GOVERNMENT POLYTECHNIC, KOLHAPUR.

(AN AUTONOMOUS INSTITUTE OF GOVERNMENT OF MAHARAHTRA)

“INDUSTRIAL

TRAINING”

A
Training Report Submitted
In Partial Fulfillment of the Requirements
For the Award of Diploma In
ELECTRICAL ENGINEERING.

SUBMITTED BY
Ms. Chougale Rutuja P.
Roll No: - 213172

UNDER THE GUIDANCE OF

Prof. Adlinge R. B.
(Lecturer in Electrical Engineering Dept.)

1
 INDEX

SR.NO. CONTENTS PAGE NO.

1. CERTIFICATE 4
2. CERTIFICATE FROM INDUSTRY 5
3. ACKNOWLEDGEMENT 6
4. COMPANY PROFILE 8
5. SUGAR PROCESS FLOW DIAGRAM 9
6. COGENERATION 10
A) STEAM TURBINE COGENERATION SYSTEMS
B) BACK-PRESSURE/EXTRACTION
7. BOILER 11
A) TYPES OF BOILER
B) KKSSK LTD. BOILER SPECIFICATION
C) FUEL ANALYSIS: (BAGASSE)-------------------------
D) BOILER MOUNTINGS & ACCESSORIES

8. DCS/SCADA 16
9. TURBINE 17
A) TURBINE SPECIFICATION
B) TURBINE INTERNALS & ROTOR
10. ALTERNATOR 19
A) CLASSIFICATION
B) SPECIFICATION
11. AC-EXCITER 23
12. PERMANENT MAGNET GENERATOR(PMG) 24
13. AUTOMATIC VOLTAGE REGULATOR(AVR) 25
14. VARIABLE FREQUENCY DRIVE (VFD) 26
15. TRANSFORMER 27
A)TYPES OF TRANSFORMER
B)SPECIFICATION
16. SWITCHGEAR 29
17. RELAY 30
18. ELECTROSTATIC PRECIPITATION(ESP) 32
a) SPECIFICATION
b) WORKING
19. MOTOR DETAILS 34
20. SYNCHRONIZATION OF TG BREAKER 35
21. MSEB-SWITCHYARD 38
22. BASIC SAFETY TERMINOLOGY 39
23. CONCLUSION 41

2
Certificate from Industry:-

4
 ACKNOWLEDGEMENT

It is my pleasure to be indebted to various people, who

directly or indirectly contributed in the development of this
work and who influenced my thinking, behavior, and acts
during the course of study.

I express my sincere gratitude to Mr. Yuvraj Bhandigare sir

and his team for providing me an opportunity to undergo
summer training.

I am thankful to Mr. D. M. Garge, Principal, Government

Polytechnic, Kolhapur and Mr. S.M. Naik, H.O.D. Electrical
Department for providing all facility and help for smooth
progress of internship.

I also extend my sincere appreciation to Prof. Adlinge R. B.,

Faculty mentor who consistently provide me all the required
valuable suggestions. I would also like to thanks all Staff
Member of Electrical Engineering Department for timely help
and encouragement of fulfillment of internship.

Lastly, I would like to thanks the almighty God and my

parents for their moral support and my friends with whom I
shared my day-to-day experience and received lots of
suggestions that improved my quality of work.

5
 Industrial Training
At Kumbhi Kasari S.S.K.Ltd.

 Name of Lecturer :- Mr. Rahul Chougale

Electrical Engg.

 Name of Student :- Ms. Chougale Rutuja

Prakash.
 Roll Number : - 213172

 Branch of Diploma :- Electrical Engineering.

Name of College : Government Polytechnic, Kolhapur.

6
 COMPANY PROFILE

Kumbhi Kasari Sahakari Sakhar karkhana Ltd., is situated at

Kuditre, Tal. Karvir, Dist.Kolhapur. It was eastiblished in the year 1964 in
co-operative sector. The existing sugarcane crushing capacity is 3000 TCD
and has been running successfully. The Karkhana has attached Co-
generation unit with an installed capacity of 2MW in Phase I. Factory have
proposed to expansion of sugar & cogeneration project ,for expansion of
changing in production capacity of sugar plant from 3000 TCD to 5000 TCD
& co-generation from 2 MW to 19.5 MW. Which would be expanded to
2000 TCD & co-generation expansion of 17.5MW in Phase ll. The Director
body of factory has widespread experience of setting up & managing large
scale industries, Hotels, Agro Based Industries and management of large
scale Entertainment and Hospitality units. The KKSSK has proposed to
expand 2MW power generation to 19.5 MW. The total bagasse required
after expansion of power generation unit to19.5 MW is 42,976 MT/M.
As per government regulation Chandradeep Narake K.K.S.S.K.L
approached MoEF New Delhi for environmental clearance for expansion of
changing in production capacity of sugar plant from 3000 TCD to 5000 TCD
& cogeneration from 2MW to 19.5MW. Regd. No. of factory: G-
282/DATED20/06/1960
The purpose of the preparation of Environment Impact Assessment
(EIA) report is not only to obtain Environment Clearance from Ministry of
Environment & Forests, Govt. of India, New Delhi, but also to understand
the likely impacts and to take Environment Protection measures during and
after commissioning of the project.
They can reuse every weast like after crushing of sugarcanes the
bagas weast is used to generate the electricity and

