has operated, the current required to maintain the relay closed is much
smaller than the current to first operate it. The "returning ratio" or "differential" is the measure of
how much the current must be reduced to reset the relay. A variant application of the attraction
principle is the plunger-type or solenoid operator. A reed relay is another example of the attraction
principle. "Moving coil" meters use a loop of wire turns in a stationary magnet, similar to a
galvanometer but with a contact lever instead of a pointer. These can be made with very high
sensitivity. Another type of moving coil suspends the coil from two conductive ligaments, allowing
very long travel of the coil.
2) STATIC RELAY
The conventional relay type of electromagnet relays can be replaced by static relays which
essentially consist of electronic circuitry to develop all those characteristics which are achieved by
moving parts in an electro-magnetic relay. Static relays are capable of performing the same
functions with the use of electronic circuit control as an electro-magnetic relay performs with the
20 | P a g e
use of moving parts or elements.
Static relays are superior to electro-magnetic relays for example, the moving parts and the contacts
are largely eliminated. The only moving element in a static relay is the final tripping contact. C.T.s
and P.T.s employed are of lesser VA rating as static relays require a very little volt-ampere for their
operation. More precise and high speed operation.
3) NUMERICAL RELAY
In utility and industrial electric power transmission and distribution systems, a digital protective
relay uses a microcontroller with software-based protection algorithms for the detection of electrical
faults.[1] Such relays are also termed as microprocessor type protective relays. They are functional
replacements for electromechanical protective relays and may include many protection functions in
one unit, as well as providing metering, communication, and self-test functions.
RELAYS BY FUNCTIONS
The various protective functions available on a given relay are denoted by standard ANSI Device
Numbers. For example, a relay including function 51 would be a timed overcurrent protective relay.
1) OVER CURRENT RELAY
A digital overcurrent relay is a type of protective relay which operates when the load current
exceeds a pickup value. The ANSI device number is 50 for an instantaneous over current (IOC) and 51
for a time over current (TOC). In a typical application the over current relay is connected to a current
transformer and calibrated to operate at or above a specific current level. When the relay operates,
one or more contacts will operate and energize to trip (open) a circuit breaker.
2) DISTANCE RELAY
Distance relay differ in principle from other forms of protection in that their performance is not
governed by the magnitude of current or the voltage in the protected circuit but rather on the ratio
of these two quantity .Distance relay are actually double actuating quantity relay with one coil
energized by voltage and other coil by current. The current element produces a positive or pick up
torque while the voltage element produces a negative or reset torque. The relay operates only when
the V/I ratio falls below a predetermined value (or set value).During a fault on the transmission line
the fault current increases and the voltage at the fault point decreases. The V/I ratio is measured at
the location of CTs and PTs. The voltage at PT location depends on the distance between PT and the
fault. If the measured voltage is lesser that means fault is nearer and vice-versa. Hence the
protection called Distance relay.
3) CURRENT DIFFERENTIAL PROTECTION
Another common form of protection for apparatus such as transformers, generators, busses and
power lines is current differential. This type of protection works on the basic theory of Kirchhoff's
current law, which states that the sum of the currents entering and exiting a node will equal zero.
Differential protection requires a set of current transformers (smaller transformers that transform
currents down to a level which can be measured) at each end of the power line, or each side of the
transformer. The current protection relay then compares the currents and calculates the difference
21 | P a g e
between the two.
4) DIRECTIONAL RELAY
A directional relay uses an additional polarizing source of voltage or current to determine the
direction of a fault. The fault can be located upstream or downstream of the relay's location,
allowing appropriate protective devices to be operated inside or outside of the zone of protection.
5) THERMAL RELAY
The coefficient of expansion is one of the basis properties of any material. Two different metals
always have different degree of linear expansion. A bimetallic strip always bends when it heated up,
due to this inequality of linear expansion of two different metals.
MPRT-MEGGER PROTECTIVE RELAY TEST SYSTEM
Megger-MPRT is specifically designed to perform routine testing of protective relays used in the
operation of electrical utilities, power plants and heavy industrial.
The ‘power box’ is the heart of the system. It employees a variety of new features including unique
voltage and current generator components the flexibility to deliver four voltages and four current or
eight current channel capability and everyone is made to order based on each costumers individual
testing requirements.
SUBSTATION EQUIPMENT
In BPCL-KR a 220kV substation is situated which gets its incoming from KSEB grid. There are many
equipment required in the substation. Some of the equipment can be listed as follows:
1. LIGHTENING ARRESTER: Lightening arrestors are the instrument that are used in the
incoming feeders so that to prevent the high voltage entering the main station. This high
voltage is very dangerous to the instruments used in the substation. Even the instruments
are very costly, so to prevent any damage lightening arrestors are used. The lightening
arrestors do not let the lightening to fall on the station. If some lightening occurs the
arrestors pull the lightening and ground it to the earth. In any substation the
22 | P a g e
main important is of protection which is firstly done by these lightening arrestors. The
lightening arrestors are grounded to the earth so that it can pull the lightening to the
ground. The lightening arrestor works with an angle of 30° to 45° making a cone.
2. C V T (CPACITIVE VOLTAGE TRANSFORMER): A capacitor voltage transformer (CVT)
is a transformer used in power systems to step-down extra high voltage signals and provide
low voltage signals either for measurement or to operate a protective relay. In its most basic
form the device consists of three parts: two capacitors across which the voltage signal is
split, an inductive element used to tune the device to the supply frequency and a
transformer used to isolate and further step-down the voltage for the instrumentation or
protective relay. The device has at least four terminals, a high-voltage terminal
for connection to the high voltage signal, a ground terminal and at least one set of
secondary terminals for connection to the instrumentation or protective relay. CVTs are
typically single-phase devices used for measuring voltages in excess of one hundred kilovolts
where the use of voltage transformers would be uneconomical. In practice the first
capacitor, C1, is often replaced by a stack of capacitors connected in series. This results in a
large voltage drop across the stack of capacitors that replaced the first capacitor and a
comparatively small voltage drop across the second capacitor, C2, and hence the secondary
terminals.
3. WAVE TRAP: Wave trap is an instrument using for tripping of the wave. The function of
this trap is that it traps the unwanted waves. Its function is of trapping wave. Its shape is like
a drum. It is connected to the main incoming feeder so that it can trap the waves which may
be dangerous to the instruments here in the substation.
4. INSTRUMENT TRANSFORMER: Current transformers are basically used to take the
readings of the currents entering the substation. This transformer steps down the current
from 800 amps to 1 amp. This is done because we have no instrument for measuring of such
a large current. The main use of this transformer is
• CURRENT TRANSFORMER: current transformer is defined as an
instrument transformer in which the secondary current is substantially
proportional to the primary current (under normal conditions of
operation) and differs in phase from it by an angle which is
approximately zero for an appropriate direction of the connections.
This highlights the accuracy requirement of the current transformer but
also important is the isolating function, which means no matter what
the system voltage the secondary circuit need to be insulated only for a
low voltage.
• POTENTIAL TRANSFORMER: The standards define a voltage
transformer as one in which the secondary voltage is substantially
proportional to the primary voltage and differs in phase from it by an
angle which is approximately equal to zero for an appropriate direction
of the connections. This in essence means that the voltage
transformer has to be as close as possible to the ideal transformer. In
an ideal transformer, the secondary voltage vector is exactly opposite
and equal to the primary voltage vector when multiplied by the turn’s
ratio. In a practical transformer, errors are introduced because some
current is drawn for the magnetization of the core and because of
23 | P a g e
drops in the primary and secondary windings due to leakage reactance
and winding resistance. One can thus talk of a voltage error which is the
amount by which the voltage is less than the applied primary voltage
and the phase error which is the phase angle by which the reversed
secondary voltage vector is displaced from the primary voltage vector.
5. BUS BAR: The bus is a line in which the incoming feeders come into and get into the
instruments for further step up or step down. The first bus is used for putting the incoming
feeders in la single line. There may be double line in the bus so that if any fault occurs in the
one the other can still have the current and the supply will not stop. The two lines in the bus
are separated by a little distance by a conductor having a connector between them. This is
so that one can work at a time and the other works only if the first is having any fault.
6. CIRCUIT BREAKER: The circuit breakers are used to break the circuit if any fault occurs in
any of the instrument. These circuit breaker breaks for a fault which can damage other
instrument in the station. For any unwanted fault over the station we need to break the line
current. This is only done automatically by the circuit breaker. The use of SF6 circuit breaker
is mainly in the substations which are having high input kv input, say above 220kv and more.
The gas is put inside the circuit breaker by force i.e. under high pressure. When if the gas
gets decreases there is a motor connected to the circuit breaker. The motor starts operating
if the gas went lower than 20.8 bar. There is a meter connected to the breaker so that it can
be manually seen if the gas goes low. The circuit breaker uses the SF6 gas to reduce the
torque produce in it due to any fault in the line. The circuit breaker has a direct link with the
instruments in the station, when any fault occur alarm bell rings.
7. TRANSFORMER: There are three transformers in the incoming feeders so that the three
lines are step down at the same time. In case of a 220KV or more KV line station auto
transformers are used. The transformer is transported on tailor to substation site and as far
as possible directly unloaded on the plinth. Transformer tanks up to 25 MVA capacity are
generally oil filled, and those of higher capacity are transported with N2 gas filled in them
+ve pressure of N2 is maintained in transformer tank to avoid the ingress of moisture. This
pressure should be maintained during storage, if necessary by filling N2 Bushings - generally
transported in wooden cases in horizontal position and should be stored in that position.
There being more of fragile material, care should be taken while handling them. Radiators –
These should be stored with ends duly blanked with gaskets and end plates to avoid in gross
of moisture, dust, and any foreign materials inside. The care should be taken to protect the
fins of radiators while unloading and storage to avoid further oil leakages. The radiators
should be stored on raised ground keeping the fins intact.
8. ISOLATOR: The use of this isolator is to protect the transformer and the other instrument
in the line. The isolator isolates the extra voltage to the ground and thus any extra voltage
cannot enter the line. Thus an isolator is used after the bus also for protection.
9. CONTROL AND RELAY PANEL: The control and relay panel is of cubical construction
suitable for floor mounting. All protective, indicating and control elements are mounted on
the front panel for ease of operation and control. The hinged rear door will provide access to
all the internal components to facilitate easy inspection and maintenance. Provision is made
for terminating incoming cables at the bottom of the panels by providing separate line-up
terminal blocks. FUnder voltage and over voltage relays. Neutral Current Unbalance Relays
24 | P a g e
are for both Alarm and Trip facilities breaker control switch with local/remote selector
switch, master trip relay and trip alarms acknowledge and reset facilities.
10. DC POWER SUPPLY: All but the smallest substations include auxiliary power supplies. AC
power is required for substation building small power, lighting, heating and ventilation,
some communications equipment, switchgear operating mechanisms, anti-condensation
heaters and motors. DC power is used to feed essential services such as circuit breaker trip
coils and associated relays, supervisory control and data acquisition (SCADA) and
communications equipment. This describes how these auxiliary supplies are derived and
explains how to specify such equipment.
PROTECTION IN SUBSTATION
There are many protection for the equipment in a substation. Some of the import protection are
listed below:
• Overcurrent protection
• Earth fault protection
• Restricted earth fault protection
• Combined earth fault and phase protection
• Differential protection
CONCLUSION
As a part of our curriculum, I was required to undergo in-plant training. And the company I got to
train is BPCL – Kochi Refinery. The training was scheduled to be for 10 days starting from 6th
July to
17th
July 2015. The duration was from morning 9 pm to evening 4 pm, being an electrical student my
area of interest was Power and Utility section.
On 6th
July 2015, we were asked to report at the city office of Kochi refinery at Marudu, kundannoor
at 9am where we were issued with the identity cards. The basic rules which we had to follow while
inside the company etc. were discussed there by Mr.Balakrishnan (deputy manager) of learning and
development department. After giving basic introduction and further details about the company, I
was asked to directly meet at the main office at Ambalamugal the very next day.
The next day I was allotted the respective department which was the P&U department. I was
allowed to do the training under Mr.Jai Kishen sir. After arrainging a meeting with him, I got a basic
idea of what I had to do there. Then sir had a schedule for us for the entire training which included a
5 days training at Captive Power Plant (CPP), 1 day at 220kV power station, 2 days at DHDS plant, 1
day at CDU-2 plant. I was assigned a guide, Mr.Jibu Varghese, who helped me a lot in coordinating
my training period and I deeply thank him for making time for me in his busy schedule. In between
Mr.Jai Kishen sir himself found time to take a review on me after visiting the plants one by one. I am
grateful that I got an opportunity to learn and experience from the plant visit and the knowledge
provided by Mr.Jai Kishen sir is very helpful in knowing how exactly the plant works.
25 | P a g e
Last but not the least I thank all the staff members who helped me in getting this beautiful learning
experience form the training and made time for me to teach me in various aspects of plant working.
REFRENCES
• Bharatpetroleum.com/kochirefinery
• Operation manual of POWER & UTILITY
• Wikipedia
• Books (M.G SAY, B.L.THAREJA)
26 | P a g e

