1. A
Report For
Industrial Training
Taken At:
DURATION: - 1-06-2013 to 30-06-2013
SUBMITTED TO:
Mr. Vinay Mehta Mr. Inder Kundnani
Jt. VP (Elect.) Dy. -Manager (Training)
HOD Electrical (F & P) DSCL, Kota
SFC, KOTA
SUBMITED BY:
DIVYANSHU SHARMA
(ELECTRICAL ENGINEERING)
GLOBAL COLLEGE OF TECHNOLOGY
JAIPUR
1
2. I am very grateful to MR. Inder Kundnani (Dy. Manager) for giving me
the opportunity to undergo practical summer training in this esteemed
organization in Electrical(F & P)under the guidance of Mr. Vinay Mehta
and Mr. Ashok Rathore .They look personal interest in my training &
provide all necessary guidance.
My sincere thanks to Mr. Vinay Mehta, Jt. VP (E) & Mr. Ashok Rathore ,
Dy. GM (Electrical ) of Electrical (F & P ) Department for supporting me
in my day to day work & monitoring my progress , giving valuable
suggestion to improve my work.
My thanks to Mr. O.P Jain, Mr. Manoj Sharma, Mr. Rajeev Paliwal,
Mr. M K Sharma, Mr. I S Mehta, Mr. Nitin Sharma, Mr. Pramod Trivedi.
They supervised my work & helped me in understanding entire Electrical
Generation, Protection & Distribution. They were the key persons in
teaching the complexities of whole system. They used their experience to
help me. I am also thankful to Mr. Rajeev Ohri & Mr. RA Soni for their
guidance I prepare my training report.
2
3. In this modern world today energy has become the source by which all the
activities are done. Power is the basic need of any industry. Got a worthy
chance to undergo my training S.F.C power plant.
Late Shri Lala Shriram founded this industry in 1962. This is progressive
industry which developed high quality cement Urea, P.V.C., Carbide &
Caustic Soda.
Now a day chemical industry plays an important role in nations
development training in this industry was an enlightening experience I came
to acknowledge the production of electricity and its distribution the various
protection scheme and the load sharing between parallel bus-bar
arrangement system transformations of A.C TO D.C by rectifier
transformers. I got an insight into various types of relays ad circuit breakers.
My area of work was Electrical generation distribution and equipment
protection, electrical maintenance sections of electrical (F&P) e.g. Cement,
CES, Ammonia-urea Substation and POWER PLANT. I learn about
checking of C.T. different type of motors and relays and breakers.
In the end I would like to acknowledge that training in this progressive
industry was really very fruitful.
3
4. In 1989 Delhi Cloth & General Mills (DCM Ltd.) was set up in Delhi under
dynamic leadership of late Lala Shriram. Number of wide range of products
like textiles ,sugar, vanaspati fertilizer, industrial chemicals and alcohols ,
potable alcohols, Rayon tiers cords and fabrics electronics calculations
computers and engineering products are being manufactured by its different
units established in all over India n 1990 DCM ltd. was restructured into
four companies viz. DCM Shriram Consolidated limited (DSCL),DCM
limited (DCM ltd.,) and Shriram industries limited (SIL) DSCL has six units
out of this units viz. Shriram fertilizers and chemicals and Shriram Cement
Works and DSCL Building products are situated at Kota which is out from
city and distance about 6 Kms(near Kansuan) and called DSCL Shriram
nagar, Kota.
Kota is known as industrial capital of Rajasthan because different kind of
industries exists in the town Kota city is 240 Km south of jaipur and 469
Km south west of Delhi. In an around this city Atomic, Thermal, Gas and
Hydro Power Plants are situated. The city is situated at river bank of
perennial river CHAMBAL in eastern Rajasthan where broad gauge of
western railway connects it with all over country and national highways viz.
Jaipur Jabalpur (No.12) and Shivpuri Pindware (No.76) are passing through
the city. An aerodrome is also situated in the hearts of the city.
DCM Shriram consolidated limited (DSCL). has Eights units viz. Shriram
Fertilizers & Chemicals, Shriram Cement Works , Shriram Polytech , DSCL
Building Product located at Kota and Swatantra Bharat Mills at Tonk, DCM
Silk Mill at Tonk Shriram Alkalies & Chemicals at Bharaunch (Gujarat) and
Sugar plant at Shajahanpur (up)
Shriram Fertilizers & Chemicals limited diversified into five plants namely
Caustic Soda plant PVC and compounding plant, Fertilizers plant Carbide
plant and Power plant and Cement , plant at these plants are in one
premises in kota.
4
6. Industrial sector has to face long power cut specially during agriculture
season & periods of peak demand. Besides this reliability of electric supply
from power grid is very uncertain .In addition to those electricity tariff is
also increased frequently.