PROJECT DETAILS:-
The management of Kumbhi Kasari Sahakari Sakhar Karkhana Ltd.
Propose production capacity of sugar plant from 3000 TCD to 5000 TCD &
co-Executive Summary M/s. Kumbhi Kasari Sahakari Sakhar Karkhana Ltd.
Kuditre. Page 2 generation from 2 MW to 19.5 MW.at Kuditre, Tal- Karvir,
Dist - Kolhapur. Chairman is Chandradeep Narake, MLA & Shamarao
Godhade is Vice Chairman of K.K.S.S.K.

7
Sugar Process Flow Diagram

8
Cogeneration

Cogeneration or Combined Heat and Power (CHP) is defined as the

sequential generation of two different forms of useful energy from a single
primary energy source, typically mechanical energy and thermal energy.
Mechanical energy may be used either to drive an alternator for producing
electricity, or rotating equipment such as motor, compressor, pump or fan
for delivering Figure. Thermal energy can be used either for direct process
applications or for indirectly producing steam, hot water, hot air for dryer
or chilled water for process cooling. Cogeneration provides a wide range of
technologies for application in various domains of economic activities. The
overall efficiency of energy use in cogeneration mode can be up to 85 per
cent and above in some cases.
9
Steam Turbine Cogeneration systems
The two types of steam turbines most widely used are the
backpressure and the extraction Another variation of the steam turbine
topping cycle cogeneration system is the extraction-back pressure turbine
that can be employed where the end-user needs thermal energy at two
different temperature levels. The full-condensing steam turbines are
usually incorporated at sites where heat rejected from the process is used
to generate power. The specific advantage of using steam turbines in
comparison with the other prime movers is the option for using a wide
variety of conventional as well as alternative fuels such as coal, natural gas,
fuel oil and biomass. The power generation efficiency of the demand for
electricity is greater than one MW up to a few hundreds of MW. Due to the
system inertia, their operation is not suitable for sites with intermittent
energy demand.

10
Boiler
IBR Steam Boilers means any closed vessel exceeding 22.75 liters in
capacity and which is used expressively for generating steam under
pressure and includes any mounting or other fitting attached to such vessel,
which is wholly, or partly under pressure when the steam is shut off.

Types of Boiler
1)Based on fuel used
a) coal fired-stoker fired, fluidized bed, pulverized coal
b) Oil fired
c)Gas/Sulfuric acid fired
d)bagasse fired
e)Husk/Wood Fired

2) Based on Heat source

a) Combustion of solid, liquid, gases fuels
b)Electrical/Nuclear energy

3) Based on Flue & Water Path

a) Smoke tube boiler
b) Water tube boiler-Single drum, BI Drum, Multiple Drum, Drum less

4) Based on Water circulation

a) Natural
b)Forced
c)Combined

5) Based On number of Tubes

a) Single tube
b) Multi tubular

6) Based On Shape
a) A shape
b) D Shape
c) O shape

7) Based on Operating Pressure

a) Low
b)Medium
c)High/Supercritical
11
8) Based on Draft
a)Natural
b)Forced
c)Induced
d)Balanced

9) Based on Atomization
a) Manually operated
b) Semi Automatic
c) Fully Automatic
KKSSK Ltd. Boiler Specification

MR-15290
MCR Steaming Capacity : 100 TPH
Steam Pressure at MSSV : 87 Kg/cm2
Main Steam Temperature : 515±5 deg C
Boiler Design Pressure : 102.5 Kg/cm2
Boiler Type- Bi Drum, Water tube, Membrane wall, Traveling Grate,
Bagasse fired, Natural circulation, Top supported & balanced draught
boiler.
Fuel Analysis: (Bagasse)

In the following table, we present the Ultimate Analysis details of bagasse,

which is used as the fuel in the Boiler.

Sr. No. Description Value Unit

1. Moisture 50 %
2. Pol 1.99/2.30 %
3. Component % by wt.
A Carbon 22.05 %
B Hydrogen 4.05 %
C Sulfur 0.04 %
D Oxygen 22.54 %
E Nitrogen 0.2 %
F Ash 1.40 %

12
Boiler Mountings & Accessories
Boiler mountings are a set of safety devices installed for the safe
operation of a boiler. There are seven main mountings on a boiler shell,

1) safety valve,

2) steam stop valve,

3) vent valve,
4)pressure gauge,

13
5) water level indicator,

6) feed check valve, and

7) fusible plug.