More Related Content

What's hot

BPCL Supply Chain Management
BPCL Supply Chain Management BPCL Supply Chain Management
BPCL Supply Chain Management Manju Mani
 
Indian Gas Scenario
Indian Gas ScenarioIndian Gas Scenario
Indian Gas ScenarioJayanta Bora
 
Clean Frac'ing Conference Presentation
Clean Frac'ing Conference PresentationClean Frac'ing Conference Presentation
Clean Frac'ing Conference PresentationBritt Thomas
 
GE ADGT Application iGas
GE ADGT Application iGasGE ADGT Application iGas
GE ADGT Application iGasGE코리아
 
GE ADGT Application CHP-Cogen-CC
GE ADGT Application CHP-Cogen-CCGE ADGT Application CHP-Cogen-CC
GE ADGT Application CHP-Cogen-CCGE코리아
 
Masciali Gabriele - Responsabile Commerciale - Ecomotive Solutions
Masciali Gabriele - Responsabile Commerciale - Ecomotive SolutionsMasciali Gabriele - Responsabile Commerciale - Ecomotive Solutions
Masciali Gabriele - Responsabile Commerciale - Ecomotive SolutionsWEC Italia
 
Connecting Colorado’s Economy: Energy
Connecting Colorado’s Economy: EnergyConnecting Colorado’s Economy: Energy
Connecting Colorado’s Economy: EnergyPorts-To-Plains Blog
 
March 2014 World Oil: Greener completions advance in the Marcellus
March 2014 World Oil: Greener completions advance in the MarcellusMarch 2014 World Oil: Greener completions advance in the Marcellus
March 2014 World Oil: Greener completions advance in the MarcellusBaker Hughes
 
Oil Producers Turn Wellhead Flare Gas Headaches into Benefits
Oil Producers Turn Wellhead Flare Gas Headaches into BenefitsOil Producers Turn Wellhead Flare Gas Headaches into Benefits
Oil Producers Turn Wellhead Flare Gas Headaches into BenefitsStephen Rach
 
Developing a new generation of energy efficiency products for reciprocating e...
Developing a new generation of energy efficiency products for reciprocating e...Developing a new generation of energy efficiency products for reciprocating e...
Developing a new generation of energy efficiency products for reciprocating e...Bowman Power
 
Evaluation of Electric-Turbo-Compounding Technology applied to Marine Diesel-...
Evaluation of Electric-Turbo-Compounding Technology applied to Marine Diesel-...Evaluation of Electric-Turbo-Compounding Technology applied to Marine Diesel-...
Evaluation of Electric-Turbo-Compounding Technology applied to Marine Diesel-...Bowman Power
 
Bowman Power Innovation Showcase - Cleantech Forum Asia 19
Bowman Power Innovation Showcase - Cleantech Forum Asia 19Bowman Power Innovation Showcase - Cleantech Forum Asia 19
Bowman Power Innovation Showcase - Cleantech Forum Asia 19Bowman Power
 
09.02.2012 Baganuur Coal Mine Expansion: Opportunities for investors, Baganuu...
09.02.2012 Baganuur Coal Mine Expansion: Opportunities for investors, Baganuu...09.02.2012 Baganuur Coal Mine Expansion: Opportunities for investors, Baganuu...
09.02.2012 Baganuur Coal Mine Expansion: Opportunities for investors, Baganuu...The Business Council of Mongolia
 
The AFCR and its Contributions to the Back End of the Fuel Cycle
The AFCR and its Contributions to the Back End of the Fuel CycleThe AFCR and its Contributions to the Back End of the Fuel Cycle
The AFCR and its Contributions to the Back End of the Fuel CycleSNC-Lavalin
 

What's hot (15)

BPCL Supply Chain Management
BPCL Supply Chain Management BPCL Supply Chain Management
BPCL Supply Chain Management
 
Indian Gas Scenario
Indian Gas ScenarioIndian Gas Scenario
Indian Gas Scenario
 
Clean Frac'ing Conference Presentation
Clean Frac'ing Conference PresentationClean Frac'ing Conference Presentation
Clean Frac'ing Conference Presentation
 
Training chp
Training chpTraining chp
Training chp
 
GE ADGT Application iGas
GE ADGT Application iGasGE ADGT Application iGas
GE ADGT Application iGas
 
GE ADGT Application CHP-Cogen-CC
GE ADGT Application CHP-Cogen-CCGE ADGT Application CHP-Cogen-CC
GE ADGT Application CHP-Cogen-CC
 
Masciali Gabriele - Responsabile Commerciale - Ecomotive Solutions
Masciali Gabriele - Responsabile Commerciale - Ecomotive SolutionsMasciali Gabriele - Responsabile Commerciale - Ecomotive Solutions
Masciali Gabriele - Responsabile Commerciale - Ecomotive Solutions
 
Connecting Colorado’s Economy: Energy
Connecting Colorado’s Economy: EnergyConnecting Colorado’s Economy: Energy
Connecting Colorado’s Economy: Energy
 
March 2014 World Oil: Greener completions advance in the Marcellus
March 2014 World Oil: Greener completions advance in the MarcellusMarch 2014 World Oil: Greener completions advance in the Marcellus
March 2014 World Oil: Greener completions advance in the Marcellus
 
Oil Producers Turn Wellhead Flare Gas Headaches into Benefits
Oil Producers Turn Wellhead Flare Gas Headaches into BenefitsOil Producers Turn Wellhead Flare Gas Headaches into Benefits
Oil Producers Turn Wellhead Flare Gas Headaches into Benefits
 
Developing a new generation of energy efficiency products for reciprocating e...
Developing a new generation of energy efficiency products for reciprocating e...Developing a new generation of energy efficiency products for reciprocating e...
Developing a new generation of energy efficiency products for reciprocating e...
 
Evaluation of Electric-Turbo-Compounding Technology applied to Marine Diesel-...
Evaluation of Electric-Turbo-Compounding Technology applied to Marine Diesel-...Evaluation of Electric-Turbo-Compounding Technology applied to Marine Diesel-...
Evaluation of Electric-Turbo-Compounding Technology applied to Marine Diesel-...
 
Bowman Power Innovation Showcase - Cleantech Forum Asia 19
Bowman Power Innovation Showcase - Cleantech Forum Asia 19Bowman Power Innovation Showcase - Cleantech Forum Asia 19
Bowman Power Innovation Showcase - Cleantech Forum Asia 19
 
09.02.2012 Baganuur Coal Mine Expansion: Opportunities for investors, Baganuu...
09.02.2012 Baganuur Coal Mine Expansion: Opportunities for investors, Baganuu...09.02.2012 Baganuur Coal Mine Expansion: Opportunities for investors, Baganuu...
09.02.2012 Baganuur Coal Mine Expansion: Opportunities for investors, Baganuu...
 
