MSDS DEPARTMENT, JSW STEEL LTD, TORANAGALLU 1

ACKNOWLEDGEMENT

I would like to express my deep sense of gratitude to each and every person associated with this
internship and everyone who has guided me through this phase.
I would like to thanks to HR department, JSW Steel Ltd, Toranagallu, Bellary whose administration
helped us for the successful completion of this training.
I personally would like to thank DPAO of R&D, Utilities, TQM for their kind involvement.
I would like to express my deepest gratitude towards my parents for their kind co-operation and
encouragement which helped me in completion of this internship.
I would like to express my special gratitude and thanks
Prashanth sir for giving us proper attention and time while explaining the intricacies of various
systems.
I would also like to thank the industrial personnel who helped us through the training.

MSDS DEPARTMENT, JSW STEEL LTD, TORANAGALLU 2

 ABSTRACT
Largest Industrial power distribution system in India.Receives power from JSW energy, JSWPL,
Captive Power Plants & KPTCL Grid.Distribute power to all the steel plant units, Ancillaries and
Oxygen plants.Co-ordinate with customers for un-interrupted and reliable supply of electrical
energy.Reports generation for analysis. Coordination between Generating Units & Shops.Protection
of HT distribution system.Ensure steady State & Transient stability.Fault analysis and pin-pointing
the cause and subsequent improvement in that area.Establishment of economic load distribution
system.

MSDS DEPARTMENT, JSW STEEL LTD, TORANAGALLU 3

 CONTENTS

CHAPTER 1 - INTRODUCTION

CHAPTER 2 - SAFETY AWARENESS

CHAPTER 3 - EQUIPMENT MAINTAINED BY MSDS

CHAPTER 4 - UTILITY – POWER SECTION

CHAPTER 5 - SCADA

CHAPTER 6 - POWER TRANSFORMER’S DETAILS

CHAPTER 7 - ISLANDING

CHAPTER 8 - POWER PLANT DETAILS

CHAPTER 9 - TRANSFORMER

CHAPTER 10 – SWITCHGEAR

CHAPTER 11 - PROJECTS

MSDS DEPARTMENT, JSW STEEL LTD, TORANAGALLU 4

CHAPTER 1 - INTRODUCTION
JSW Steel is among India's largest steel producers, with a capacity of 10 MT as of
2011.Sajjan Jindal led enterprise JSW Group is one of the largest business conglomerates in India
with a strong presence in the core economic sector. JSW Group has diversified interests in steel,
energy, minerals and mining, aluminium, infrastructure and logistics, cement and information
technology.

In 1994, in order to achieve the vision of moving up the value chain and building a strong,
resilient company, Jindal Vijayanagar Steel Ltd. (JVSL) was set up, with its plant located at
Toranagallu in the Bellary-Hospet area of Karnataka, the heart of the high-grade iron ore belt and
spread over 12000 acres of land.

JSW Steel offers the entire gamut of steel products – Hot Rolled, Cold Rolled, Galvanized,
Galvalume, Pre-painted Galvanized, Pre-painted Galvalume, TMT bars, Wire Rods & Special Steel
Bars, Rounds & Blooms. JSW Steel has manufacturing facilities at Toranagallu in Karnataka,
Vasind&Tarapur in Maharashtra and Salem in Tamil Nadu.

Fig: Main Step down Station

MSDS DEPARTMENT, JSW STEEL LTD, TORANAGALLU 5

 CHAPTER 2 - SAFETY AWARENESS
Safety: protecting ourselves from the hazards existent in the industry is called safety.

Hazard: is a dangerous occurrence that can happen in the industry.

Few hazards in the Steel Plant are: Hot Metal Hazards, Gas based Hazards (CO), Dust Hazards,
Noise Hazards, and Electric Hazards.

However these can be avoided by simple steps.

1. Hot Metal Hazards: Hot metals falling on the skin can cause serious injury, Hence jeans
trousers and jeans Jackets must be worn at all times while working in the plant.
2. Gas based Hazards (CO): CO a poisonous gas that replaces the oxygen in the haemoglobin. A
“CO Pointer/ Monitor” is always attached to the person working in a CO concentrated area. A person
can safely work in an area of 50ppm CO concentration for about 8 hours. He needs to vacate the area
after that. A 1200ppm concentration will put a person to coma in 15mins. It can be fatal.
Further to prevent the effect of any other poisonous gases “Gas Masks” are used.
3. Noise Hazards: “Ear Plugs” or “Ear Muffs” are used to maintain the decibel level within safe
limits of 85Db. The former reduces the decibel by 20-30Db and the latter by 30-40Db.
4. Dust Hazards: Dust exposure can cause various lung disorders including lung cancer. Hence
“Masks” are worn while working in a dusty area.
5. Height Hazards: While working at heights safety harness has to be worn to prevent any sort of
fall resulting in injuries. Fall arrestors are also used.