Electrically energy plays a vital role in industries among in production
method. The application includes motor, driver’s process of heating,
lighting etc.
Keeping this in view most of industries have switched over to their own
generation plants within in the premises. These power plant are called
“CAPTIVE POWER PLANT”
SFC also has a CAPTIVE power plant having installed capacity of
125.3MW.
This is THERMAL POWER consisting 5 units:-
35 MW
30 MW,
10.0 MW,
10.3 MW
40 MW
POWER GENERATION:-
1)P35-TG-GENERATOR 35.0 38.0
2)P30-TG-GENERATOR 30.0 30.7
3)P10-TG-GENERATOR 10.0 10.5
4)P10.3-TG-GENERATOR 10.3 10.3
5)P40-TG-GENERATOR 40.0 44.0
TOTAL 125.3 133.5
POWER CONSUMPTION:-
6
7. S.NO NAME OF PLANTS POWER CONSUMPTION (MW)
1 CASUSTIC SODA 33.8
2 PVC & COMPDG 05
3 CEMENT PLANT 05
4 FERTILISER 33
5 CARBIDE 54.3
6 POWER PLANT AUX 10
7
OTHERS LTG. &
CANAL
WATER Pumping
Station
02
TOTAL 143.1
Total of the above DSCL produce 93% of Electric Power consumption of
the industry is meeting.
Out of its own coal based power plant and only 7% i.e. 10.1 MW electric
power is drawn from RRVPNL (RSEB) for Production and emergency.
Facing any electric power problem and achieve its targets of productions
successfully and systematically.
ESSENTIAL EQUIPMENTS
1.) BOILER
2.) TURBINE
3.) ALTERNATOR
4.) ELECTROSTATIC PRECIPTION (ESP)
AUXILIARY EQUIPMENTS
1.) COAL HANDLING PLANT
2.) PULVERIZING PLANT
3.) DRAFT FANS
4.) ASH HANDLING PLANTS
7
8. 5.) CONDENSER
6.) COOLING TOWER
7.) FEED WATER HEATER
8.) ECONOMIZER
9.) SUPER HEATER REHEATER
10.) AIR PREHEATER
BOILERS
The function of boilers is to convert water into steam at a required rate of
evaporation and at the desired temperature and pressure to suit the turbine,
which it serves.
The number and capacities to be installed will depend on the output of turbo
alternators. Other factors to be included are station load factor site, transport
facilities and quality of fee water and fuel.
In DSCL, the water tube boiler is used in which we used pulverized fuel.
Boiler is separated into two main sections:-
FURNACE SECTION
CORRECTIVE SECTION
The air is provided in to the boiler through forced drought fan this air in
proper proportion is mixed with coal & burnt oil. Water tubes through
HEAT EXCHANGE PROCESS carry the heat generated away.
They are in “PARTIAL STEAM & PARTIAL WATER FORM” The
steam is lifted up to the boiler drum through “NATURAL DRAUGHT”
They are circulated through “SUPER HEATER” from where dry steam
comes out.
For generation of steam here in this plant there are total 5 boilers 2 for
35MW, 2 for 30MW & 1 for 10MW generators. 35MW boilers are
Pulverized Bed Boilers (15mm coal) while 30MW & 10MW boilers are
Fluidized Bed Boilers (6mm coal).These are Tangentially Fired Boiler.
Boiler specifications:
8
9. 35 MW BOILER No.1:
MAKE MITSUBISHI
REGISTER NO. RJ338
DESIGN PRESSURE 115Kg/cm2
STEAM TEMP. 520’c
EVAPORATION 90,000Kg/H
HYD TEST PRESS. 144Kgf/cm2
35 MW BOILER No.2:
MAKE MITSUBISHI
REGISTER NO. RJ340
DESIGN PRESSURE 115Kg/cm2
STEAM TEMP. 520’c
EVAPORATION 90,000Kg/H
HYD TEST PRESS. 144Kgf/cm2
30 MW BOILER NO.1
REGISTATION NO. MP/3161
RATED PRESSURE 72.4Kgf/Cm2
9
10. RATED TEMP. 496’C
HYD TEST PRESSURE 90.4KGF/Cm2
30 MW BOILER NO.2
REGISTATION NO. MP/293
RATED PRESSURE 72.4Kgf/Cm2
RATED TEMP. 496’C
HYD TEST PRESSURE 90.4KGF/Cm2
10 MW BOILER
REGISTATION NO. PI 3044
RATED PRESSURE 34.1Kgf/Cm2
RATED TEMP. 430’C
HYD TEST PRESSURE 610 PSI
30MW DEARATOR
Working For vaporization
Order no. 640408
Operating pressure 0.45 Kgf/Cm
10
11. TURBINE STAGE:
A steam turbine converts heat energy of steam into mechanical energy and
drives the generator it uses the principle that the steam when issuing from a
small opening attains a high velocity. The velocity attained during
expansion depends on initial and final heat contents of the steam. This
difference between initial and final heat contents represents the heat energy
conversion into Kinetic energy. These are of two type impulse & reaction.