The AFCR and its Contributions to the Back End of the Fuel Cycle
The AFCR and its Contributions to the Back End of the Fuel CycleThe AFCR and its Contributions to the Back End of the Fuel Cycle
The AFCR and its Contributions to the Back End of the Fuel Cycle
 

Viewers also liked

Summer Training Project Report On BPC Ltd.
Summer Training Project Report On BPC Ltd.Summer Training Project Report On BPC Ltd.
Summer Training Project Report On BPC Ltd.Peush Prabhakar
 
Summer internship project report
Summer internship project reportSummer internship project report
Summer internship project reportManish Singh
 
Summer training project report on Internal Audit Functions and its performanc...
Summer training project report on Internal Audit Functions and its performanc...Summer training project report on Internal Audit Functions and its performanc...
Summer training project report on Internal Audit Functions and its performanc...Debasish Phukan
 
Talent mnagement- MBA(HR) project
Talent mnagement- MBA(HR) projectTalent mnagement- MBA(HR) project
Talent mnagement- MBA(HR) projectAmol30586
 
Summer internship project hr mba mms
Summer internship project hr mba mmsSummer internship project hr mba mms
Summer internship project hr mba mmsSria
 
Recruitment and selection powerpoint presentation
Recruitment and selection powerpoint presentationRecruitment and selection powerpoint presentation
Recruitment and selection powerpoint presentationAndrew Schwartz
 
RECRUITMENT AND SELECTION
RECRUITMENT AND SELECTIONRECRUITMENT AND SELECTION
RECRUITMENT AND SELECTIONAIMS Education
 

Viewers also liked (7)

Summer Training Project Report On BPC Ltd.
Summer Training Project Report On BPC Ltd.Summer Training Project Report On BPC Ltd.
Summer Training Project Report On BPC Ltd.
 
Summer internship project report
Summer internship project reportSummer internship project report
Summer internship project report
 
Summer training project report on Internal Audit Functions and its performanc...
Summer training project report on Internal Audit Functions and its performanc...Summer training project report on Internal Audit Functions and its performanc...
Summer training project report on Internal Audit Functions and its performanc...
 
Talent mnagement- MBA(HR) project
Talent mnagement- MBA(HR) projectTalent mnagement- MBA(HR) project
Talent mnagement- MBA(HR) project
 
Summer internship project hr mba mms
Summer internship project hr mba mmsSummer internship project hr mba mms
Summer internship project hr mba mms
 
Recruitment and selection powerpoint presentation
Recruitment and selection powerpoint presentationRecruitment and selection powerpoint presentation
Recruitment and selection powerpoint presentation
 
RECRUITMENT AND SELECTION
RECRUITMENT AND SELECTIONRECRUITMENT AND SELECTION
RECRUITMENT AND SELECTION
 

Similar to bpcl

INTRODUCTION project apurv (1)
INTRODUCTION project apurv (1)INTRODUCTION project apurv (1)
INTRODUCTION project apurv (1)apurv rathore
 
Tarun Project Report On NTPC Kanti
Tarun  Project Report On NTPC KantiTarun  Project Report On NTPC Kanti
Tarun Project Report On NTPC KantiTarun Kumar
 
Training Report DCCPP, Dholpur
Training Report DCCPP, Dholpur Training Report DCCPP, Dholpur
Training Report DCCPP, Dholpur Yuvraj Singh
 
Ntpc (national thermal power corporation) sipat mechanical vocational trainin...
Ntpc (national thermal power corporation) sipat mechanical vocational trainin...Ntpc (national thermal power corporation) sipat mechanical vocational trainin...
Ntpc (national thermal power corporation) sipat mechanical vocational trainin...haxxo24
 
ramgarh gas thermal power plant training report by bhagu
ramgarh gas thermal power plant training report by bhaguramgarh gas thermal power plant training report by bhagu
ramgarh gas thermal power plant training report by bhaguBhagu Bhatia Devikot
 
Kota tharmal plant new.pdf
Kota tharmal plant new.pdfKota tharmal plant new.pdf
Kota tharmal plant new.pdfRahulLodha11
 
training report NTPC Muzaffarpur Bihar
training report  NTPC Muzaffarpur Bihar training report  NTPC Muzaffarpur Bihar
training report NTPC Muzaffarpur Bihar Dilip kumar
 
Ranjan NTPC KAHALGAON ppt
Ranjan  NTPC KAHALGAON pptRanjan  NTPC KAHALGAON ppt
Ranjan NTPC KAHALGAON pptRanjan kumar
 
Practical Training Report on RGTPP Ramgarh Jaisalmer
Practical Training Report on RGTPP Ramgarh JaisalmerPractical Training Report on RGTPP Ramgarh Jaisalmer
Practical Training Report on RGTPP Ramgarh JaisalmerKamleshkumar bishnoi
 
G03404047050
G03404047050G03404047050
G03404047050theijes
 
Ntpc (national thermal power corporation) sipat mechanical vocational trainin...
Ntpc (national thermal power corporation) sipat mechanical vocational trainin...Ntpc (national thermal power corporation) sipat mechanical vocational trainin...
Ntpc (national thermal power corporation) sipat mechanical vocational trainin...haxxo24
 
National fetilizers limited captive power plant
National fetilizers limited  captive power plantNational fetilizers limited  captive power plant
National fetilizers limited captive power plantNikhilesh joshi
 

Similar to bpcl (20)

INTRODUCTION project apurv (1)
INTRODUCTION project apurv (1)INTRODUCTION project apurv (1)
INTRODUCTION project apurv (1)
 
Tarun Project Report On NTPC Kanti
Tarun  Project Report On NTPC KantiTarun  Project Report On NTPC Kanti
Tarun Project Report On NTPC Kanti
 
Training Report DCCPP, Dholpur
Training Report DCCPP, Dholpur Training Report DCCPP, Dholpur
Training Report DCCPP, Dholpur
 
Ntpc (national thermal power corporation) sipat mechanical vocational trainin...
Ntpc (national thermal power corporation) sipat mechanical vocational trainin...Ntpc (national thermal power corporation) sipat mechanical vocational trainin...
Ntpc (national thermal power corporation) sipat mechanical vocational trainin...
 
ramgarh gas thermal power plant training report by bhagu
ramgarh gas thermal power plant training report by bhaguramgarh gas thermal power plant training report by bhagu
ramgarh gas thermal power plant training report by bhagu
 
Ntpc dadri
Ntpc dadriNtpc dadri
Ntpc dadri
 
Lovely Amit
Lovely AmitLovely Amit
Lovely Amit
 
Kota tharmal plant new.pdf
Kota tharmal plant new.pdfKota tharmal plant new.pdf
Kota tharmal plant new.pdf
 
Ntpc report harsh
Ntpc report  harshNtpc report  harsh
Ntpc report harsh
 
Ntpc report
Ntpc reportNtpc report
Ntpc report
 
training report NTPC Muzaffarpur Bihar
training report  NTPC Muzaffarpur Bihar training report  NTPC Muzaffarpur Bihar
training report NTPC Muzaffarpur Bihar
 
Ranjan NTPC KAHALGAON ppt
Ranjan  NTPC KAHALGAON pptRanjan  NTPC KAHALGAON ppt
Ranjan NTPC KAHALGAON ppt
 
SUMMER Training report AT NTPC FOR INSTRUMENTATION (kbunl)
SUMMER Training report AT NTPC FOR INSTRUMENTATION (kbunl)SUMMER Training report AT NTPC FOR INSTRUMENTATION (kbunl)
SUMMER Training report AT NTPC FOR INSTRUMENTATION (kbunl)
 
ONGC Summer Training Report
ONGC Summer Training ReportONGC Summer Training Report
ONGC Summer Training Report
 
Practical Training Report on RGTPP Ramgarh Jaisalmer
Practical Training Report on RGTPP Ramgarh JaisalmerPractical Training Report on RGTPP Ramgarh Jaisalmer
Practical Training Report on RGTPP Ramgarh Jaisalmer
 
internship report of Kepco
internship report of Kepcointernship report of Kepco
internship report of Kepco
 
G03404047050
G03404047050G03404047050
G03404047050
 
NTPC Dadri Gas plant
NTPC Dadri Gas plantNTPC Dadri Gas plant
NTPC Dadri Gas plant
 
Ntpc (national thermal power corporation) sipat mechanical vocational trainin...
Ntpc (national thermal power corporation) sipat mechanical vocational trainin...Ntpc (national thermal power corporation) sipat mechanical vocational trainin...
Ntpc (national thermal power corporation) sipat mechanical vocational trainin...
 