14
 Boiler accessories are those appliances and plants which are installed
along with a boiler to improve the operating condition and overall
efficiency of the boiler plant.
There are several boiler accessories, and those are:
1. Economizer

2. Superheater

3. Steam separator
4. Steam trap

15
5. Feed pump

DCS/SCADA

16
Turbine

A steam turbine is a heat engine converting the heat energy of

steam supplied to it, into useful work. The available heat energy or ‘Heat
Drop’ can be computed as the change in steam condition from stop valve to
exhaust branch. Steam flow at high velocity results from expansion of the
steam through a series of nozzles which convert the heat energy into
kinetic energy. This kinetic energy is transformed into useful work as the
steam mass progresses through the turbine. The change in direction
experienced by the steam as it impinges on the moving blades imparts a
reactive force on the blades – producing torque on the rotor shaft. In order
to convert large amounts of energy into useful work with maximum
efficiency, it is necessary to expand the pressure energy of the steam flow
in a series or stages. Each stage comprises a set of nozzles followed by a
fully bladed disc or wheel.
I. TURBINE Specification
Power Rated kW - 17500
Inlet Steam Pressure ATA - 83
Inlet Steam Temperature ⁰C - 510
Inlet Steam Flow TPH - 100
Bleed Steam Pressure ATA - 8
Bleed Steam Flow TPH - 4.5
Wheel case Pressure kg/cm²(g) - 48.81
Steam Exhaust Pressure ATA - 2.5
Turbine Speed RPM - 8303
Alternator Speed RPM - 1500
Turbine Trip Speed Range RPM - 9050-9299
First Critical Speed Range RPM - 3850-4850
No. of Stages Nos - 7
Steam Inlet Size - - 8"
Turbine Weight including oil Kg - 33000
Direction of rotation - - ACW from turbine end

II. GEAR BOX

Type - - Double Helical
Model - - N2319C
Input Speed RPM - 8303
Output Speed RPM - 1500

17
Turbine Internals & Rotor

18
Alternator
An alternator is an electrical generator that
converts mechanical energy to electrical energy in the form of alternating
current A conductor moving relative to a magnetic field develops
an electromotive force (EMF) in it (Faraday's Law). This EMF reverses its
polarity when it moves under magnetic poles of opposite polarity. Typically,
a rotating magnet, called the rotor turns within a stationary set of
conductors wound in coils on an iron core, called the stator. The field cuts
across the conductors, generating an induced EMF (electromotive force), as
the mechanical input causes the rotor to turn.
The rotating magnetic field induces an AC voltage in the stator windings.
Since the currents in the stator windings vary in step with the position of
the rotor, an alternator is a synchronous generator.
Classification
Alternators may be classified by method of excitation, number of phases,
the type of rotation, cooling method, and their application.
1) By excitation
There are two main ways to produce the magnetic field used in the
alternators, by using permanent magnets which create their own persistent
magnetic field or by using field coils. The alternators that use permanent
magnets are specifically called magnetos.
In other alternators, wound field coils form an electromagnet to
produce the rotating magnetic field.A device that uses permanent magnets
to produce alternating current is called a permanent magnet alternator
(PMA). A permanent magnet generator (PMG) may produce either
alternating current, or direct current if it has a commutator.
2) Direct-connected direct-current (DC) generator
This method of excitation consists of a smaller direct-current (DC)
generator fixed on the same shaft with the alternator. The DC generator
generates a small amount of electricity just enough to excite the field coils
of the connected alternator to generate electricity. A variation of this
system is a type of alternator which uses direct current from a battery for
initial excitation upon start-up, after which the alternator becomes self-
excited.

19
3) Transformation and rectification
This method depends on residual magnetism retained in the iron core to
generate weak magnetic field which would allow a weak voltage to be
generated. This voltage is used to excite the field coils for the alternator to
generate stronger voltage as part of its build up process. After the initial AC
voltage buildup, the field is supplied with rectified voltage from the
alternator
4) Brushless alternators
A brushless alternator is composed of two alternators built end-to-end on
one shaft. Until 1966, alternators used brushes with rotating field.[20] With
advancement in semiconductor technology, brushless alternators are
possible. Smaller brushless alternators may look like one unit but the two
parts are readily identifiable on the large versions. The larger of the two
sections is the main alternator and the smaller one is the exciter. The
exciter has stationary field coils and a rotating armature (power coils). The
main alternator uses the opposite configuration with a rotating field and
stationary armature. A bridge rectifier, called the rotating rectifier
assembly, is mounted on the rotor. Neither brushes nor slip rings are used,
which reduces the number of wearing parts. The main alternator has a
rotating field as described above and a stationary armature (power
generation windings).
Varying the amount of current through the stationary exciter field coils
varies the 3-phase output from the exciter. This output is rectified by a
rotating rectifier assembly, mounted on the rotor, and the resultant DC
supplies the rotating field of the main alternator and hence alternator
output. The result of all this is that a small DC exciter current indirectly
controls the output of the main alternator.[21]
5) By number of phases
Main articles: Single-phase generator and Polyphase coil
Another way to classify alternators is by the number of phases of their
output voltage. The output can be single phase, or polyphase. Three-phase
alternators are the most common, but polyphase alternators can be two
phase, six phase, or more.
6) By rotating part
The revolving part of alternators can be the armature or the magnetic field.
The revolving armature type has the armature wound on the rotor, where
the winding moves through a stationary magnetic field. The revolving
armature type is not often used.[19] The revolving field type has magnetic
field on the rotor to rotate through a stationary armature winding. The
20
advantage is that then the rotor circuit carries much less power than the
armature circuit, making the slip ring connections smaller and less costly;
only two contacts are needed for the direct-current rotor, whereas often a
rotor winding has three phases and multiple sections which would each
require a slip-ring connection. The stationary armature can be wound for
any convenient medium voltage level, up to tens of thousands of volts;
manufacture of slip ring connections for more than a few thousand volts is
costly and inconvenient.
7) Cooling methods
Many alternators are cooled by ambient air, forced through the enclosure
by an attached fan on the same shaft that drives the alternator. In vehicles
such as transit buses, a heavy demand on the electrical system may require
a large alternator to be oil-cooled. In marine applications water-cooling is
also used. Expensive automobiles may use water-cooled alternators to
meet high electrical system demands.