Both impulse and reaction turbine have a number of stages in which
pressure drop took place generally the number of stages in a reaction turbine
is more than those in an impulse turbine of the same rating.
IMPULSE TURBINE
In impulse turbine steam is expanded in turbine nozzle and attains a high
velocity. The steam jet collides on the blades fixed on the rotor periphery in
this turbine complete expansion of steam takes place in the nozzle constant
during flow of steam over the turbine blades. Thus the pressure on the two
sides of the blades is the same.
REACTION TURBINE
In a reaction turbine only partial expansion take place in the nozzle &
further expansion took place as the steam flows over the rotor blades. There
is difference in pressure on the two sides of the moving blades & thus
rotates. SFC has these both type of turbine.
TURBINE SPECIFICATION
30 MW TURBINE
Make SIEMENS – SCHUCKERT GERMANY
Type Steam Turbine
Mech. No M1923
11
12. Speed 1000 RPM
Initial Temp. 482/500°c
Initial Pressure 49.7/65 Kgf/cm
Output 24000-30000 Kw
10 MW TURBINES
Make
STAL-LAVAL TURBINES
FINSPONG SWEEDON
Type DDK 65
Order No. 2156
Speed 3000RPM
Initial Temp. 426’C
Initial Pressure 29Kgf/cm2
Output 10000KW
35 MW TURBINE:
Make
MITSUBISHI ESCHER STEAM
TURBINE
Maximum Output 35000KW
Speed 3000RPM
Maximum Steam Pressure 115Kgf/cm2
12
13. Maximum Steam Temp. 523’C
Normal Steam Temp Pressure 100Kgf/cm2
Normal Steam Temp. 515’C
1st
Excitation Steam Pressure 14Kgf/cm2
Maximum 1st
Ext. Quality 55T/H
2nd
Ext. Steam Pressure 4Kgf/cm2
Maximum 2nd
Ext. Quality 46T/H
Vacuum 698mm/Hg
Machine No. 505
GENERATOR STAGE:
The generator stator is tight construction, Supporting and enclosing stator
winding core & hydrogen coolers. The cooling machine hydrogen is
contained within the frame and circulated by fans mounted at either ends of
rotor. The generator is driven by a direct-coupled steam turbine at a speed of
3000 rpm. The generator is designed for continuous operation at its rated
output parameter and will withstand within the prescribed limits. The
condition identical operation such as sudden three-phase short circuit etc.
Temperature detectors and other device installed or connected within the
machine permits the measurement of winding, teeth core and internal
section plants provides stiffness to support the core, decrease vibration and
impart necessary mechanical strength to withstand the gas pressure
encounter even under extreme operating condition. The stator frame is
supported on the foundation through footing welded to sides of shell. The
end shield coolers, hydrogen from the generator and the entire generator is
leak proof owing the exposure nature of the design to withstand any
undesired explosion and over pressure that may develop according to
internal conversion the stator casing listed hydraulically with a pressure of 7
atm.
Main Parts of Generator:-
Stator Core:-
13
14. The Stator core is build-up of segment core, annealed insulating lamination
of hot and cold rolled high quality silicon steel to give minimum electrical
losses. The laminations are insulated with a thermo setting quarters and
insulators. The arrangement reduce additional losses due to circulating
current which would otherwise be present due to self inducing non uniform
flux distribution in the coil slot. The main insulation for the bar consists of
resin mica based thermosetting insulating.
Figure : Internal View of A Generator – Turbine Coupling
Stator Winding:-
The stator winding is double layer lap wound, single-phase short pitch. The
top and bottom are bronzed and insulated at either end to form a turn several
such transform a double layer, lap-wound single-phases short pitch type.
The end winding formed within the volute shaped broad end is included
towards the machine axis by 20’, thus forming a “basket” winding with total
included concave angle of 40’, this minimizes the stray load losses in the
stator and zone. The end winding has been thoroughly reinforced with
epoxy glasses laminate spaces to avoid vibration during running condition
and also to withstand the forces resulting from the fault condition such as
short circuit or improper synchronizing.
14
15. Figure:
Stator
Windings
Generator
Terminal
Bushing:
Since output
leads 3-longer
and three
have been
brought out at
the bottom of
the casing of the exciter side, external connection are to be made of three
short terminals which are intended for natural and to be extra length enables.