National fetilizers limited captive power plant
National fetilizers limited  captive power plantNational fetilizers limited  captive power plant
National fetilizers limited captive power plant
 

bpcl

  • 1. REPORT ON IN-PLANT TRAINING CONDUCTED BY DURATION OF TRAINING: - 6.7.2015 TO 17.7.2015 (10 DAYS) SUBMITTED BY:- BHARGAV KUMAR TRIPATHY 107112014 ELECTRICAL AND ELECTRONICS ENGINNERING NATIONAL INSTITUTE OF TECHNOLOGY TIRUCHIRAPPALLI 1 | P a g e
  • 2. CERTIFICATE This is to certify Mr. BHARGAV KUMAR TRIPATHY who is presently pursuing B.TECH in ELECTRICAL AND ELECTRONICS ENGINEERING at NATIONAL INSTITUTE OF TECHNOLOGY, TIRUCHIRAPPALLI has successfully completed the In-Plant training conducted at BPCL KOCHI REFINERY and has attended the course regularly and has submitted the report on the training conducted. Signature and seal of the guide: 2 | P a g e
  • 3. INTRODUCTION The Kochi Refinery (KR) is a public crude oil refinery in the city of Kochi, in the state of Kerala, India. It has a production capacity of 9.5 million tons per annum. Formerly known as Cochin Refineries Limited and later renamed as Kochi Refineries Limited, it was acquired by Bharat Petroleum Corporation Limited in the year 2006. HISTORY Kochi Refinery started on 27 April 1963 when Government of India, Phillips Petroleum Company of USA and Duncan Brothers of Calcutta signed an agreement for the construction of a petroleum refinery in south India, in Kochi, Kerala. The company was formally registered, as Cochin Refineries Ltd (CRL), on 6 September 1963 at Ernakulam. Phillips Petroleum International Corporation was the prime contractors for the construction of the refinery. Construction work started in March 1964 and the first unit came on stream just after 29 months in September 1966. The Prime Minister of India Ms.Indira Gandhi inaugurated it on 23 September 1966. In 2006, Kochi Refinery was acquired by the Bharat Petroleum Corporation Limited. CAPACITY The refinery had an original design capacity of 2.5 million metric tons per annum (mmtpa) which was increased to 3.3 mmtpa in 1973. Production of liquefied petroleum gas (LPG) and aviation turbine fuel (ATF) commenced after this expansion. Refining capacity was further enhanced to 4.5 mmtpa in November 1984 when a fluidized catalytic cracking unit (FCCU) of 1 MMTPA capacity was added. In Dec 1994, refining capacity was increased to 7.5 mmtpa (150,000 bpsd) along with revamp of FCCU to 1.4 MMTPA. A fuel gas de-sulphurisation unit was installed as part of this project to minimise sulphur dioxide emission. CRL entered into petrochemical sector in 1989 when aromatic production facilities with a design capacity of 87,200 tons per annum of benzene and 12,000 tons per annum of toluene was commissioned. In the year 2000, a 2 MMTPA Diesel Hydro De- sulphurisation (DHDS) plant was added to reduce the sulphur content in Diesel. In August 2010, the refining capacity was further increased to 9.5 mmtpa (190,000 bpsd). A captive power plant of 26.3 MW was commissioned in 1991. An additional captive power plant of 17.8 MW was commissioned in 1998 thus making the refinery self-sufficient in power. An LPG bottling plant of capacity 44,000 TPA was commissioned in 2003. A Bitumen Emulsion plant of 10000 TPA capacity has also been commissioned in 2004. A Biturox Bitumen Oxidation Unit of 378,000 TPA capacity was successfully commissioned and started-up in 2008. MERGER WITH BPCL 3 | P a g e
  • 4. Bharat Petroleum Corporation Limited (BPCL) acquired the Government of India's shares in KRL in March 2001. Consequent to the merger Order dated 18 August, 2006 issued by Ministry of Company Affairs, the refinery has been amalgamated with Bharat Petroleum Corporation, hence forth to be known as BPCL-Kochi Refinery. COMPETENCY Today Kochi Refinery is a frontline entity as the unit of the Fortune 500 company, BPCL. With a turnover of around US$2500 million, the refinery aims to strengthen its presence in refining and marketing of petroleum products and further grow into the energy and petrochemical sectors. Kochi Refinery produces all fuel based refinery products viz liquefied petroleum gas, naphtha, gasoline, kerosene, aviation turbine fuel, gas oil, fuel oil, and bitumen. The foray into direct marketing began since 1993 through marketing its aromatic products: benzene and toluene. The company entered the International Petroleum business stream when its first parcel of Fuel Oil was exported in January 2001. Since then the company has exported around 100 parcels. In the last financial year the refinery exported products worth over US$280 million. SPECIALTY PRODUCTS Kochi Refinery makes Specialty products for domestic markets Viz. Benzene, Toluene, White Spirit, Poly Iso Butane and Sulphur .Kochi Refinery offers supplies of any grade Fuel Oil (both 180 cst and 380 cst) and Low Aromatic Naphthalene (High Paraffinic) to the international market. Kochi Refinery also produces specialty grade bitumen products like Natural Rubber Modified Bitumen, Bitumen Emulsion etc .The Fuel Oil has been bench marked in the Singapore and Dubai Fuel Oil markets. Currently Kochi Refinery is known as BPCL Kochi Refinery (BPCL KR). KR is undergoing a capacity expansion which will make it a 15MMTPA refinery. This project called Integrated Refinery Expansion Project will also mark KR's foray into petrochemical business. This is a 20000 cores rupees project. POWER & UTILITY SECTION (P&U) In BPCL Kochi refinery the generation and utilization of power utilities is taken care by P&U Department which is subdivided in electrical section and utilities section. Electrical section takes care of the electrical maintenance, power generation and distribution. Utilities section takes care of generation and distribution of various utilities operation. DGM (P&U) heads the P&U department, Senior Manager in utilities and electrical section assists him. The power necessity and steam demand have increased considerably since commissioning of refinery in 1966.A 2.5 MW TG set was commissioned in 1985 along with FCCU and CO boiler. In 1991 a gas turbine cogeneration plant of base load capacity of 21.98 MW and HRSG of steam generation capacity 50 T/Hr were commissioned. Power and steam demands increased further due to new projects. Therefore in addition to existing GT and 2.5MW TG anew hp steam boiler UB7 and a condensing and double extraction type STG of 17.8MW capacity were installed and commissioned in 1997. Along with DHDS plant consisting of 2 boilers UB8 and UB9 of HP steam capacity of 60t/hr each and nitrogen plant was also commissioned in 2000. To make up the shortfall in steam 4 | P a g e
  • 5. production from CO Boiler due to FCCU revamp, UB 10 boiler of capacity 80t/hr was commissioned in 2005. CAPTIVE POWER PLANT (CPP) KSEB GRID Power from the main bus 1 or 2 is stepped down to 33KV using transformers TR1and TR2 which is received in a 33KV ABB GIS, two 33KV cable feeders bring KSEB power to BPCL and is received as grid incomer 1 & 2 at 33KV Siemens GIS in GT2 substation. Power requirement of BPCL-KR is around 55MW under full load operation of all processing plants.Power is generated and distributed from CPP using two Gas Turbine Generators GTG1 and GTG2 one steam turbine generator STG (not in use considering the economics and cost). It also receives power from 220 KV KSEB substation at Ambalamugal via two 33KV feeders -GRID incomer 1&2. Power is then distributed two 11KV/33KV substations from which is distributed to individual loads. Apart from this there is a 2.5 MW turbo Generator TG whose generation is controlled by Utilities section. Tie transformers 1, 2, 4 ties 33 KV gas insulated substation GIS to Switch gear SWGR 2101. In secondary distribution system power received at 33KV substation are converted to 6.6, 3.3KV, 415 ac, 230V ac, 110V ac, 110V dc. The black start transformer is used when bothGT2 and KSEB lines are faulty. The GIS bus will be charged when using black start transformer. The stationary auxiliary transformer is used by the auxiliary equipment in the system. The terminal voltage of all the 3 generators are 11KV and GT2 is connected to 33KV lines after stepping up the voltage using step-up transformer. As GT1 and STG are both connected to 11KV lines, power transformer is not used. The GIS bus is a 2 bus structure as shown below. A 2 bus structure is preferred for the continuity of service i.e. even if 1 bus fails other is able to supply. WORKING OF GT2 AT A GLANCE GT2 consists of a diesel engine, turbine, gearbox and compressor. The speed of diesel engine is 2000 rpm. When it attains a speed of 1000 rpm firing is given to the compressor which consists of air and fuel. When a spark is given to the compressor it ignites the gas used to run the turbine. The diesel engine is used separately for turbines as it requires high starting power which is obtained from the diesel engine. Diesel engine, generator and the turbine is connected to the same shaft. Diesel engine is used for the starting purpose of the turbine, once the turbine attains rated speed (5000rpm) FSNL, diesel engine is removed. At 60% of the turbine speed, fuel to diesel engine is cut, so its speed begins to fall while, the turbine remains in the same speed. Turbine and diesel engine is mechanically connected using a jaw clutch. Once the speed of the diesel engine decreases, the jaw clutch widens and it falls back from the shaft and thus after starting it disconnects from the shaft. The maximum speed of the generator is 3000rpm, but the turbine runs at 5000rpm. As they are connected to the same shaft, a gear box mechanism is used to decrease the speed of the turbine and feed it to the generator. EXCITATION SYSTEM IN GT2 5 | P a g e
  • 6. To avoid sparking due to a flow of high excitation current through brushes, brushless dc excitation scheme is implemented. It consists of the following components:-  Rotating diode rectifier  3 phase main exciter  3 phase pilot exciter  Digital Automatic voltage regulator The permanent magnet generator (PMG) consists of a permanent magnet and a coil, as the magnet is placed in the shaft, it rotates and an emf is induced. This ac is given to AVR. From there it is given to the exciter which is a single phase ac generator with stator on the shaft. Again in the exciter ac is produced which is rectified in a rectifier and is given as the excitation to the rotor of the main generator. The AVR is used for:-  To convert ac to dc  Regulation of output voltage of the main generator (this should be constant). When it decreases AVR increases its excitation and thus the terminal voltage increases and vice versa. SYNCHRONIZATION, CONTROL AND ANNUNCIATION PANEL (SCAP) This is a panel that is used for centralized monitoring control, status indication and annunciation of generators and transformers and also 33 or 11 KV breakers. For continuity in service synchronization or paralleling of generators GT1 or GT2 with the KSEB line is done. For 2 machines to be connected in parallel, its terminal voltage, frequency and phase sequence should be same. This is achieved through a synchroscope and synchronization trolley. SYNCHRONIZATION TROLLEY This is provided for synchronizing any breaker represented on SCAP. 20 pin synchronous sockets are provided for each breaker with synchronization provision. Socket may be connected to the synchronization trolley using connector cables.  Diesel Engine Battery bank: The starter for diesel engine requires 12 V dc, which is provided using lead- acid batteries. UNINTERRUPTED POWER SUPPLY (UPS) Uninterrupted 110V ac power to meet critical loads can’t withstand a momentary interruption or other ac mains disturbance in supply voltage. Every UPS shall be provided with separate battery bank for energy storage, which shall be used during the periods of main power interruption. Following loads are connected:-  Critical instrumentation and process control.  Critical communication equipment.  Microprocessor based distribution digital control system. A typical UPS consists of rectifier, inverter bypass supply, battery bank. Rectifier is a thyristor based circuit used to provide dc voltage to keep battery bank in floating charging. The inverter converters 6 | P a g e