21
Generator specification

1 Make TDPS
2 Output KVA 22000
3 Type SGEN-100A-4P-130-25
4 Standard IEC 60034
5 Weight Kg 90600
6 No. of poles 4
7 No. phases 3
Enclosure
8 IP54
system
9 Voltage AC Volts 11000
10 Current AC Amps 1312
11 Frequency Hz 50
12 Speed RPM 1500
Limiting
13 RPM 1800
Speed
14 Power factor 0.8
Type of stator
15 STAR
connection
16 Exc. Voltage Volts 114 DC
17 Exc. Current Amps 897
C Gear Box
1 Make SEISA Gear Ltd Osaka Japan
2 Model NDL 7585T
Normal power
3 KW 17500
rating
4 Input speed RPM 6800
5 Output speed RPM 1500
6 Ration 01:04.53

22
AC Exciter
The exciter supplies direct current to the field winding of the
generator, at whatever voltage is required to overcome the resistance of
the winding. The rating of the exciter is specified as its output power,
current, and voltage corresponding to the rating (or maximum capability, if
different) of the generator, recognizing the temperature of the generator's
field winding.
Over the years, many types of exciters have been used, but the type
most commonly used was the commutator-type dc generator. This is very
rarely used for new generators today. A new turbine generator is usually
supplied with one of the following types of exciter: (1) shaft-
driven alternator with solid-state diode rectifiers, (2) solid-
state thyristor rectifiers supplied by a transformer deriving its power from
the power system or from within the generator (the latter is a form of self-
excitation), or (3) shaft-driven alternator with its output winding on the
rotor, its output rectified by rotating solid-state rectifiers, commonly called
a “brushless exciter.”
In addition to its normal function of providing the proper level of direct
current to the generator's field winding as required for the apparent power
being supplied, the terminal voltage, and power factor of the generator
load, the exciter must also be able to produce a ceiling voltage (which is
higher than rated exciter voltage) and to operate at that condition for a
specified brief period, as required by the voltage response ration which is
part of the excitation system specification.
When the exciter is a rotating machine driven by the generator shaft,
it becomes part of the turbine generator shaft system and must be
designed to accommodate axial motions due to thermal expansion of the
turbine and generator rotors, and vertical motions of the generator shaft
due to bearing oil film and thermal expansion of the generator bearing
support.

23
PMG
The PMG (Permanent Magnet Generator) is a system which is used for
secondary exciting. The PMG provides stable and reliable electric energy for
AVR regardless the generator’s terminal voltage. The generator with PMG
excitation system can provide 300 % rated current during short-circuit,
which occurs for 5-10 seconds.In a standard AC generator, the AVR is fed
from the generator terminals.
In systems which have high inductive loads that cause a large transient
voltage dip in the stator voltage before the AVR can compensate, the AVR
suffers, because its input voltage is reduced. This can lead to situations
where the AVR is not able to bring the voltage back to its preset value,
because the terminal voltage has fallen too far and hence its power source
isn't available.
The advantage from the PMG is that the power to the AVR is kept near
constant, allowing the AVR to quickly recover the voltage of the AC
generator back to its nominal preset value. The AVR reacts quicker reducing
the transient voltage dip associated with applying a load to an AC
alternator.
The PMG system also provides the advantage that no residual
magnetism is required in order to start the excitation process at start up,
whereas for shunt or auxiliary wound machines, if the residual magnetism
is lost, the generator voltage will fail to build up.