Suitable dimensioned ring type/current transformer to be inserted. The
conductor of the generator terminals bushing is hollow copper with a copper
pieced bronzed at the end to avoid leakage of hydrogen. The hollow position
enables the bushing also to be hydrogen cooled. The ends of bushing are
individually tested for hydrogen leakage and also for high voltage before
assembling in stator casing.
Bearing
Generating bearing have spherical seats and consist of steel bodies, metal is
on the inner surface of bearing browse to provide a smooth bearing surface
which can be easily removed. The bearings are forced lubricated by oil and
a pressure of 2 to 3 Atm. From the same pump that supplies oil to the
turbine, bearing and governing provision has been made to measure the
rotor bearing temperature by inserting a resistance thermometer in an oil
pocket directly with the bearing and the shaft steel housing at either end of
the machine are insulated from the generated frame to prevent the flow of
current.
15
16. Rotor
The turbo generator rotor is forged upon a single piece in get of special
chromium, nickel and molybdenum alloy steel. Additional dummy slots and
sub slots and sub slots provide adequate passage for the cooling medium for
rotor body and winding.
The field coils are held in the slots against centrifugal forced by wedges;
both magnetic and non-magnetic type being used to ensure a better
waveform of flux distribution.
Figure : Types of Rotor
Rotor Winding:-
The coils are manufactured of rectangular cross-section with ventilation
holes punched in it. The individual terms of every coil are insulated by
epoxy glass laminated ‘L’ shaped thoughts. Epoxy glasses laminate space in
the end winding separate and support the oil and restrict the movement
under the stress due to rotational forces.
Rotor Balancing:-
Finally balancing of the fully assembled rotor is carried out at the rated
speed in a purpose dynamic balancing machine, incorporate specially
designed bearings and electronic apparatus to indicate the location specially
provided along the rotor body or filled in the groove in the end rings, fans
and coupling.
Slip Rings:-
The slip rings are made of forged steel. They are located side by side on the
exciter side of the generator shaft. The slip rings towards the exciter side are
to be given positive polarity and one towards the retaining side is to be
given negative polarity initially. Positive polarity is defined here as that
16
17. which results in an upscale reading when the positive lead of a D.C.
voltmeter is connected to the ring. They have helical grooved and screwed
holes in the body for cooling purpose by the air excitation current is
supplied to the rotor winding through the slip-rings which are connected
through semiconductor, steel excitation loads suitably insulated and
assembled in the bore at the center of rotor forging. The excitation leads is
connected to the winding on one end of slip ring on the other side with
insulated studs passing through the radial holes in the rotor shaft.
Function of Excitation System:-
The main function of excitation system is to supply required excitation
current at the rated load condition of turbo generator. It should be able to
adjust field current of the generator either by normal control or automatic
control, so that for all operation between no load and rater load the terminal
voltage at the system machine is maintained at its value.
PART OF ALTERNATOR:-
1.) STATOR BODY
2.) STATOR CORE
3.) STATOR WINDING
4.) DISTILLATE HEADER
5.) TERMINAL BUSHING
6.) END SHIELD
7.) ROTATOR
8.) BEARINGS
9.) BRUSH GEAR
GENERATOR SPECIFICATIONS:-
30 MW GENERATORS
Make Siemens Germany
Type FT 520/58-3000
Phase 3
Frequency 50
Voltage 11500V
17
18. KVA 37500KVA
Amps 1885Amp
Rating Continuous
Coupled excitation volt 210 V
Coupled excitation Amps 345 A
Arm Connection Star Connection
10 MW GENERATORS:
Make ASEAN VASTERS SWEDEN
Type GTP 65/135
Phase 3
Frequency 50Hz
Voltage 11000V
KVA 1250KVA
Amps 656amps.
Rating Continuous
MAGNETIC VOLTAGE 220V
Magnetic amp. 215A
Arm connection Star Connection
Power Factor 0.8
Magnetic amp. 215A
35 MW GENERATORS:
Make MITSUBISHI
Type MP
Phase 3
Frequency 50Hz
Voltage 110 00V
KVA 43750KVA
Amps 2269amps.
18
19. Speed 3000rpm
Rating Continuous
MAGNETIC VOLTAGE 250V
Magnetic amp. 411A
Arm connection Star Connection
Power Factor 0.8
Poles. 2
10.3 MW GENERATOR:
KVA 12875 KVA
P.F. 8
Phase 3
Frequency 50Hz
Speed 1500rpm
Excitation Voltage DC 93 V
Excitation Current 7.7A
Weight 26800Kg
40 MW GENERATORS:
Make BHFI India
Type EARSO/15-30/8-3
Phase 3
Frequency 50Hz
Voltage 11000V
KVA 50,000KVA
Amps 2624amps.