CHAPTER 3 - EQUIPMENT MAINTAINED BY MSDS

MSDS DEPARTMENT, JSW STEEL LTD, TORANAGALLU 6
 Switch Gear – 3170 Nos
 Transformer – 1047 Nos
 Wind Mill – 25 KW
 Solar at JSMSH – 70 KW
 Solar at GHS Torangallu – 5 KW
 Pump house – 15
 DG set – 30 Nos
 Weigh Bridge- 73 Nos
 Street Lighting through out the plant & Township

CHAPTER 4 - UTILITY – POWER SECTION

 Two SwitchYards
 220KV
 400KV
 Both are connected with Inter Connecting Transformer
 400KV
 Two LILO Lines for Grid connection
 4x300MW Generating Units
 4Transformers
MSDS DEPARTMENT, JSW STEEL LTD, TORANAGALLU 7
 220KV
 Two Radial Lines for Grid connection
 2x130MW Generating Units
 12 Transformers
 33KV
 130+100+76MW Generating Units.
 6.6KV
 15+15+5MW Generating Units.

CHAPTER 5 - SCADA
 SCADA stands for Supervisory Control and Data Acquisition.

 Collects data from various transducers at a plant or in other remote locations and then
sends these data to a central computer which then manages and controls the data.

 At MSDS, the data from the numerical relays is transmitted via RS 485 port to the
RTU. In RTU the data is processed by the processors & is displayed on the HMI using SICAM 230
software.

 Existing SCADA

 IEC 103Protocol.

 115 Relays.

 Redundancy incorporated at all levels.

MSDS DEPARTMENT, JSW STEEL LTD, TORANAGALLU 8

 Expansion Features

 IEC61850 Protocol.

 Remote parameterization & Disturbance Recording.

 Fast & Reliable.

 Rugged-com Switches specially designed for Substation Automation.

 SIEMENS SICAM 230 software.

Fig: SCADA OVERVIEW

CHAPTER 6 - POWER TRANSFORMER’S DETAILS

MSDS DEPARTMENT, JSW STEEL LTD, TORANAGALLU 9

 6.1 Operation philosophy
Maintain 100% Redundancy at 33KV System. Switchover from Transformer’s During Shutdown
and emergencies Islanding in case of 400KV and 220KV line disturbances keeping emergency /
Critical loads intact .Tie from CPP at 33KV to take care of loading either during tripping of generator
or Transformer.

CHAPTER 7 - ISLANDING
 ISLANDING means Isolation from external sources & running with own generators
MSDS DEPARTMENT, JSW STEEL LTD, TORANAGALLU 10
 Total Complex load around 930MW
 Islanding generation 300 MW
 Power to only Critical loads for faster restoration once Grid is normalized.
 Upgraded Scheme
 34 Modes System has been developed to make the system almost Dynamic.
 The system has been fine tuned to minimize the fluctuations in generation during Grid
disturbance.
 Smaller slabs of 10 MW smoothens the governor operation & reduce the burden on the
generators.
 Post islanding frequency based shedding has been incorporated

7.1Conditions for Islanding

 A grid is said to be disturbed when:

 there is an under voltage (U/V)
 there is over voltage (O/V)
 there is under frequency (U/F)
 there is over frequency (O/F)
 there is a rapid fall or rise in frequency ( +dF/dT or –dF/dT )
 there is a power failure in the grid
 there is a fault in the grid

CHAPTER 8 - POWER PLANT DETAILS

MSDS DEPARTMENT, JSW STEEL LTD, TORANAGALLU 11

We
8.1 Schematic of JSW’s EHV power system

8.2 JSW power data

MSDS DEPARTMENT, JSW STEEL LTD, TORANAGALLU 12

 SHOP POWER CONSUMPTION IN MW

COKE OVEN 23

BENEFICIATION PLANT 25

AGGLOMERATION 128

DRI 50

IRON MAKING 150

STEEL MAKING 150

HOT STRIP MILL 90

LONG PRODUCTS 28

COLD ROLLING MILL 40

OTHER ANCILIARY UNITS 246

PEAK DEMAND 930

CHAPTER 9 - TRANSFORMER
MSDS DEPARTMENT, JSW STEEL LTD, TORANAGALLU 13
 The static electrical device which transfers the voltage from one level to another level by the
principle of self and mutual induction without change in frequency.
9.1 Types of Transformer