24
AVR

The automatic voltage regulator is used to regulate the voltage. It

takes the fluctuate voltage and changes them into a constant voltage. The
fluctuation in the voltage mainly occurs due to the variation in load on the
supply system. The variation in voltage damages the equipment of the
power system. The variation in the voltage can be controlled by installing
the voltage control equipment at several places likes near the transformers,
generator, feeders, etc., The voltage regulator is provided in more than one
point in the power system for controlling the voltage variations.
In DC supply system the voltage can be controlled by using over
compound generators in case of feeders of equal length, but in the case of
feeders of different lengths the voltage at the end of each feeder is kept
constant using feeder booster. In AC system the voltage can be controlled
by using the various methods likes booster transformers, induction
regulators, shunt condensers, etc.,

Working Principle of Voltage Regulator

It works on the principle of detection of errors. The output voltage of

an AC generator obtained through a potential transformer and then it is
rectified, filtered and compared with a reference. The difference between
the actual voltage and the reference voltage is known as the error voltage.
This error voltage is amplified by an amplifier and then supplied to the main
exciter or pilot exciter.

25
VFD
A Variable Frequency Drive (VFD) is a type of motor controller that
drives an electric motor by varying the frequency and voltage supplied to
the electric motor. Other names for a VFD are variable speed drive,
adjustable speed drive, adjustable frequency drive, AC drive, Microdrive,
and inverter.

Frequency (or hertz) is directly related to the motor’s speed (RPMs). In

other words, the faster the frequency, the faster the RPMs go. If an
application does not require an electric motor to run at full speed, the VFD
can be used to ramp down the frequency and voltage to meet the
requirements of the electric motor’s load. As the application’s motor speed
requirements change, the VFD can simply turn up or down the motor speed
to meet the speed requirement.

26
Transformer-
A transformer is defined as a passive electrical device that transfers
electrical energy from one circuit to another through the process
of electromagnetic induction.

Types of transformer

1)Step up and Step down Transformer,

2)Power Transformer,
3) Distribution Transformer,
4) Instrument transformer comprising current and Potential Transformer,
5)Single phase and Three phase transformer,
6)Auto transformer, etc.

27
Transformer Specification

Make – VOLT AMP, Rating – 5MVA,Voltage-

Converter
1 11/0.433/0.433 KV, Current – 262.43/3333.43/3333.43
Transformer - 1
Amps, Vector Group –Dyn11znO, sr.no.15459/1,5360ltrs
Make – VOLT AMP, Rating – 5MVA,Voltage- 11/0.433/0.433KV,
Converter
2 Current – 262.43/3333.43/3333.43 Amps, Vector Group –
Transformer - 2 Dyn11znO, sr.no.15459/2,5360ltrs
Distribution Make – VOLT AMP, Rating – 2.5MVA,Voltage- 11/0.433 KV,
3
Transformer Current – 132 /3333 Amps, Vector Group – Dyn11

Make – Bharat Bijali, Rating – 63MVA, Voltage- 11/11.5KV, Current

Generator
4 – 3306.6 /3162.9Amps, Vector Group – YNd11,Sr.No.5171/1,
Transformer
Quantity-29400 ltrs

Power Make – Bharat Bijali, Rating – 44/55MVA, Voltage- 11/110(132)KV,

5 Evacuation Current – 2309 /192Amps, Vector Group – YNd1, With OLTC
Transformer +10% to -15% instep of 1.25%,Sr.No.5170/1, 26600 ltrs

ESP 121.6KVA, ESP transformer rectifier set, I/p Voltage:415V, 293A,

6
Transformer set O/p: 110KV, 1200mA, Sl.No.8395-01-09-2010, 536 ltrs

28
switchgear
In an electric power system, switchgear is composed of electrical
disconnect switches, fuses or circuit breakers used to control, protect and
isolate electrical equipment. Switchgear is used both to de-energize
equipment to allow work to be done and to clear faults downstream. This
type of equipment is directly linked to the reliability of
the electricity supply.
The earliest central power stations used simple open knife switches,
mounted on insulating panels of marble or asbestos. Power levels and
voltages rapidly escalated, making opening manually operated switches too
dangerous for anything other than isolation of a de-energized circuit. Oil-
filled switchgear equipment allows arc energy to be contained and safely
controlled. By the early 20th century, a switchgear line-up would be a
metal-enclosed structure with electrically operated switching elements
using oil circuit breakers. Today, oil-filled equipment has largely been
replaced by air-blast, vacuum, or SF6 equipment, allowing large currents
and power levels to be safely controlled by automatic equipment
1) Oil
Oil circuit breakers rely upon vaporization of some of the oil to blast a
jet of oil along the path of the arc. The vapor released by the arcing consists
of hydrogen gas. Mineral oil has better insulating property than air.
Whenever there is a separation of current carrying contacts in the oil, the
arc in circuit breaker is initialized at the moment of separation of contacts,
and due to this arc the oil is vaporized and decomposed to mostly hydrogen
gas and ultimately creates a hydrogen bubble around the electric arc. This
highly compressed gas bubble around the arc prevents re-striking of the arc
after current reaches zero crossing of the cycle. The oil circuit breaker is
one of the oldest types of circuit breakers.
2) Air
Air circuit breakers may use compressed air (puff) or the magnetic
force of the arc itself to elongate the arc. As the length of the sustainable
arc is dependent on the available voltage, the elongated arc will eventually
exhaust itself. Alternatively, the contacts are rapidly swung into a small
sealed chamber, the escaping of the displaced air thus blowing out the arc.
Circuit breakers are usually able to terminate all current flow very quickly:
typically between 30 ms and 150 ms depending upon the age and
construction of the device.