  • 7. dc to 110v ac using thyristor controlled circuits. A servo based voltage regulator adjusts output voltage of the bypass supply to 110V ac. Bypass supply may be used during planned maintenance of UPS or during failure of both UPS. BATTERY CHARGES Thyristor controlled battery charges are used to rectify 415V ac supply to a voltage suitable for charging a battery bank. For Ni-Cd battery banks, the charger feeds DC loads and charges the battery bank at float voltage in normal condition. LOAD SHEDDING AND ISLANDING SCHEME LOAD SHEDDING SCHEME Generation capacity available at any point of time is sufficient to cater the load requirement. If total available generation capacity is less than load requirement (due to tripping of generators, disconnected of power carrying links to bus bar etc.) there is a possibility of generators to trip one by one on overload resulting to Blackout. To avoid this, frequency based load shedding scheme was introduced to ensure that loads are shed on its non-critically, until the available generation can cater more critical loads thereby saving critical plant loads and avoiding a blackout. ISLANDING SCHEME When BPCL-KR captive generation is parallel with KSEB any fault outside KR electrical system (faults in KSEB) will also be fed by KR captive generation. The same happens if there is a failure in KSEB grid voltage. It is essential to make KR system independent of KSEB grid during times of instability or faults, thus ensuring that doesn’t disturb KR system. This is done using relays. Relays sense the voltage of grid 1 & 2 to monitor the voltage, rate of change of voltage, frequency, rate of change of frequency and the direction of fault current of KSEB grid. Selectivity of islanding sensitivity is based on availability of captive generators and is implemented in islanding relays using setting group change logic. Logic enables group A with more sensitivity settings for islanding relays when all the generators are running in parallel thus islanding relay uses setting group B with lesser sensitivity settings, which restricts occurrence of islanding only to more severe faults in KSEB thereby ensuring higher availability of KSEB during a shortage in captive generation. PROCEESING UNITS The crude oil processed in the refinery is classified into 1) Indigenous 2) Low sulphur imported crude 3) High sulphur imported crude BH crude is low in sulphur content and high sulphur crude imported from the Persian gulf region (PG) is having higher sulphur content as today more than 60 different crude oils have been processed in the units the important process units and there features are explained below DIESEL HYDRO DESULPHURIZATION (DHDS) UNIT High speed diesel (HTS) contains contaminants like organic sulphur nitrogen and metal compounds 7 | P a g e
  • 8. with contribute to increased level of air pollution, equipment corrosion etc. The diesel hydro desulphurization (HSD) converts the sulphur in presence of hydrogen to H2S so that sulphur level in HSD is reduced less than 100ppm. The unit utilizes a fixed bed catalyst process to upgrade the quality of petroleum distillate fractions by decomposing the contaminants with a negligible effect on the boiling range of feed. The hydrogen required for the purpose is obtained by steam naphtha reforming as feedstock. The raw feedstock utilized to generate hydrogen is first desulphurised in the final desulphurization unit (FDS) to sulphur level of less than 0.05ppm. The sweet feed (free of sulphur) is then performed to convert higher hydrocarbon to methane. The methane rich feed is then reformed. The hydrogen obtained by reforming is around 70% pure. The pressure swing adsorption (PSA) unit further enhances the purity of hydrogen to 99.99% volume. H2S gas from DHDS is treated with amine to enrich it and then the H2S rich gas is treated in sulphur recovery unit SRU to obtain sulphur as a byproduct. The sulphur is obtained by clauses process. The acid gas from the clauses reactor is treated in maximum clauses recovery concept unit to recover sulphur to maximum possible extend. HTLC STARTER The HTLC (High Torque Low Current) Starter is Converteam’s patented motor starting method for high inertia loads using a low voltage with input and output transformers to control motor torque and limit current when starting a medium/high voltage motor. The HTLC is a solution to motor starting problems where Direct on Line (DOL) starting is not feasible due to high inrush current, causing problems on the distribution system or where a reduced voltage starter cannot provide enough torque to achieve breakaway and accelerate the motor to full speed. The conventional starting method for medium voltage induction motor is to start them DOL. This typically results in 600% inrush current while motor is accelerating. The breakaway or locked rotor torque for a motor is around 80%. At remote sites with long power line feeds, the utility will not permit the use of high current DOL starter’s .The unusual approach is to use a reduced voltage soft starter. The net result of this reduced starting torque is that the motor would not be able to break the “stiction” therefore limiting acceleration or simply stalling. The Converteam HTLC overcomes both of these problems. In excess of 60% torque is available at breakaway requiring less than 10% current at starting , increasing to approximately 30% at full load speed. The HTLC starter can be used to start most unloaded compressors with MV/HV motors up to around 20000HP as a practical limit. The HTLC is equipped with an input isolation transformer to change the medium voltage supply to a low voltage level, typically 690V. The VFD i chosen to deliver the current needed to start the motor and connected load. The auto transformer use three resistors connected in series with the windings at low frequencies to add impedance to the circuit and limit the transformer saturation current. As the frequency increases, the resistors are removed from the circuit and the transformers then operates normally. 8 | P a g e
  • 9. The VFD operator at its own variable frequency and will not be in synchronism with the grid when the motor reaches the full speed. In order to match the grid frequency the inverter will typically run at a frequency slightly above the grid so that the VFD and the grid will match the phase rotation and can accommodate any variations in the supply frequency. The HTLC contains a synchronizing relay that determines when the two are frequency and phase matched. When the match is detected a signal is sent to close the bypass circuit breaker or contactor in the Medium Voltage Switchgear. Once the breaker closes the inverter load will increase as it is still running at a frequency slightly higher than the suppy but still in parallel with it. At this point the HTLC output circuit breaker will open, the drive will shut off and the motor is then operated solely from the utility supply. The HTLC input power can be removed at this point as the starter is no longer required. HTLC Features 1) Reduces starting inrush current from 600% to 10%. 2) Over 60% Breakaway torque available 3) Multiple motors started from a single HTLC starter. 4) Up to 12 starts per hour permitted. 5) Bump less transfer to line at 50 or 60 Hz. 6) Significantly less costly than fully rated VFD. SYNCHRONOUS MOTOR STARTING The standard synchronous motor, those designed for line supply and fixed speed, have brushless dc excitation and use built in induction motor features for starting. For the soft or weak line condition (allowed current <100%) the >400% Direct on line current will be unacceptable. Reducing the voltage will reduce the starting torque in proportion to the voltage squared, so there may not be enough torque. The HTLC system utilizes a VFD to ramp up the voltage and frequency from start to 100% speed. For a typical induction motor this allows a very effective motor utilization achieving near 1 per unit torque/current at all speeds. The relatively poor induction motor characteristics prevent the synchronous motor from achieving good torque efficiency. For a given motor the ratio of Torque/Stator current is maximum of 0.4 at 90% speeds (10% slip). Even with the benefit of a VFD providing the maximum torque efficiency at all speeds the value of 0.4 wold mean we need >100% stator current for 44% breakaway torque. The great benefit of the asynchronous motor is that torque is proportional to the product of the stator and excitation flux. If excitation can be 100% the required stator current for 44% torque reduces to 44% or less. This solution requires an AC exciter CRUDE DISTILLATION UNIT (CDU) The crude oil distillation unit (CDU) is the first processing unit in virtually all petroleum refineries. The CDU distills the incoming crude oil into various fractions of different boiling ranges, each of which are then processed further in the other refinery processing units. The CDU is often referred to as the atmospheric distillation unit because it operates at slightly above atmospheric pressure. The 9 | P a g e
  • 10. incoming crude oil is preheated by exchanging heat with some of the hot, distilled fractions and other streams. It is then desalted to remove inorganic salts (primarily sodium chloride). Following the desalter, the crude oil is further heated by exchanging heat with some of the hot, distilled fractions and other streams. It is then heated in a fuel-fired furnace to a temperature of about 398 °C and routed into the bottom of the distillation unit. The cooling and condensing of the distillation tower overhead is provided partially by exchanging heat with the incoming crude oil and partially by either an air-cooled or water-cooled condenser. Additional heat is removed from the distillation column by a pump around system. The residue from an atmospheric distillation tower can be sent to a vacuum distillation tower, which recovers additional liquid at 4.8 to 10.3 kPa. The vacuum, which is created by a vacuum pump or steam ejector, is pulled from the top of the tower. Relative to atmospheric columns, vacuum columns have larger diameters and their internals are simpler. Often, instead of trays, random packing and demister pads are used. The overhead stream – light vacuum gas oil – can be used as a lube base stock, heavy fuel oil, or as feed to a conversion unit. Heavy vacuum gas oil is pulled from a side draw. The vacuum residue can be used to make asphalt, or it can be sent to a coker or visbreaker unit for further processing. Some of the products obtained are Naptha, Heavy Naptha, Kerosene diesel and reduced crude oil. BPCL-KR has two distillation units with capacities 4.5MMTPA and 5.0MMPTA adding to a total of installed capacity of 9.5MMPTA. SPM The SPM facility at offshore Kochi. An offshore crude oil receipt facility consisting of an offshore single point mooring (SPM) facility and an associated shore tank farm (situated in Vypin). This was commissioned on December 2007. The refinery is equipped to receive crude oil in Very Large Crude Carriers (VLCCs). PROCESS Kochi Refinery presently has a crude oil processing capacity of 9.5 MMTPA (Million Tons per Annum) in its two Crude Distillation units (CDU-1 and CDU-2). The refinery currently processes about 30% of Indigenous and 70% Imported crude oils. Crude oil is transported in ships from the point of origin to Kochi and is received through a Single Point Mooring (SPM) facility. Kochi SPM, located approximately 20 km off the shore of Puthuvypeen, is capable of handling Very large Crude Carriers (VLCC) with crude oil carrying capacities up to 3.0 Lakh Tons. Crude oil from SPM is received in offshore tanks in Puthuvypeen and is then pumped to the refinery. SINGLE POINT MOORING A Single buoy mooring (SBM) (also known as single-point mooring or SPM) is a loading buoy anchored offshore, that serves as a mooring point and interconnect for tankers loading or offloading gas or liquid products. SPMs are the link between geostatic subsea manifold connections and weathervaning tankers. They are capable of handling any size ship, even very large crude carriers (VLCC) where no alternative facility is available. PARTS There are four parts in the total buoying system: the body of the buoy, mooring and anchoring elements, product transfer system and other components. 10 | P a g e