 Power Transformer
 Distribution Transformer
 Interconnecting Transformer
 Generating Transformer
 Drive Transformer
 Furnace Transformer
 Electrostatic precipitator Transformer
 Neutral grounding Transformer
 Welding Transformer

9.2 Power Transformer

Transformer having rating more than 200kva is power transformers .Usually this transformers are
placed near the generating and substations to either step up or step down voltage levels The
transformers which are used to transform the transmission voltage to the voltage level of primary
feeders are called substation transformers .

9.3 Components of a Typical Power Transformer

MSDS DEPARTMENT, JSW STEEL LTD, TORANAGALLU 14

 Fig: Power Transformer

 Tank
The transformer tank or enclosure of a power transformer is fabricated of welded
steel. The tank contains the transformer core and coil assembly. It is normally filled with mineral oil
or a synthetic nonflammable insulating liquid that is used as an insulating and cooling medium.
 Acoustic Enclosure
In residential locations, to reduce noise from the transformers an acoustic enclosure is built
around the transformer tank. The bushings, conservator, explosion vent and cooling radiators and
fans are exterior to the enclosure .Hazards – Noise from transformer; enclosed area .
 Access Cover
Located on the top of the tank, it allows access to the inside of the tank for
inspection and repairs .Hazards – Oil filled tank, confined space - Follow work procedures for
entering transformer.
 Transformer Core and Coils
The transformer core is built of iron or steel, and it provides the magnetic circuit to link the
transformer windings .The transformer coils or windings provide the electrical circuit for current
flow in the transformer. The source winding is known as the primary winding and the winding
delivering power is known as the secondary winding.
 Terminal or Headboard
In order to meet the varying requirements of a certain load, or changes in the supply
voltage to the transformer, it is necessary to adjust the turns ratio (i.e., voltage ratio). This may be
accomplished by bringing taps from the windings up to a terminal
board or headboard. These terminals may be connected together by links or straps to

MSDS DEPARTMENT, JSW STEEL LTD, TORANAGALLU 15

 select the number of turns that give the desired ratio.

 Off Load Tapchanger (OLTC)

To change the turns ratio on the source winding, a switch is operated by a handwheel on
the exterior of the tank. The handwheel is used to operate a switch within the tank via an exterior
operating rod and interior insulated operating rods. The switch takes the form of fixed terminals or
contacts arranged in a circle. Turning the handwheel moves the contact or finger around the centre of
the circle to complete the circuit and give the desired ratio. This is known as changing tap positions
and is performed with the transformer off potential since these switches cannot open a circuit
carrying current.
Hazards –Possible failure if operated on potential. Mechanical failure of moving
devices.
 Underload Tapchanger (ULTC)
To respond to changing voltage levels on the load side of the transformer is accomplished
by adjusting the transformers turns ratios. The underload Tapchanger switch is designed to change
the tapped windings while carrying load current. It is normally operated by a motor and can be
operated by hand. The tapchanger can be located electrically in the low voltage winding or
electrically in the neutral end of the high voltage winding. The motor and control cabinet for the
tapchanger is located on the side of the transformer. Hazards –Mechanism cabinet - AC motor
operated requires isolation from motor AC supply for work on tapchanger.
 Bushings
The electrical power circuits must be insulated where they enter the tank. A bushing
provides an insulated oil-tight and weather-tight entrance for the conductor into the transformer. It is
usually composed of an outer porcelain body, and at higher voltages, additional insulation in the form
of oil and wound paper is used within the porcelain column.
 Conservator
On larger transformers (over 500 KVA), a reservoir of oil is maintained in a tank at a level
above the cover of the transformer which is connected to the transformer by a pipe. This is known as
a conservator tank (expansion tank) and keeps the main tank completely full of oil at all times,
permitting expansion and contraction. An oil level indicator with an alarm circuit is provided to
indicate the oil level in the conservator tank.
 Breather
The conservator tank has a breather to the outside. In order to take care of the expansion
and contraction of the cooling liquid with varying temperatures, smaller units have an air space above