19
20. Rating Continuous
Coupled excitation volt 280V
Coupled excitation Amp. 800A
Arm connection Star Connection
ELECTROSTATIC PRECIPITOR (ESP):
It’s a precipitator of the ash particle and reduces the dust particle in
atmosphere in ESP. Positive electrode are present which is adhesive to the
heavy particle of the dust & separate out. ESP uses the 415v transformer
which is give as DC voltage in electrode.
INTRODUCTION:-
Flue gasses coming out contains dust/ash of various sizes which causes air
pollution so to separate these particles from flue gas it is sent to ESP where
the ash gets separated and smoke passes through the chimney.
When the dust particles passes through high electric field the neutral dust
particles gets negatively charged due to emitting electrodes and gets
collected by the collecting electrode, which is positively changed electrodes,
and for this purpose 1 phase high voltage rectifier transformer are used.
THEORY:-
ESP is a highly efficient device for extraction of suspended particles & Fly
Ash from the industrial flue gases.
WORKING PRINCIPLE:-
ESP can handle large volume of gasses from which solid particles are to be
removed.
Advantages of ESP are:
(1) High collection efficiently
(2) Low resistance path for gas flow
(3) Treatment of large volume at high temperature
20
21. (4) Ability of coping with corrosive atmosphere.
An ESP can be defined as a device, which utilizes electrical forces to
separate particles from the flue gasses.
Forced Draft Fan (F.D. fan) :-
To take air from the atmosphere at ambient temperature to supply all the
combustion air can either be sized to overcome all the boiler loss or just put
the air in the furnace; Speed varies between 600 to 1500 rpm.
Induced Draft Fan (I.D. fan) :-
Used only in balanced draft units to suck the gases out of the furnace and
through them into the stack. It handles fly ash laden gases at temperature of
125° to 200°. Speed seldom exceeds 1000 rpm.
PROTECTION OF GENERATORS
35 MW GENERATORS:
1) OVER CURRENT REALY
2) POWER FACTOR RELAL
3) POWER RELAY
4) LOSS OF EXCIATION RELAY
5) SEQUENCES CURRENT RELAY
6) RATIO DIFFERENTIAL RELAY
7) VOLTAGE RELAY
8) FIELD GROUND RELAY
9) TIMING RELAY
30 MW GENERATORS:
1) OVER CURRENT AND EARTH FAULT RELAY
2) ANTI PUMPING RELAY
3) AUXIL LARY RELAY FOR PRESSURE SWITCH
4) LOCKOUT RELAY
5) INSTANEOUS AND DEFIN ITE RELAY
6) LOCK FORWARD POWER RELAY
7) UNDER VOLTAE RELAY
8) FIELD FAILURE RELAY
9) DEFINITE TIME RELAY
10) COMPOSITE GENERATER PROTECTION RELAY
11) DIFFERENTIAL PROTECTION RELAY
21
22. 12) REVERSE POWER EARTH FAULT RELAY
13) SENSITIVE EARTH FAULT RELAY
14) REVERSE POWER RELAY
15) NEGATIVE PHASE SEQUENCE RELAY
10&10.3 MW GENERATOR:
1) DIFFERENTIAL RELAY
2) INTER TURN STATOR WINDING PROTECTION RELAY
3) FIELD WINDING PROTECTION & EARTH FAULTRELAY
4) MAXIMUM CURRENT RELAY FOR EARH FAULT
5) OVER CURRENT AND EARTH FAULT
6) TIMING RELAY
7) TEMPERATURE RELAY
8) SIGNAL
9) AUXILLARY RELAY
10) TRIPPING
11) TIME LAG OUT OVER CURRENT RELAY
40MW GENERATORS:
1.) DIFFERENTIAL RELAY
2.) OVER CURRENT AND EARTH FAULT
3.) VOLTAGE RESISTANT OVERCURRNT PROTECTION
4.) NEGATIVE PHASE SEQUENCE RELAY
5.) STATOR EARTH FAULT PROTECTION
6.) DIRECTIONAL EARTH FAULT PROTECTION
7.) UNDER VOLTAGE PROTECTION STAGE 1st
8.) UNDER VOLTAGE PROTECTION STAGE 2nd
9.) OVER VOLTAGE PROTECTION STAGE 1st
10.) OVER VOLTAGE PROTECTION STAGE 2nd
11.) UNDER FREQUENCY PROTECTION STAGE 1st
12.) UNDER FREQUENCY PROTECTION STAGE 2nd
13.) OVER FLUXING PROTECTION STAGE 1st
14.) OVER FLUXING PROTECTION STAGE 2nd
22
24. 1. AMMONIA PLANT
2. UREA PLANT
INTRODUCTION:
Ammonia plant with rated capacity of 450 TPD was installed &
commissioned in Feb 1969.