  • 11. BUOY BODY The buoy body usually is supported on static legs attached to the seabed, with a rotating part above water level connected to the (off) loading tanker. The two sections are linked by a roller bearing, referred to as the "main bearing". The moored tanker can freely weather vane around the buoy and find a stable position due to this arrangement. MOORING AND ANCHORING PARTS Moorings fix the buoy to the seabed. Buoy design must account for the behavior of the buoy given applicable wind, wave and current conditions and tanker sizes. This determines the optimum mooring arrangement and size of the various mooring leg components. Anchoring points are greatly dependent on local soil condition. TRANSFORMER A transformer is an electrical device that transfers electrical energy between two or more circuits through electromagnetic induction. Commonly, transformers are used to increase or decrease the voltages of alternating current in electric power applications. A varying current in the transformer's primary winding creates a varying magnetic flux in the transformer core and a varying magnetic field impinging on the transformer's secondary winding. This varying magnetic field at the secondary winding induces a varying electromotive force (EMF) or voltage in the secondary winding. Operation of a transformer at its designed voltage but at a higher frequency than intended will lead to reduced magnetizing current. At a lower frequency, the magnetizing current will increase. Operation of a transformer at other than its design frequency may require assessment of voltages, losses, and cooling to establish if safe operation is practical. For example, transformers may need to be equipped with 'volts per hertz' over-excitation relays to protect the transformer from overvoltage at higher than rated frequency. TIE transformers in BPCL-KR are connected between GIS and HT-101/SWGR-2101 switchgear. The scheme is as shown. The transformers are situated at GT-2 substation and 11kV cables are led from HT-101 switchgear to live isolation breaker (LIB) situated at GT-2 substation. From LIB, transformers feed and the neutral isolation breakers (NIB) is given on both sides of the transformer. 11 | P a g e
  • 12. Fig: TIE transformer ENERGY LOSSES Real transformer energy losses are dominated by winding resistance joule and core losses. Transformers' efficiency tends to improve with increasing transformer capacity. The efficiency of typical distribution transformers is between about 98 and 99 percent. As transformer losses vary with load, it is often useful to express these losses in terms of no-load loss, full-load loss, half-load loss, and so on. Hysteresis and eddy current losses are constant at all load levels and dominate overwhelmingly without load, while variable winding joule losses dominating increasingly as load increases. The no-load loss can be significant, so that even an idle transformer constitutes a drain on the electrical supply. Designing energy efficient transformers for lower loss requires a larger core, good-quality silicon steel, or even amorphous steel for the core and thicker wire, increasing initial cost. The choice of construction represents a trade-off between initial cost and operating cost. Transformer losses arise from: 1) Winding joule losses 2) Core losses 3) Hysteresis losses 4) Eddy current losses 5) Stray losses TIE TRANSFORMER SPECIFICATION: 12 | P a g e
  • 13. MAKE BHEL MVA 37.5 VOLTAGE (HT/LT) 33/11 kV CURRENT (HT/LT) 656.8/1968.24 A COOLING ONAN OTL BHEL MAKE VECTOR GROUP YNyn0 PARTS OF TRANSFORMER 1) WINDINGS Windings are usually arranged concentrically to minimize flux leakage. The conducting material used for the windings depends upon the application, but in all cases the individual turns must be electrically insulated from each other to ensure that the current travels throughout every turn. For small power and signal transformers, in which currents are low and the potential difference between adjacent turns is small, the coils are often wound from enameled magnet wire, such as Formvar wire. Larger power transformers operating at high voltages may be wound with copper rectangular strip conductors insulated by oil-impregnated paper and blocks of pressboard. The windings of signal transformers minimize leakage inductance and stray capacitance to improve high-frequency response. Coils are split into sections, and those sections interleaved between the sections of the other winding. Power-frequency transformers may have taps at intermediate points on the winding, usually on the higher voltage winding side, for voltage adjustment. Taps may be manually reconnected, or a manual or automatic switch may be provided for changing taps. Automatic on-load tap changers are used in electric power transmission or distribution, on equipment such as arc furnace transformers, or for automatic voltage regulators for sensitive loads. Audio-frequency transformers, used for the distribution of audio to public address loudspeakers, have taps to allow adjustment of impedance to each speaker. A center-tapped transformer is often used in the output stage of an audio power amplifier in a push-pull circuit. Modulation transformers in AM transmitters are very similar. 2) COOLING Cutaway view of liquid-immersed construction transformer. The conservator (reservoir) at top 13 | P a g e
  • 14. provides liquid-to-atmosphere isolation as coolant level and temperature changes. The walls and fins provide required heat dissipation balance. To place the cooling problem in perspective, the accepted rule of thumb is that the life expectancy of insulation in all electric machines including all transformers is halved for about every 7 °C to 10 °C increase in operating temperature, this life expectancy halving rule holding more narrowly when the increase is between about 7 °C to 8 °C in the case of transformer winding cellulose insulation. 3) INSULATION DRYING Construction of oil-filled transformers requires that the insulation covering the windings be thoroughly dried of residual moisture before the oil is introduced. Drying is carried out at the factory, and may also be required as a field service. Drying may be done by circulating hot air around the core, or by vapor-phase drying (VPD) where an evaporated solvent transfers heat by condensation on the coil and core. 3) BUSHINGS Larger transformers are provided with high-voltage insulated bushings made of polymers or porcelain. A large bushing can be a complex structure since it must provide careful control of the electric field gradient without letting the transformer leak oil. 4) BUCHHOLZ RELAY It is a very sensitive gas and oil operated instrument which safely detect the formation of gas or sudden pressure inside the oil transformer. 5) CONSERVATOR It is used to provide adequate space for the expansion of oil when transformer is loaded or when ambient temperature changes. 6) SILICA GEL BREATHER It sucks the moisture from the air which is taken by transformer so that dry air is taken by transformer. 7) DOUBLE DIAPHRAGM EXPLOSION VENT It is used to discharge excess pressure in the atmosphere when excess pressure is developed inside the transformer during loading. 8) OIL LEVEL INDICATOR It is used to show the oil level in the transformer. 9) WINDING TEMPRATURE INDICATOR Used to show the temperature of transformer winding. 10) RADIATORS 14 | P a g e
  • 15. These are used for cooling of the transformer oil. PROTECTION FOR TRANSFORMERS 1. Faults generating production of gases, mainly: • Micro arcs resulting from incipient faults in the winding insulation • Slow degradation of insulation materials • Inter turns short circuit 2. Faults generating internal over pressures with simultaneously high level of line over currents: • Phase to earth short circuit • Phase to Phase short circuit. These faults may be the consequence of external lightning or switching over voltage. Depending on the type of the transformer, there are two kinds of devices able to detect internal faults affecting an oil filled transformer. 3. Buchholz Relay The Buchholz dedicated to the transformers equipped with an air breathing conservator. The Buchholz is installed on the pipe connecting the tank of the transformer to the conservator. It traps the slow emissions of gasses and detect the flow back of oil due to the internal over pressures 4. Backup Protection • Differential protection • Restricted earth fault protection 15 | P a g e
  • 16. • Circuit breaker fail to trip • Oil temperature trip • Winding temperature trip • Inter trip • Buchholz trip GAS INSULATED SUBSTATION (GIS) The 33kV switchgear at GT-2 substation is of Siemens make. It is a Gas Insulated Switchgear in which the current carrying conductors is placed inside a gas chamber. This will reduce the spacing requirement and thus reducing the size of switchgear. The gas used is SF6 and the breakers are vacuum interrupts. The substation facility comprises 3 compartments sealed with a 1.35 kg/cm2 rated pressure SF6 gas and a control circuit compartment with control devices mechanism and a gas pressure monitoring device. The main circuit live section is divided into a bus bar compartment in which the bus running through all the cubicles. A load side device compartment consist of a vacuum circuit breaker and isolator. The bus bar compartment and the load-side device compartments are gas-sectionalized from each other. CTs are mounted in cable compartment and VTs are top mounted. The gas-tight compartments and the gas seals ensure long service life. A gas density monitor which is temperature compensated provides accurate readings on the internal gas condition of the switchgear. The rated current is 2500A and has a fault current capacity of 40kA, there are 22 panel consisting of the following 1. 2 generator incomer feeders 2. 2 grid (KSEB) incomer feeders 3. 2 feeders for SAT 4. 6 outgoing feeders 5. 2 spare outgoing feeders 6. 2 bus couplers 7. 2 bus sectionalizer 8. 4 TIE transformer feeders • CIRCUIT BREAKER OPERATION 1. Manual operation: Refer to the Breaker Installation Manual and the caution plate of the operating device for the 16 | P a g e