MSDS DEPARTMENT, JSW STEEL LTD, TORANAGALLU 16

 the oil, which is connected to atmosphere by a breather. This breather is, arranged to prevent the
entry of moisture, snow, etc, into the transformer.
 Oil Gauge
Located on the side of the Conservator tank, it indicates the level of oil in the tank and will
provide annunciation when level drops below the gauge limit. On transformers without a conservator
tank, an oil level gauge is located on the side of the tank to indicate oil level in the tank.
 Explosion Vent
When an electrical fault occurs under oil, very high pressures are possible. These
pressures could readily burst the sheet steel tank if some means were not used to guard against this.
The explosion vent consists of a large diameter pipe (4 inches or larger) extending slightly above the
conservator tank of the transformer and curved in the direction of the ground. A diaphragm is fitted at
the end of the pipe; it will rupture at a relatively low pressure to release the forces from within the
transformer to atmosphere. On some transformers, a second diaphragm is located at the bottom of the
pipe where the explosion vents connects to the transformer tank. This prevents oil from entering the
explosion vent except under fault pressure.
 Qualitrol Valve
Newer transformers have been equipped with self-resetting pressure relief vents known as
Qualitrol valves. The vent may be mounted on the top or side of the transformer. When the fault
pressure in the transformer reaches a predetermined level, it forces open a seal that is under spring
pressure. The pressure is then vented to atmosphere. In some installations, these valves will also
initiate tripping of the transformer zone.
 Gas Relay
The gas relay is located at the top of the transformer and is used to detect gas or air in the
transformer.
All transformers are capable of withstanding a vacuum and have a vacuum valve
located on the top of the transformer. Transformers are filled with oil under vacuum to remove
moisture and air in the tank; this improves the insulation value of both the solid and liquid insulation.
 Oil Drain and Sample Valve
In order to conveniently add or remove liquid from the tank, a valve is fitted at the
bottom of the tank. It is usually connected to a sump to ensure that all liquid will be removed.
Adjacent to this is 1/2 in. needle valve, also leading to the sump, which is used for drawing off a
sample of liquid for test purposes. By taking liquid from the lowest point in the tank, any free water
should appear in the sample and give warning of contamination of the liquid.
 Transformer Cooling

MSDS DEPARTMENT, JSW STEEL LTD, TORANAGALLU 17

 In smaller size, liquid-filled types of transformers, natural convection carries the heat of the
insulating medium to the walls of the tank. As the size of the transformer
increases so does the heat generated, additional means of cooling the transformer are
required - Radiator, Fans and Pumps.
 Radiators
Radiators are fitted to the tank so that a larger surface is reached by the liquid
flowing into the top, down the tubes of the radiators and back into the bottom of
the transformer.
 Cooling Fans
Fans blow air across the radiators to increase the cooling of the oil.

 Cooling Pumps
Pumps are used to pump the oil through the radiators.
 Water Cooled
In some installations, water may be used to cool the transformer. This is done by installing
water-cooling coils inside the main tank or by leading the oil from the main tank to a separate water-
cooled heat exchanger.
 Water Spray Cooling
Some installations use a water spray on the transformer and cooling radiators to
provide additional cooling. Hazards – Fans and pumps are AC driven – require AC supply open when
working on Fans and Pumps.
 Temperature Indicators
Various temperature sensing devices are used to indicate the operating temperature of the
transformer. The number and use of the devices varies with the size and application of the
transformer. On small transformers that require no fans or pumps, the indicating device may be in the
form of a liquid-filled thermometer mounted at the top of the tank. Larger transformers with fans and
pumps can have up to three temperature sensing devices:
_ liquid temperature gauge
_ winding temperature gauge
_ thermocouples
 Liquid Temperature Gauge (Top Oil)
The liquid temperature indicator is usually the gas-filled type, with the sensing bulb fitted
into a well cover near the top of the tank, and the indicator at the bottom of
the tank, at eye level. Contacts are provided to annunciate an alarm and, in some cases, start fans and
pumps.
MSDS DEPARTMENT, JSW STEEL LTD, TORANAGALLU 18
 Winding Temperature Gauge (Hot Spot)
A winding temperature indicator is generally the same design as the liquid
temperature indicator. The purpose of this indicator is to simulate the hottest point
in the transformer.