24
25. The Engineering Fabrication & erection work was executed by m/s Chiyoda
Chemical Engineering & Construction co LTD. Japan. & the project was
complete well within time Schedule.
After overcoming the initial teething problems production was establish at
480 TPD. In Sep. 1974 plant capacity was enhanced to 600 TPD, with
essential of 120TPD for Ammonia synthesis loop & some additional
compressors.
PROCESS
Urea making
CNG
CRACKING
HYD & HYDROCARBONS
CARBON DI OXIDE
N2+3H2+2NH3
NH3+CO2 (REACTOR)
NH2CONH2 (LIQUID)
CRYSTALLIZATION
PRILLS OF UREA
CONVBEYERS
BAGGING PLANT
WEIGHING
PACKING
DESPATCH
COMPRESSOR HOUSE
S.NO. MOTORS USED IN POWER TYPE
1 Old Turbo Compressor 4.0 MW Slip ring I.M
2 New turbo compressor 5.5 MW SCIM
3 CO2 A 1.75 MW Synchronous
4 CO2 B 1.75 MW Synchronous
5 Synthesizer A 4.8 MW Synchronous
6 Synthesizer B 4.8 MW Synchronous
7 AMMONIA A 1.05 MW Slip Ring IM
8 AMMONIA B 1.05 MW Slip Ring IM
9 Additional synthesizer 4.8 MW Synchronous (brush less)
10 Additional Co2 1.75 MW Synchronous (brush less)
11 Additional air 1.35 MW Synchronous (brush less)
SYNCHRONOUS MOTOR:
25
26. Rotor has 8 pole and poles have damper winding. This entire winding is
short circuited. Initially for around 33 sec it work as squirrel cage motor &
then DC supply is given & then moves with the constant speed.
Synchronous motor is a double exited motor;-
Rotor - DC Supply
Stator - AC Supply
SPECIFICATIONS OF SYNCHRONOUS MOTOR
Type TAK
Power 1750 KW
Phase 3
Poles 18
Speed 333 RPM
Voltage 11000 V
Current 101A
Cycles 50 Hz
Power factor 0.95
Excitation Voltage 220 v
Field Current 35.3 A
Ambient Temp 50 °C
Armature Temp 60 °C
Field Temp Rise 60 °C
SPECIFICATIONS OF SLIP RING INDUCTION MOTOR
Type MSE-GPX
Power 4000 KW
Phase 3
Poles 2
Speed 2970 RPM
Voltage 11000 V
Current 238A
Cycles 50 Hz
Power factor 0.95
Secondary voltage 1680
Secondary amp 1415
Ambient Temp 40 °C
Field Temp Rise 60 °C
L.T MOTORS:
26
27. All motors having rating 415 V or below are called LT motors It. May be:-
Induction motor
Synchronous Motor
DOL STARTER-
It is used for starting purpose of L.T motors
EMERGENCY POWER CHANGE OVER SCHEME:-
In emergency power change over scheme we have TIE between two buses
Bus is getting charge from 11KVpower plant. If due to some fault this
supply is not available then emergency change over scheme is used .In it
there is a automatic switch which is automatically connects the bus to the
RRVPNL(RSEB), if power plants is not available & vice versa
VISIT OF THE PLANT-
1. Produce Ammonia: -
Chemical formula: - NH3
Molecular Weight: - 17.03
Melting Point: -77.7° C
Directly Use of the natural synthesis gas.
In Reformer. Reformer two type :
1) Primary reformer
NGS + Nickel Catalitic Steam -- 750°C = CO +CO2
2) Secondary reformer
Nickel Catalitic Steam + N2 =CO
2) High-pressure reformer
NGS + CO + CO2 ----900°C - = CO + H2 + Co2
After that High & Low temperature Shift Convertor both are same working
for making to the CO2 Gas with 450°C & 230°C
Remaining [CO] 230° - 430430°C - [CO2]
Remaining N2, H2 & CO2 are pass to the high pressure condenser in this
condenser hot with the potassium carbonate than this condenser are
absorbed to the CO2 gas & not uses to the K2CO3.
27
28. Using by the methenator mixer to calcium carbonate (CACO2) & methane
(CH4) with the 10ppm (N2 & H2,) in compressor house & the ratio of H2 &
N2 gas 3:1.after that make to the ammonia (NH3)
N2 + 3 (H2) --- Iron catalic (500°c)--- 2(NH3)
After that this ammonia are separate down in the Horton sphere there are
two Horton sphere presence in A/U plant.Each capacity 1000 tonne. This
Ammonia (NH3) used in making urea.