  • 17. operation of the breaker. 2. Electrical operation: Turn the local breaker control switch (TNC) handle on the front door panel to OFF or ON or remotely switch the breaker. The status of the device can be checked with the indicators located at the front door. • EARTHING OF BUS AND SWITCHES 1. An interlock allows the bus to be earthed when all the feeder switches are disconnected from the bus (Dead Bus Check). 2. This is to ensure the respective bus is dead before earthing. This applies to both single and double bus design. 3. Motorised version of the earth switch is provided as standard package. 4. Unless specified, only a manual earth switch is allocated. Any special interlocks for earthing operations will be shown in the technical project drawings. • SAFETY INTERLOCKS IN GIS SWITCHGEARS Following Interlocks are provided in GIS switchgear for safety purpose during operation & maintenance:- 1. Mechanical & Electrical interlocks prevent the operation of disconnector switch, when the breaker is ON. 2. Disconnector switch can be operated only when VCB is off. 3. Closure of VCB is not possible when the disconnector switch is in operation. 4. At a time, Disconnector switch can be operated either electrically or mechanically but not simultaneously. 5. Closure of VCB is not possible unless the spring is fully charged. • VACCUM BREAKER The mechanism and drive is bolted out side of the circuit breaker tank and the three pole assemblies are bolted inside SF6 tank. They are connected via contact wipe springs and coupling rods through gas tight sealing bushes to the insulators to the vacuum interrupter moving terminals. The sealing ring is mounted in the brass hub on the tank. The mechanism is of the stored energy, motor wound or manually charged spring operated type. It is suitable for auto reclosing duties. Basically it comprises a closing spring charging system and a spring charged latch, a closing cam, the close / trip latch which is displaced to trip the closed circuit breaker, and the drive to the poles in the form of the secondary shaft. In addition there are the spring release solenoid, the trip solenoid, the auxiliary switches and manual operation On-Off push buttons. When the closing spring is CHARGED and the circuit breaker indicates Open, the circuit breaker can be closed by either the electrical release of the closing spring or by the manual close pushbutton. 17 | P a g e
  • 18. This causes the main shaft and thus the drive cam to rotate driving the secondary shaft anti- clockwise via the roller. When the circuit breaker is fully closed, the close/trip latch locates behind the roller holding the circuit breaker closed and indicating Close. GAS TURBINE The gas turbines are of BHEL make GT-1 is of frame 6 having an ISO rating of 42.3MW. The generator of GT-2 is of BHEL make having an ISO rating of 34.5MW at 0.8pf load. It is also having Brusheless Excitation Scheme (BLE). GT-2 is provided with neutral grounding. The designed open cycle efficiency is 32% compared to 28.5% of frame 5 GT-1. It is designed for 3 types of fuel LCO, Naptha and KERO- 2. The expected fuel consumption at rated load is 10T/hr. GT-2 is hooked to the 33kV GIS through a step up transformer .The cooling is done by air which in turn is cooled by water. GT-2 Specification:- MAKE BHEL MVA 43.12 MW 34.5 STATOR (kV) 11kV ROTOR 207V EXCITATION BRUSHLESS MODEL TRAI 80024P POWER FACTOR 0.8 Electrical Power Generation In electricity generating applications the turbine is used to drive a synchronous generator which provides the electrical power output but because the turbine normally operates at very high rotational speeds of 12,000 r.p.m or more it must be connected to the generator through a high ratio reduction gear since the generators run at speeds of 1,000 or 1,200 r.p.m. depending on the AC frequency of the electricity grid. In a practical gas turbine, mechanical energy is irreversibly transformed into heat when gases are compressed (in either a centrifugal or axial compressor), due to internal friction and turbulence. GT-1 Specification:- MAKE BHEL MVA 27.5 MW 22 EXCITATION BRUSHLESS SPEED 3000rpm POWER FACTOR 0.8 18 | P a g e
  • 19. Turbine Configurations Gas turbine power generators are used in two basic configurations Simple Systems consisting of the gas turbine driving an electrical power generator. RELAY PROTECTION In electrical engineering, a protective relay is a device designed to trip a circuit breaker when a fault is detected. The first protective relays were electromagnetic devices, relying on coils operating on moving parts to provide detection of abnormal operating conditions such as over-current, over- voltage, reverse power flow, over- and under- frequency. Microprocessor-based digital protection relays now emulate the original devices, as well as providing types of protection and supervision impractical with electromechanical relays. Electromechanical protective relays at a hydroelectric generating plant. The relays are in round glass cases. The rectangular devices are test connection blocks, used for testing and isolation of instrument transformer circuits. The theory and application of these protective devices is an important part of the education of an electrical engineer who specializes in power systems. The need to act quickly to protect circuits and equipment as well as the general public often requires protective relays to respond and trip a breaker within a few thousandths of a second. In these cases it is critical that the protective relays are properly maintained and regularly tested. OPERATION PRINCIPLES Electromechanical protective relays operate by either magnetic attraction, or magnetic induction. Unlike switching type electromechanical relays with fixed and usually ill-defined operating voltage thresholds and operating times, protective relays have well-established, selectable and adjustable time/current (or other operating parameter) operating characteristics. Protection relays may use arrays of induction disks, shaded-pole magnets, operating and restraint coils, solenoid-type operators, telephone-relay contacts, and phase-shifting networks. Protective relays can also be classified by the type of measurement they make. A protective relay may respond to the magnitude of a quantity such as voltage or current. Induction types of relay can respond to the product of two quantities in two field coils, which could for example represent the power in a circuit. Although an electromechanical relay calculating the ratio of two quantities is not practical, the same effect can be obtained by a balance between two operating coils, which can be arranged to effectively give the same result. By use of a permanent magnet in the magnetic circuit, a relay can be made to respond to current in 19 | P a g e
  • 20. one direction differently from in another. Such polarized relays are used on direct-current circuits to detect, for example, reverse current into a generator. These relays can be made bistable, maintaining a contact closed with no coil current and requiring reverse current to reset. For AC circuits, the principle is extended with a polarizing winding connected to a reference voltage source. Light weight contacts make for sensitive relays that operate quickly, but small contacts can't carry or break heavy currents. Often the measuring relay will trigger auxiliary telephone-type armature relays. In a large installation of electromechanical relays, it would be difficult to determine which device originated the signal that tripped the circuit. This information is useful to operating personnel to determine the likely cause of the fault and to prevent its re-occurrence. Relays may be fitted with a "target" or "flag" unit, which is released when the relay operates, to display a distinctive colored signal when the relay has tripped. TYPES ACCORDING TO CONSTRUCTION 1) ELECTROMECHANICAL Electromechanical relays can be classified into several different types as follows: a) Attracted armature b) Moving coil c) Induction d) Motor operated e) Mechanical f) Thermal "Armature"-type relays have a pivoted lever supported on a hinge or knife-edge pivot, which carries a moving contact. These relays may work on either alternating or direct current, but for alternating current, a shading coil on the pole is used to maintain contact force throughout the alternating current cycle. Because the air gap between the fixed coil and the moving armature becomes much smaller when the relay has operated, the current required to maintain the relay closed is much smaller than the current to first operate it. The "returning ratio" or "differential" is the measure of how much the current must be reduced to reset the relay. A variant application of the attraction principle is the plunger-type or solenoid operator. A reed relay is another example of the attraction principle. "Moving coil" meters use a loop of wire turns in a stationary magnet, similar to a galvanometer but with a contact lever instead of a pointer. These can be made with very high sensitivity. Another type of moving coil suspends the coil from two conductive ligaments, allowing very long travel of the coil. 2) STATIC RELAY The conventional relay type of electromagnet relays can be replaced by static relays which essentially consist of electronic circuitry to develop all those characteristics which are achieved by moving parts in an electro-magnetic relay. Static relays are capable of performing the same functions with the use of electronic circuit control as an electro-magnetic relay performs with the 20 | P a g e
  • 21. use of moving parts or elements. Static relays are superior to electro-magnetic relays for example, the moving parts and the contacts are largely eliminated. The only moving element in a static relay is the final tripping contact. C.T.s and P.T.s employed are of lesser VA rating as static relays require a very little volt-ampere for their operation. More precise and high speed operation. 3) NUMERICAL RELAY In utility and industrial electric power transmission and distribution systems, a digital protective relay uses a microcontroller with software-based protection algorithms for the detection of electrical faults.[1] Such relays are also termed as microprocessor type protective relays. They are functional replacements for electromechanical protective relays and may include many protection functions in one unit, as well as providing metering, communication, and self-test functions. RELAYS BY FUNCTIONS The various protective functions available on a given relay are denoted by standard ANSI Device Numbers. For example, a relay including function 51 would be a timed overcurrent protective relay. 1) OVER CURRENT RELAY A digital overcurrent relay is a type of protective relay which operates when the load current exceeds a pickup value. The ANSI device number is 50 for an instantaneous over current (IOC) and 51 for a time over current (TOC). In a typical application the over current relay is connected to a current transformer and calibrated to operate at or above a specific current level. When the relay operates, one or more contacts will operate and energize to trip (open) a circuit breaker. 2) DISTANCE RELAY Distance relay differ in principle from other forms of protection in that their performance is not governed by the magnitude of current or the voltage in the protected circuit but rather on the ratio of these two quantity .Distance relay are actually double actuating quantity relay with one coil energized by voltage and other coil by current. The current element produces a positive or pick up torque while the voltage element produces a negative or reset torque. The relay operates only when the V/I ratio falls below a predetermined value (or set value).During a fault on the transmission line the fault current increases and the voltage at the fault point decreases. The V/I ratio is measured at the location of CTs and PTs. The voltage at PT location depends on the distance between PT and the fault. If the measured voltage is lesser that means fault is nearer and vice-versa. Hence the protection called Distance relay. 3) CURRENT DIFFERENTIAL PROTECTION Another common form of protection for apparatus such as transformers, generators, busses and power lines is current differential. This type of protection works on the basic theory of Kirchhoff's current law, which states that the sum of the currents entering and exiting a node will equal zero. Differential protection requires a set of current transformers (smaller transformers that transform currents down to a level which can be measured) at each end of the power line, or each side of the transformer. The current protection relay then compares the currents and calculates the difference 21 | P a g e