 Thermocouples
There are generally two thermocouples in a large transformer and they are located adjacent to each
other in an oil-filled well in the top oil. These devices are be used to provide remote indication and
annunciation.. Hazards – DC supply for temperature indication.
 Fire Detectors
On larger transformers, Heat Activated Devices (HADs) are located around the top of the
tank. The HAD contains a thermocouple to detect excessive heat that would be produced should the
transformer catch fire. The HAD is used to initiate a Transformer Fire annunciation to the Controller.
Hazards – DC supply to HADs – when work on them required.
 Deluge Fire Protection
Large Transformers located at indoor transformer stations have a water deluge fire
protection system to extinguish a fire. Hazards – pressurized water – requires Deluge isolated when
working on the transformer.

9.4 Neutral earthing transformer

Neutral transformer is a device used to create neutral point in a three phase three wires system.

Fig: 3-phase star -connected system with neutral earthed

 The advantages of earthing transformers are -

 Eliminate increase in line to neutral voltages during earth faults.

 Early isolation of faulty electrical equipments.

 Provides an earthing path for ground fault current during earth faults.

 It can be used additionally as station transformer for Low voltage power.

MSDS DEPARTMENT, JSW STEEL LTD, TORANAGALLU 19

 No change in line to line voltages during single line to earth faults.

CHAPTER 10 - SWITCHGEAR
In an electric power system, switchgear is the combination of electrical disconnect
switches fuses or circuit breakers are used to control, protect and isolate electrical equipment.
Switchgear is used both to de-energize equipment to allow work to be done and to clear faults
downstream . This type of equipment is important because it is directly linked to the reliability of the
electricity supply.

Electrical circuit breaker is a switching device which can be operated manually as well as
automatically for controlling and protection of electrical power system respectively.

Relay Operation
1. Differential relay Responds to vector difference between two
MSDS DEPARTMENT, JSW STEEL LTD, TORANAGALLU 20
 or more similar electrical quantities.
Operates when the impedance between relay point and fault point is below a
2. Impedance relay
specified value.
Responds to increase in current. The relay operates when the current exceeds a
3. Over current relay
present level
4. Instantaneous relay A quick operating relay (less than 0.2-second operating times).
A relay without moving parts. In this the measurement is performed by a
5. Static relay
stationary circuit.

10.1 Types of Circuit Breakers:

According to their arc quenching (rapid cooling) media the circuit breaker can be divided as:

 Air circuit breaker

 Oil circuit breaker
 Vacuum circuit breaker
 SF6 circuit breaker

According to their services the circuit breaker can be divided as:

• Outdoor circuit breaker

• Indoor circuit breaker

According to the operating mechanism of circuit breaker they can be divided as:

• Spring operated circuit breaker

• Pneumatic circuit breaker
• Hydraulic circuit breaker

According to the voltage level of installation types of circuit breaker are referred as:

• High voltage circuit breaker (> 72 kV)

• Medium voltage circuit breaker (1-72 kV)
• Low voltage circuit breaker (< 1 kV)
• The maximum voltage per interrupter is 100 kV for air-blast and SF6 breakers, 170 kV for
minimum oil breakers

MSDS DEPARTMENT, JSW STEEL LTD, TORANAGALLU 21

 Air circuit breakers (ACB)

The circuit breaker which operates in air at atmospheric pressure. The working principle of this
breaker is rather different from those in any other types of circuit breakers. The main aim of all kind
of circuit breaker is to prevent the reestablishment of arcing after current zero by creating a situation
where the contact gap will withstand the system recovery voltage. The air circuit breaker does the
same but in different manner. For interrupting arc it creates an arc voltage in excess of the supply
voltage. Arc voltage is defined as the minimum voltage required maintaining the arc. This circuit
breaker increases the arc voltage by mainly three different ways:

• It may increase the arc voltage by cooling the arc plasma. As the temperature of arc plasma is
decreased, the mobility of the particle in arc plasma is reduced; hence more voltage gradient is
required to maintain the arc.
• It may increase the arc voltage by lengthening the arc path. As the length of arc path is
increased, the resistance of the path is increased, and hence to maintain the same arc current more
voltage is required to be applied across the arc path. That means arc voltage is increased.
• Splitting up the arc into a number of series arcs also increases the arc voltage.

There are mainly two types of ACB available.