29
3) Gas
Sulfur hexafluoride circuit breaker
Gas (SF6) circuit breakers sometimes stretch the arc using a magnetic
field, and then rely upon the dielectric strength of the SF6 gas to quench the
stretched arc.
4) Hybrid
Hybrid switchgear modules
Hybrid switchgear is a type which combines the components of
traditional air-insulated switchgear (AIS) and SF6 gas-insulated switchgear
(GIS) technologies. It is characterized by a compact and modular design,
which encompasses several different functions in one module.
5) Vacuum
Circuit breakers with vacuum interrupters have minimal arcing
characteristics (as there is nothing to ionize other than the contact
material), so the arc quenches when it is stretched by a small amount (<2–
8 mm). Near zero current the arc is not hot enough to maintain a plasma,
and current ceases; the gap can then withstand the rise of voltage. Vacuum
circuit breakers are frequently used in modern medium-voltage switchgear
to 40,500 volts. Unlike the other types, they are inherently unsuitable for
interrupting DC faults. The reason vacuum circuit breakers are unsuitable
for breaking high DC voltages is that with DC there is no "current zero"
period. The plasma arc can feed itself by continuing to gasify the contact
material.

30
Relay
Definition: The relay is the device that open or closes the contacts to cause
the operation of the other electric control. It detects the intolerable or
undesirable condition with an assigned area and gives the commands to the
circuit breaker to disconnect the affected area. Thus protects the system
from damage

Working Principle of Relay

It works on the principle of an electromagnetic attraction. When the circuit

of the relay senses the fault current, it energises the electromagnetic field
which produces the temporary magnetic field.

This magnetic field moves the relay armature for opening or closing
the connections. The small power relay has only one contacts, and the high
power relay has two contacts for opening the switch.

The inner section of the relay is shown in the figure below. It has an
iron core which is wound by a control coil. The power supply is given to the
coil through the contacts of the load and the control switch. The current
flows through the coil produces the magnetic field around it.

Due to this magnetic field, the upper arm of the magnet attracts the
lower arm. Hence close the circuit, which makes the current flow through
the load. If the contact is already closed, then it moves oppositely and
hence open the contacts.

30
Construction of Relay
The relay operates both electrically and mechanically. It consists
electromagnetic and sets of contacts which perform the operation of the
switching. The construction of relay is mainly classified into four groups.
They are the contacts, bearings, electromechanical design, terminations
and housing.

Contacts – The contacts are the most important part of the relay that
affects the reliability. The good contact gives limited contact resistance and
reduced contact wear. The selection of the contact material depends upon
the several factors like nature of the current to be interrupted, the
magnitude of the current to be interrupted, frequency and voltage of
operation.

Bearing – The bearing may be a single ball, multi-ball, pivot-ball and jewel
bearing. The single ball bearing is used for high sensitivity and low friction.
The multi-ball bearing provides low friction and greater resistance to shock.

Electromechanical design – The electromechanical design includes the

design of the magnetic circuit and the mechanical attachment of core, yoke
and armature. The reluctance of the magnetic path is kept minimum for
making the circuit more efficient. The electromagnet is made up of soft
iron, and the coil current is usually restricted to 5A and the coil voltage to
220V.

Terminations and Housing – The assembly of an armature with the magnet

and the base is made with the help of spring. The spring is insulated from
the armature by moulded blocks which provide dimensional stability. The
fixed contacts are usually spot welded on the terminal link.

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Electrostatic precipitation(ESP)

Electrostatic precipitation (ESP) is a highly efficient method of

removing entrained particulate contaminants from exhaust gases and is
extensively used in these industries to limit particulate emissions. In view of
this, information on construction, working, design, erection,
commissioning, operation and maintenance of electrostatic precipitators;
and emission standards is given in this booklet

KKSSK Ltd.Thermax ESP Technical Details :

1) ESP Suitable for Boiler Capacity : 100 TPH ISGEC Make TG Boiler
2) Fuel Fired in Boiler : 100% Bagasse, 100% Imported Coal
3) Flue Gas Volume at ESP Inlet : 100% Bagasse : 268956 m3/hr
4) Flue Gas Volume at ESP Inlet : 100% Bagasse : 178560 m3/hr
5) Dust Load at ESP Inlet : 6 gm/Nm3
6) No. of Gas Passages : 23
7) Distance between collecting plates : 400 mm
8) Height of collecting plate : 24 feet
9) No. of Field : 2
10) No of Hoppers : 4 Nos
11) Width of Field : 12.125 feet
12) Design Temp : 250 Deg C
13) Design Pressure : +/- 400 mmWc
14) Total Collecting Plates : 381 Nos
15) Total Emitting Electrodes : 365 Nos
16) TR Set Rating : 120 KV, 400 mA
17) TR Qty : 2
18) Total Collection Area : 2487.2 m2
19) Outlet emission at ESP outlet : < 115 mg/nm3