  • 22. between the two. 4) DIRECTIONAL RELAY A directional relay uses an additional polarizing source of voltage or current to determine the direction of a fault. The fault can be located upstream or downstream of the relay's location, allowing appropriate protective devices to be operated inside or outside of the zone of protection. 5) THERMAL RELAY The coefficient of expansion is one of the basis properties of any material. Two different metals always have different degree of linear expansion. A bimetallic strip always bends when it heated up, due to this inequality of linear expansion of two different metals. MPRT-MEGGER PROTECTIVE RELAY TEST SYSTEM Megger-MPRT is specifically designed to perform routine testing of protective relays used in the operation of electrical utilities, power plants and heavy industrial. The ‘power box’ is the heart of the system. It employees a variety of new features including unique voltage and current generator components the flexibility to deliver four voltages and four current or eight current channel capability and everyone is made to order based on each costumers individual testing requirements. SUBSTATION EQUIPMENT In BPCL-KR a 220kV substation is situated which gets its incoming from KSEB grid. There are many equipment required in the substation. Some of the equipment can be listed as follows: 1. LIGHTENING ARRESTER: Lightening arrestors are the instrument that are used in the incoming feeders so that to prevent the high voltage entering the main station. This high voltage is very dangerous to the instruments used in the substation. Even the instruments are very costly, so to prevent any damage lightening arrestors are used. The lightening arrestors do not let the lightening to fall on the station. If some lightening occurs the arrestors pull the lightening and ground it to the earth. In any substation the 22 | P a g e
  • 23. main important is of protection which is firstly done by these lightening arrestors. The lightening arrestors are grounded to the earth so that it can pull the lightening to the ground. The lightening arrestor works with an angle of 30° to 45° making a cone. 2. C V T (CPACITIVE VOLTAGE TRANSFORMER): A capacitor voltage transformer (CVT) is a transformer used in power systems to step-down extra high voltage signals and provide low voltage signals either for measurement or to operate a protective relay. In its most basic form the device consists of three parts: two capacitors across which the voltage signal is split, an inductive element used to tune the device to the supply frequency and a transformer used to isolate and further step-down the voltage for the instrumentation or protective relay. The device has at least four terminals, a high-voltage terminal for connection to the high voltage signal, a ground terminal and at least one set of secondary terminals for connection to the instrumentation or protective relay. CVTs are typically single-phase devices used for measuring voltages in excess of one hundred kilovolts where the use of voltage transformers would be uneconomical. In practice the first capacitor, C1, is often replaced by a stack of capacitors connected in series. This results in a large voltage drop across the stack of capacitors that replaced the first capacitor and a comparatively small voltage drop across the second capacitor, C2, and hence the secondary terminals. 3. WAVE TRAP: Wave trap is an instrument using for tripping of the wave. The function of this trap is that it traps the unwanted waves. Its function is of trapping wave. Its shape is like a drum. It is connected to the main incoming feeder so that it can trap the waves which may be dangerous to the instruments here in the substation. 4. INSTRUMENT TRANSFORMER: Current transformers are basically used to take the readings of the currents entering the substation. This transformer steps down the current from 800 amps to 1 amp. This is done because we have no instrument for measuring of such a large current. The main use of this transformer is • CURRENT TRANSFORMER: current transformer is defined as an instrument transformer in which the secondary current is substantially proportional to the primary current (under normal conditions of operation) and differs in phase from it by an angle which is approximately zero for an appropriate direction of the connections. This highlights the accuracy requirement of the current transformer but also important is the isolating function, which means no matter what the system voltage the secondary circuit need to be insulated only for a low voltage. • POTENTIAL TRANSFORMER: The standards define a voltage transformer as one in which the secondary voltage is substantially proportional to the primary voltage and differs in phase from it by an angle which is approximately equal to zero for an appropriate direction of the connections. This in essence means that the voltage transformer has to be as close as possible to the ideal transformer. In an ideal transformer, the secondary voltage vector is exactly opposite and equal to the primary voltage vector when multiplied by the turn’s ratio. In a practical transformer, errors are introduced because some current is drawn for the magnetization of the core and because of 23 | P a g e
  • 24. drops in the primary and secondary windings due to leakage reactance and winding resistance. One can thus talk of a voltage error which is the amount by which the voltage is less than the applied primary voltage and the phase error which is the phase angle by which the reversed secondary voltage vector is displaced from the primary voltage vector. 5. BUS BAR: The bus is a line in which the incoming feeders come into and get into the instruments for further step up or step down. The first bus is used for putting the incoming feeders in la single line. There may be double line in the bus so that if any fault occurs in the one the other can still have the current and the supply will not stop. The two lines in the bus are separated by a little distance by a conductor having a connector between them. This is so that one can work at a time and the other works only if the first is having any fault. 6. CIRCUIT BREAKER: The circuit breakers are used to break the circuit if any fault occurs in any of the instrument. These circuit breaker breaks for a fault which can damage other instrument in the station. For any unwanted fault over the station we need to break the line current. This is only done automatically by the circuit breaker. The use of SF6 circuit breaker is mainly in the substations which are having high input kv input, say above 220kv and more. The gas is put inside the circuit breaker by force i.e. under high pressure. When if the gas gets decreases there is a motor connected to the circuit breaker. The motor starts operating if the gas went lower than 20.8 bar. There is a meter connected to the breaker so that it can be manually seen if the gas goes low. The circuit breaker uses the SF6 gas to reduce the torque produce in it due to any fault in the line. The circuit breaker has a direct link with the instruments in the station, when any fault occur alarm bell rings. 7. TRANSFORMER: There are three transformers in the incoming feeders so that the three lines are step down at the same time. In case of a 220KV or more KV line station auto transformers are used. The transformer is transported on tailor to substation site and as far as possible directly unloaded on the plinth. Transformer tanks up to 25 MVA capacity are generally oil filled, and those of higher capacity are transported with N2 gas filled in them +ve pressure of N2 is maintained in transformer tank to avoid the ingress of moisture. This pressure should be maintained during storage, if necessary by filling N2 Bushings - generally transported in wooden cases in horizontal position and should be stored in that position. There being more of fragile material, care should be taken while handling them. Radiators – These should be stored with ends duly blanked with gaskets and end plates to avoid in gross of moisture, dust, and any foreign materials inside. The care should be taken to protect the fins of radiators while unloading and storage to avoid further oil leakages. The radiators should be stored on raised ground keeping the fins intact. 8. ISOLATOR: The use of this isolator is to protect the transformer and the other instrument in the line. The isolator isolates the extra voltage to the ground and thus any extra voltage cannot enter the line. Thus an isolator is used after the bus also for protection. 9. CONTROL AND RELAY PANEL: The control and relay panel is of cubical construction suitable for floor mounting. All protective, indicating and control elements are mounted on the front panel for ease of operation and control. The hinged rear door will provide access to all the internal components to facilitate easy inspection and maintenance. Provision is made for terminating incoming cables at the bottom of the panels by providing separate line-up terminal blocks. FUnder voltage and over voltage relays. Neutral Current Unbalance Relays 24 | P a g e
  • 25. are for both Alarm and Trip facilities breaker control switch with local/remote selector switch, master trip relay and trip alarms acknowledge and reset facilities. 10. DC POWER SUPPLY: All but the smallest substations include auxiliary power supplies. AC power is required for substation building small power, lighting, heating and ventilation, some communications equipment, switchgear operating mechanisms, anti-condensation heaters and motors. DC power is used to feed essential services such as circuit breaker trip coils and associated relays, supervisory control and data acquisition (SCADA) and communications equipment. This describes how these auxiliary supplies are derived and explains how to specify such equipment. PROTECTION IN SUBSTATION There are many protection for the equipment in a substation. Some of the import protection are listed below: • Overcurrent protection • Earth fault protection • Restricted earth fault protection • Combined earth fault and phase protection • Differential protection CONCLUSION As a part of our curriculum, I was required to undergo in-plant training. And the company I got to train is BPCL – Kochi Refinery. The training was scheduled to be for 10 days starting from 6th July to 17th July 2015. The duration was from morning 9 pm to evening 4 pm, being an electrical student my area of interest was Power and Utility section. On 6th July 2015, we were asked to report at the city office of Kochi refinery at Marudu, kundannoor at 9am where we were issued with the identity cards. The basic rules which we had to follow while inside the company etc. were discussed there by Mr.Balakrishnan (deputy manager) of learning and development department. After giving basic introduction and further details about the company, I was asked to directly meet at the main office at Ambalamugal the very next day. The next day I was allotted the respective department which was the P&U department. I was allowed to do the training under Mr.Jai Kishen sir. After arrainging a meeting with him, I got a basic idea of what I had to do there. Then sir had a schedule for us for the entire training which included a 5 days training at Captive Power Plant (CPP), 1 day at 220kV power station, 2 days at DHDS plant, 1 day at CDU-2 plant. I was assigned a guide, Mr.Jibu Varghese, who helped me a lot in coordinating my training period and I deeply thank him for making time for me in his busy schedule. In between Mr.Jai Kishen sir himself found time to take a review on me after visiting the plants one by one. I am grateful that I got an opportunity to learn and experience from the plant visit and the knowledge provided by Mr.Jai Kishen sir is very helpful in knowing how exactly the plant works. 25 | P a g e
  • 26. Last but not the least I thank all the staff members who helped me in getting this beautiful learning experience form the training and made time for me to teach me in various aspects of plant working. REFRENCES • Bharatpetroleum.com/kochirefinery • Operation manual of POWER & UTILITY • Wikipedia • Books (M.G SAY, B.L.THAREJA) 26 | P a g e