 1) Plain air circuit breaker

 2) Air-blast circuit breaker

Fig: ABB Low voltage air breaker,

600V/400A

Fig: Air blast circuit breaker rated for 500 kV

MSDS DEPARTMENT, JSW STEEL LTD, TORANAGALLU 22

Plain break

Air-break circuit breakers extinguish the arc by simply stretching it until the dielectric strength of the
gap is larger than the voltage across the gap. The longer arc has a larger cooling surface and higher
resistance, which decreases the current flow and the amount of heat created. To stretch the arc, horn
gap shaped contacts are used. Due to a natural convection, the arc moves upwards. To further
increase the length, the arc is stretched by forcing it into an arc chute made of metal barriers or
insulating material. The metal barriers chop the arc into many smaller arcs. Used from 120 V up to
15 kV.

Fig: Air breaker - plain break

Air-blast break

In the air-blast breaker the arc is not stretched. To extinguish the arc, a blast of compressed air is
directed into the arc path to cool the ionized gas and remove it from the gap between the contacts.
The contacts are held closed by a spring. A blast of air into the interrupting head forces the contacts
to open. The contacts will close as soon as the air flow stops. The compressed air can be blown into
the arc perpendicular to it (cross blast), or along its axis (axial blast). All modern breakers use the
axial blast. The air blast circuit breakers are built up to the highest used voltages (765 kV) by
connecting several interrupter heads in series.

Fig: a) Axial air-blastb)breaker

Axial air-blast breaker

Miniature circuit breakers

For miniature circuit breakers (or MCB) used in households refer to the Small air breakers for low
voltage domestic circuits.
MSDS DEPARTMENT, JSW STEEL LTD, TORANAGALLU 23
Oil circuit breakers (OCB)

Mineral oil has better insulating property than air. The oil is used to insulate between the phases and
between the phases and the ground, and to extinguish the arc. When electric arc is drawn under oil,
the arc vaporizes the oil and creates a large bubble of hydrogen that surrounds the arc. The oil
surrounding the bubble conducts the heat away from the arc and thus also contributes to deionization
and extinction of the arc. Disadvantage of the oil circuit breakers is the flammability of the oil, and
the maintenance necessary (i.e. changing and purifying the oil). The oil circuit breaker is the one of
the oldest type of circuit breakers.

Bulk oil circuit breakers (BOCB)

Bulk oil circuit breaker (or BOCB) is a such type of the circuit breakers where oil is used as arc
quenching media as well as insulating media between current carrying contacts and earthed parts of
the breaker. The oil used here is same as transformer insulating oil. These types of breakers are
designed in all voltage ranges from 1 kV up to 330 kV.

Fig: Bulk oil circuit breakers

Modern arc-controlled oil breakers have an arc control device surrounding the breaker contacts to
improve extinction of arc. In cross blast interrupters, the arc is drawn in front of several lateral vents.
The gas formed by the arc causes high pressure inside the arc control device. The arc is forced to bow
into the lateral vents in the pot, which increases the length of the arc and shortens the interruption
time. The axial blast interrupters use similar principle. Oil breakers are design for both three-phase
and single-phase circuit breakers. At voltages higher than 115 kV, separate tanks for each phase are
used. The practical limit for the bulk oil breakers is 275 kV.

Minimum oil circuit breakers (MOCB)

In minimum oil breakers the oil is used only for extinguishing of the arc. The arc control devices are
the same as for the bulk-oil breakers. However, unlike bulk oil circuit breakers, these designs place
the interrupting units in insulating chambers at live potential. To improve breaker performance, oil is
injected into the arc. The interrupter containers of the minimum oil breakers are made of insulating
MSDS DEPARTMENT, JSW STEEL LTD, TORANAGALLU 24
material and are insulated from the ground. This is usually referred to as live tank construction. For
high voltages (above 132 kV), the interrupters are arranged in series. The features of designing
MOCB is to reduce requirement of oil, and hence these breaker are called minimum oil circuit
breaker. These designs are available in voltages ranging from 1 kV to 765 kV using the multi-break
technique.

Fig: Minimum oil circuit breakers

Vacuum circuit breakers (VCB)

Vacuum circuit breakers are used mostly for low and medium voltages. Vacuum interrupters are
developed for up to 36 kV and can be connected in series for higher voltages. The interrupting
chambers are made of porcelain and sealed. They cannot be open for maintenance, but life is
expected to be about 20 years, provided that the vacuum is maintained. Because of the high dielectric
strength of vacuum, the interrupters are small. The gap between the contacts is about 1 cm for 15 kV
interrupters, 2 mm for 3 kV interrupters.