2. Making urea:-
1. Synthesis section
2. First stage recirculation section
3. Second stage recirculation section
4. Crystallization section
5. Prilling tower
1. Synthesis section:-
In this section takes place 200kg/cm2 pressure & 190°c Temp. The ratio of
N & C is maintained at 4:1 & Co2 new be achieved.
2. First Stage Recirculation Section-
This is recirculation section. Ammonia (NH3) & Carbon dioxide (CO2)
recovered as carbonate solution at 100°c (373k) & pour ammonia 40°c
(313k) & ammonia & carbonate back to the Synthesis section.
3. Secondary Stage Recirculation Section:-
This is recirculation again Ammonia & Carbon dioxide as carbonate
solution after condensations at 40°c in this stage.
4. Crystallization section:-
The solution of the urea is sent to the MOTHER LIQUR TANK after that
the urea having some moisture which is present so this urea is sent to the
prilling tower top to remove the moistures.
5. Prilling tower:-
Urea is passed by the Prilling tower for separation of the moisture from
urea. In the Starting Settled ammonia is mixed with water solution which
falls down in the prilling tower by the help of the prilling bucket revolver
with the 138°c-140°c than the bottom of the prilling tower reduced to the
temperature of the urea using prill cooling system. Its temperature down in
the 50°- 60 °C after that sent to the urea bagging.
28
29. CES is just like distribution substation .It distribute the power coming from
the Power plants to the various plants located in SFC campus .It distributes
the power to Carbide Plant, Caustic Soda, PVC Plant, Shriram Polytech and
DSCL Building Products (Fenesta building).
The purpose of this CES is to feed the uninterrupted, continuous power
supply to various plants according to their requirements.
(1) Switch Gear Room
(2) Condenser Room
(3) Rectifier Room
1. SWITCH GEAR ROOM:-
(1). In the switch gear room the circuit breaker and other components are
mounted with durable carriage for isolation after opening the circuit breaker
is lowered mechanically by manual gear therefore the carriage is pulled out.
The main components of draw out indoor switchgear are given below:-
(1) Bus Bar
(2) Isolating Switches
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30. (3) Current Transformers
(4) Potential transformer
(5) Circuit Breaker
(6) Earthing Arrangements
(7) Relays
(8) Inter-locking arrangement
(9) Lighting Arresters
The following types of inter-locking are provided:
(1) The CB must be in open position before it is lowered in this position.
(2) The CB can be enclosed only raising the final pug in position
(3) The CB can be close before raising plug in position.
(4) Inter-Locking between insulators, ear thing switches and CB Are
provided.
BUS BAR:-
Bus-Bars are defined as the conductors to which several incoming and
outgoing lines are connected. They are essential component of SWGR.
These are made up of copper and aluminum. The type and designs of
SWGR depend upon rated normal current and short circuit capacity. The
bus bars are enclosed in bus bars chamber. The bus bars of neighboring link
units are connected by aluminum links. The incoming and outgoing cables
are provided for metering purposes. The CT’s normally of ring type are
fitted on insulated primary. The insulation is provided by cast
resin fittings.
ISOLATION SWITCHES:-
These are capable of
(a) Interrupting the transformer magnetizing current
(b) Interrupting the charging current
(c) Interrupting load transformer switching
The main application is in connection with feed or bank transformers
feeders and these units make it possible to switch out one transformer while
the others are still on load.
CURRENT TRANSFORMERS:-
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31. This is connected in AC power circuit to feed the current in the coil of
indicating and metering instruments. The current transformers is basically
consists of iron core on which are wound the primary winding and one of
two secondary windings.
These are used for safety of the transmission system. They sense the
maximum current and step down it. It instructs breakers and relays to trip in
case of fault.
POTENTIAL TRANSFORMERS:-
It is applied to feed the potential coil of indicating and metering instruments
and relays. The primary winding of the p.t. is connected to main bus bar of
switch gear and to the secondary winding various indicating and metering
instruments and relays are connected.
CIRCUIT BREAKER:-
They are capable of breaking the circuit on fault .It is heavy– duty
equipment mainly utilized for protection on various circuit and separate
loads.
The Circuit Breaker is used by relays or by manual signal. The circuit
breakers which are used in SWGR are ABCB and SF6 Circuit Breaker.
The required function of SWGR is that it should be capable of:
1. Carry continuous max current of system
2. Breakers the circuit under abnormal condition
CIRCUIT BREAKER in Switchgear:
Switchgear has two functions in any power system. These are mentioned
below:-
1. To permit plant & distributors to be conveniently put into & taken out
of service
2. To disable the same plant lines when these become faulty to be rapidly &
safely isolated by automatic means:
Automatic isolation means:-
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32. First of them could be served by relatively simple switches &second
however required circuit breaker which is much more robust & capable of
breaking the large values of fault power (MVA). That result from fault on
major power system.