32
 Working of.ESP

An ESP works because of electrostatic attraction (like charges

repel; unlike charges attract). An ESP uses a high voltage electrostatic field
to separate dust, fume or mist from a gas stream. The precipitator consists
of vertical parallel plates (collecting plates/electrodes) forming gas
passages 12 to 16 in. (30.5 to 40.6 cm) apart. Discharge electrodes are
electrically isolated from the plates and suspended in rows between the gas
passages.
Every particle either has or can be given a charge - positive or negative. A
high voltage system provides power to the discharge electrode to generate
an electrical field. The particulate, entrained in the gas, is charged while
passing through the electrical field. The particulate is then attracted to the
grounded collector plate, and forms a dust layer on the plate.
Periodic rapping separates the accumulated dust layer from both the
collector plates and discharge electrodes (in case of wet ESP by spraying it
with a liquid). The dust layer released by the rapping collects in hoppers
and is removed by material / ash handling system. At many places in this
article, ash is used instead of particulate matter since major application of
an ESP is for ash collection.

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SYNCHRONIZATION OF TG BREAKER:

1. Ensure turbine is at rated speed & voltage is available in all metering

section of AVR, RMP & Synchronizing panel. If voltage is not available.
Check PT voltage at terminals of corresponding panel. Find out the reason
then proceed forward.
2. Put governor in Remote from DCS. Press Governor local / remote push
button from DCS (turbine Trip Graphic Page) to change mode. This will
allow operator to (increase / decrease) (speed / load) from DCS (remote) /
Synchronizing panel(remote) / TSP panel (Local). When Governor Local is
shown in DCS graphic, it will allow operator to increase / decrease speed
(when island (plant Load)) and increase / decrease load (when parallel with
grid) from Turbine supervisory Panel (TSP). TSP panel is provided with PL9 -
Yellow colour push button(Turbine Speed Raise) & PBL10 – Blue colour
push button (Turbine Speed Lower) for operation. When Governor Remote
is shown in DCS graphic, it will allow operator to increase / decrease speed
(when island (plant Load)) and increase / decrease load (when parallel with
grid) from DCS & Synchronizing panel. DCS is provided with RAISE & LOWER
Push button to increase /decrease load / speed. Synchronizing panel is also
provided with PB4 (Increase frequency) blue colour push button & PB5
(Decrease frequency) black colour push button to increase / decrease speed
(when island (plant Load)) and increase /decrease load (when parallel with
grid).
3. Ensure all breakers connected to grid are in closed direction i.e in service.
This contact can be checked in Governor Service program. TR1CB & TR2CB
should be in closed condition.
4. Ensure all annunciation of AVR, relay metering panel have been reset and
are healthy to read abnormality.
5. Select SYNCHRONIZING SELECTOR SWITCH (SSW2) in Manual mode.
SYNC MANUAL MODE ON (L8) indication glows.
6. Select the Breaker to be synchronized through SYNC BREAKER SELECT
SWITCH (SSW3). Refer breaker selection table mounted on panel to select
breakers. For example if TG breaker is to be synchronized then move
selector switch to position 1.

34
7. After selecting breaker, ensure incoming and running voltage &
frequency are displayed on synchronizing panel.
8. Match the frequency of turbine with the grid by increasing frequency
raise / lower from synchronizing panel Synchronizing panel is also provided
with PB4(Increase frequency) blue colour push button & PB5 (Decrease
frequency) black colour push button to increase / decrease speed (when
island (plant Load)) and increase / decrease load (when parallel with grid).
These push buttons will raise /lower speed of turbine if Governor Remote is
selected in DCS. Refer alternator & turbine manual for operating
frequencies.
9. Match the Voltage of alternator with the grid voltage by increasing
voltage raise /lower from synchronizing panel. Synchronizing panel is
provided with PB2(Increase Voltage) push button & PB3 (Decrease Voltage)
push button to increase / decrease voltage. These push buttons will raise /
lower voltage of turbine if Local / Remote Selector Switch of AVR is selected
in Remote.
10. Try to maintain 11 KV voltages by increasing / decreasing tap changer of
grid transformer. Refer alternator & turbine manual for operating
frequencies &voltages
11. Breaker should be in Service and all relays in reset condition.
12. Switch on the Synchroscope (SSW1).
13. Fine tune & match the Voltage and Frequency by Raise / Lower
commands. Voltage raise / lower command will go to AVR & frequency
raise / lower commands will go to governor.
14. Watch the Synchroscope rotating steadily and very slowly towards
Clockwise Direction.
15. Actuate the Breaker Close Command while Synchroscope reaches
slowly top 12’0’ Clock position & “25M acted’ indication Glows.
16. Switch off selector switches SSW1, SSW2 & SSW3.
17. Once the TG breaker is closed, governor will be automatically goes into
Auxiliary control mode (Governor F4 key glows) & turbine will be loaded up
to1 MW (default). If F4 key is not glowing then operator has to press F4 key
immediately and then press YES to enable it. F4 key will glow. If auxiliary
control mode is OFF (F4 keys if OFF) then turbine will be in floating mode
and will change load according to grid frequency. In that case, operator has