Vacuum circuit breakers

Service life of the VCB is much longer than other types of circuit breakers. There is no chance of fire
hazard as oil circuit breaker. It is much environment friendly than SF6 circuit breaker.

MSDS DEPARTMENT, JSW STEEL LTD, TORANAGALLU 25

 Sulfur-hexafluoride (SF6) circuit breakers

Gas properties

Fig: SF6 gas molecule

Sulfur-hexafluoride (SF6) is an excellent gaseous dielectric for high voltage power applications. SF6
is a colorless non-toxic gas, with good thermal conductivity and density approximately five times that
of air (6.14 kg/m3.). It does not react with materials commonly used in high voltage circuit breakers.
It has been used extensively in high voltage circuit breakers and other switchgear employed by the
power industry. Applications for SF6 include gas insulated transmission lines and gas insulated
power distribution substations. The combined electrical, physical, chemical and thermal properties
offer many advantages when used in power switchgear. Some of the outstanding properties of SF6
which make its use in power applications desirable are:

 high dielectric strength

 unique arc-quenching ability
 excellent thermal stability
 good thermal conductivity

The SF6 gas is identified as a greenhouse gas, safety regulation are being introduced in many
countries in order to prevent its release into atmosphere.

Breaker properties

The principle of operation is similar to the air blast breakers, except that SF6 is not discharged in the
atmosphere. A closed-circuit, sealed construction is used. There are mainly three types of SF6 CB
depending upon the voltage level of application:

 1) Single interrupter SF6 CB applied for up to 245 kV (220 kV) system

 2) Two interrupter SF6 CB applied for up to 420 kV (400 kV) system
 3) Four interrupter SF6 CB applied for up to 800 kV (715 kV) system

MSDS DEPARTMENT, JSW STEEL LTD, TORANAGALLU 26

 During the opening operation the gas contained inside a part of the breaker is compressed by a
moving cylinder that supports the contacts or by a piston. This forces the SF6 through the
interrupting nozzle. When the contacts separate, an arc is established. If the current is not very high,
it is extinguished at the first zero crossing by the pushing the SF6 through the arc by the piston. If the
short circuit current is high, the arc extinction may not occur at the first zero crossing, but the gas
pressure will increase sufficiently to blow the arc out. By connecting several interrupting heads in
series, SF6 breakers can be constructed for voltages of up to 765 kV.

Fig: a) SF6 CB scheme Fig: ) b) 40.5 kV, SF6 circuit breaker

CHAPTER 11 - PROJECTS
 Recently Commissioned

• 33KV 180MVAr Static Var Compensator at SMS#3

• 400KV Gas Insulated Switchgear

• 315MVA, 400/33/33KV, 160/155MVA Power Transformer

• CPP#2 220KV to 33KV Conversion Project.

 Projects In pipeline

• MSDS#6

• 160 MVA Spare Transformer

• 63MVA Power Transformer for New Oxygen Plant

• Power Supply to BF1 Augmentation

• RMHS 7LC5 33KV Sub Station

MSDS DEPARTMENT, JSW STEEL LTD, TORANAGALLU 27

• SMS-1 & 2 Augmentation

11.1 Maintenance Philosophy

 Proactive Maintenance

• Transformer Oil tests- DGA, BDV, SLUDGE, ACIDITY

• Ultrasound Testing of HT Cable Chamber

• Thermography Testing of Cable Joints

 Predictive Maintenance

• Tan delta tests for transformers

• Fire retardant coating

• Insulating single core cables wherever skinned

 Preventive Maintenance

• Scheduled Maintenance of all equipments such as Transformers, Switch Gears,

DG sets, Weigh Bridges, Pumps and Motors.

CONCLUSION:
In these four weeks of our internship we were able to understand the functions of MSDS.
With the help of the kind guidelines from our mentors I was able to learn the Electrical maintenance
work as per OEM and equipment installation, alignment, commissioning, testing and observing day
to day working performance of the machines. Finally we would like to thank the JSW Steel Plant and
all our mentors without whom it would not have been impossible for us to complete my internship.

MSDS DEPARTMENT, JSW STEEL LTD, TORANAGALLU 28

REFERENCES:
[1] www.jswsteellimited.com

[2] https://en.wikipedia.org/wiki/ jsw

[3] https://en.wikipedia.org/wiki/ circuit breaker

[4] https://en.wikipedia.org/wiki/transformer

MSDS DEPARTMENT, JSW STEEL LTD, TORANAGALLU 29