Since all plant & lines are liable to develop faults as result of mechanical
damage electrical breakdown errors in operation etc. The automatic Circuit
Breakers are used, even for the switching purpose.
Circuit breakers consist essentially of current carrying controls called
electrodes.
These are normally engaged but under pre determined conditions, separate
to interrupt the circuit when the contacts are separated an arc is struck
between them. This plays an important part in the interruption process as it
provides for the gradual transition from the current carrying to the voltage
withstanding states of the contacts. This arc is extinguished by a medium
(filled in the circuit breaker) shortly after has started and before the energy
generated from it has reached generated from it has reached to generated
from it has reached to a dangerous value.
There are certain types of circuit breakers (differentiated on the base of the
medium filled in them) such as:-
1. Air circuit Breaker
2. Minimum Oil Circuit Breaker
3. SF6 (Sulphur Hexafluoride) Circuit Breaker
4. Air Blast Circuit Breaker
5. Vacuum Circuit Breaker
6. Magnetic Circuit Breaker
SPECIFICATION OF SF6 CKT BREAKER
Lightening impulse withstand voltage 650KVp
Rated short circuit breaking current 31.5KA
First pole to clear factor 1.5
Rated duration of short circuit 3 Sec
Gas weight 9Kg
Rated voltage 145V.
Rated frequency 50Hz
Rated normal Current 3150 Amp
Rated frequency 50 Hz
Rated normal Current 3150 Amp
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33. Rated closing voltage 110 Volt DC
Rated opening voltage 110 Volt DC
SPECIFICATION OF MINIMUM OIL CKT BREAKER
Rated voltage 12KV
Insulation Level 75/35KV
Frequency 50Hz
Normal Current 2500 A
Breaking Current symmetry/asym 40/44KA
Close /Open Coil Voltage 110V, Dc
Motor Voltage 110V, Dc
Mass (Including Oil) 270Kg
Mass of Oil 12Kg
SPECIFICATION OF VACCUM CKT BREAKER
Make AREVA
Type VCB
Model ARHKK12/3140
Operating mean Spring charged
Rated voltage 12kV
Rated current 2500A
Short circuit breaking capacity 40kA
Short circuit withstand capacity 40kA
Frequency 50Hz
Insulation level 28kV
Closing coil voltage 110V Dc
Trip coil voltage 110V Dc
Spring charging motor voltage 110V Ac/Dc
LIGHTINING ARRESTERS:-
It is use protection against lightening the surge approach to the transformer,
it meets the arresters and in about 0.23 Sec. The voltage reaches the
breakdown voltage of the series gap and the arrester discharges.
In this sub-section the transformers have been provided with three lightning
arresters.
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34. 2. CONDENSER ROOM:-
Condenser room is for improving the p.f. There are capacitor banks
which are used for improving of power factor. We can connect or
disconnect these capacitors in circuit according to our demand of
power factor.
3. RECTIFYING ROOM:
Rectifier room is providing for rectifying purpose as we need
the D.C for electrolyzing process in caustic soda plant.
There are 5-rectifier transformers in C.E.S for rectifying purpose.
These are SCR based rectifier. These are 6 pulse rectifiers. 11KV A.C. is
feed to the input of the transformer and we get 440volts at the secondary
side. Then it is feed into the rectifier and we get the D.C. o/p of 535volts.
Cooling of these rectifiers is done by DM-Water, which is further cooled
through heat exchanger. The canal water is cooled in cooling tower, which
is further located near the rectifier room & this complete cooling system is
closed cycle system.
Rating of rectifier transformer:-
Rectifier transformer no. 1 to 4
Type AC (primary) DC (secondary)
No. of phase 3
Rated Power (KVA) 7760 7760
Rated Voltage (V) 11000 439
Frequency (Hz) 50
Rated Current (A) 407 10210
Type of rectifier device SCR
Type of Cooling ONAF
Rectifier transformer no. 5
Type AC (primary) DC (secondary)
No. of phase 3
Rated Power (KVA) 10580 10580
Rated Voltage (V) 11000 440
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35. Frequency (Hz) 50
Rated Current (A) 555 13880
Type of rectifier device SCR
Type of Cooling ONAF
RESULT
I have undergone a training of one month at DSCL, KOTA in which I have
studied about the generation of electricity through a steam power plant. The
distribution system and the maintenance and testing of various machines
like motors, generators and transformers. I have acquired all the necessary
details regarding the generation, transmission and distribution of power
supply.
I also gained the knowledge regarding various safety equipments like relays
circuit breakers and isolators. In all it was
The training of one month was successfully undertaken & pretty good
knowledge gaining month of my engineering career.
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