35
to press key 9 and then adjust key to increase / reduce load. Operator has
to monitor load continuously in case F4 keys is not glowing.
18. Switch on the power Factor Control in AVR after closing breaker (if
synchronized with grid) and maintain power factor 0.8 to 0.9 toward
inductive side and noteKVAR is in positive direction. If Power factor ON is
not glowing then operator has to press PF ON immediately and then press
set-point increase / decrease to improve power factor. If power factor
mode is OFF then power factor of the system bus will change continuously.
In that case, Operator has to monitor power factor continuously in case
power factor push button is not glowing and increase /decrease set point
from AVR to improve it.
19. Load turbine according to curve and difference of casing temperature. If
difference of casing temperature is greater than 30 Degree than turbine
should not be loaded further. It should be less than 30 Degree.

Turbine supervisory Panel (TSP)

36
MSEB-Switchyard

Generation Level 11 KV
Power Transformer DELTA-STAR
Capacity 110/11 KV. , 18 MVA , Cooling – ONAN
Transmission LILO

Two transmission lines are used for

importing and export of electric power,
Puikhadi and Kale
Per hour 7.5 MW is used for internal
used (CHP Plant, Mill, DM plant,
Dislery) 10 MW energy is export to
MSEDCL from the plant, in seasons and
for offseason they takes electricity
form MSEDCL

37
Basic Safety Terminology

Safety- A state in which risk of harm or damage is reduced to a level that is

as low as reasonably practical.
ALARP (As low as reasonably practical) - A level at which a risk can be
accepted, given the cost, time, manpower implications to treat the risk.
Hazard- is physical or chemical situation with potential for human injury,
damage property or environment.
Risk- combination of the likelihood of an occurrence of a hazardous event
or exposure(s) and the severity of injury or ill health that can be caused by
the event or exposure(s).
Hazard identification- process of recognizing that a hazard exists and
defining its characteristics.
Risk assessment- process of evaluating the risk(s) arising from a hazard(s),
taking into account the adequacy of any existing controls, and deciding
whether or not the risk(s) is acceptable.
Acceptable risk- risk that has been reduced to a level that can be tolerated
by the organization having regard to its legal obligations and its own HSE
policy.
HIRA- Hazard identification and risk assessment.
Incident- Event that give rise to an accident or had the potential to lead to
an accident
Accident- is an unplanned and unexpected events which causes or is likely
to cause an injury.
Unsafe Act - Practices which human beings perform which are hazardous,
i.e. rushing, short cuts, horseplay, drink or drugs abuse within the
workplace
Unsafe Condition – Physical conditions of the workplace which render it
unsafe. i.e. unguarded machines, spills.
Lost Workday Case (LWC)- Any work related injury that renders the injured
person temporarily unable to perform their normal work or restricted work
on any day after the day on which the injury occurred. In this case any day
includes rest day, weekend day, scheduled holiday, public holiday or
subsequent day after ceasing employment.
38
Restricted Work Case (RWC)- Any work related injury which renders the
injured person temporarily unable to perform all, but still some, of their
normal work on any day after the day on which the injury occurred.
Permanent Total Disability (PTD)-Any work related injury that permanently
incapacitates an employee and results in termination of employment.
First Aid Case (FAC)- Any single treatment and subsequent observation of
minor scratches, cuts, burns, splinters, etc. that do not normally require
medical care by a physician. Such treatment and observation is considered
first aid case even if provided by a physician or registered professional
personnel. (Note that FAC is not included into Total Recordable Cases).
Medical Treatment Case (MTC)- Any work related injury that involves
neither lost workdays nor restricted workdays, but which requires
treatment by a physician or other medical specialist. (In case an MTC has
been classed as LWC or LTI, then avoid reporting it as MTC).
Loss Time Injury(LTI)- Incident in which worker/employee doesn’t report to
duty within 48 Hrs.
Fatality (FAT)-A death resulting from a work related injury or occupational
illness, regardless of the time intervening between the exposure or incident
causing the injury or illness and the death.
Near Miss - A Near Miss is an Incident involving Safety or Health but did
not cause damage/loss or human injury
OR
Potentially significant event that did not occur due to prevailing conditions,
but could have resulted from a sequence of events that did occur

39
Conclusion
Throughout my Training Program, I could more
understand about the Power plant/Cogeneration System. After
complete my industrial training program, I know ‘about
Operation & Maintenance of Power plant.
The activities that I had learned during industrial training
really useful for me in future to face challenges in working
environment. The internship was also good to find out what my
strengths and weakness. And the practically which types of
problems occurs and how they face this types of problems. The
maintenance of the plant. And the motors used, in
cogeneration department there are only two motors operating
on star delta starters and the other motors operated on
VFD(Variable Frequency Drive). For every motor their was a
vfds the benefit of the vfd is that it save the energy
consumptions and the desiarable output with low efforts.

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