Industrial Internship Report on

“Generation and Distribution”

Undergone at
BILAGI SUGAR MILL LIMITED, BADAGANDI

Submitted in partial fulfilment of the requirements for the award of degree of

Bachelor of Engineering
in
Electrical and Electronics Engineering

Submitted by
Roopa Oddin
2BA20EE038

Basaveshwar
Engineering
College
Bagalkot-587102, Karnataka

Department of Electrical and Electronics Engineering

Certificate
This is to certify that the Internship titled “Generation and Distribution” is
carried out by Miss.Roopa Oddin,(USN:2BA20EE038), at Bilagi Sugar Mills
Limited, Badagandi. This report satisfies the academic requirements with
reference to Internship work prescribed for VII semester for the award of
Bachelor of Engineering degree in Electrical and Electronics.

Dr.S.Y.Goudappanavar Dr. B. F. Ronad Dr. D. S.Jangamshetti

Faculty Advisor Internship Coordinator Head of Department
Acknowledgement

I express sincere gratitude to Dr. S. S. Injangeri(Principal) and Dr. D. S. Jangamshetti (Head

of the Department Electrical and Electronics Engineering), Basaveshwar Engineering
College, Bagalkot for his support and encouragement.

I place on record and warmly acknowledge the continuous encouragement, invaluable

supervision, timely suggestion and inspired guidance offered by our guide Dr. B. F.
RonadDepartment of Electrical and Electronics Engineering in Basaveshwar Engineering
College,Bagalkot in bringing this internship to a successful completion.

I take opportunity to thank BILAGI SUGAR MILL LIMITED, BADAGANDI for providing a
wonderful environment in their industry.

I express sincere gratitude to Mr. Manjunath Meti (Management Co-ordinator) and Co-Gen
Employees of BILAGI SUGAR MILL LIMITED, BADAGANDI for permitting us to make use of
the facilities available inthe industry to carry out the industrial training/internship
successfully.

-Roopa Oddin
Abstract

sugar is one of the oldest commodities in the world. It can be produced from
sugarcane, sugar beetother crops having sugar content. Wide applications of sugar make
massive demand in the domestic including international market. An assessment of
environmental impact for sugar processing industry has done in terms of production,
processing, recycling, and utilization. Sugarcane mill has a significant contribution on
government revenue and employment opportunities. It has other goodness like the
development of community system and administrative aspects of the environmental
management plan. sugar mills in India consume their own bagasse to run their mills during
the season and generate steam to run the boilers and turbines; they generate power to run
their plants. Surplus energy can be exported to the grid of the distribution licenses.

Advanced power generation systems have a big potential to be integrated into sugar cane
factories and thus help generate surplus electricity. Usually, sugar mills having mechanical
steam turbines have higher steam consumption due to the poor efficiency of the mechanical
steam turbines. Replacement of these turbines with electric drives will improve the
electrical power generation since steam will be saved.
List of Tables
Sl no Table Caption Page no
1 Company Profile 9
2 Board of Directors 9
3 Internship schedule
4 Details of existing Boilers at BSML 15

List of Figures
Fig no Figure Caption Page no
1.1.1 Industry Profile
2.1.1 Over View of sugar Industry 11
2.1.2 Cane weighbridge 11
2.1.3 Cane Unloading 12
2.1.4 Conveying cane 12
2.2.1 Crushing of Sugar cane 13
2.2.2 Juice Clarifier 14
2.2.3 Crystallization 15
2.2.4 Crystallization of Sugar 16
2.2.5 Centrifuge 16
2.2.6 Bagging 17
2.2.7 Drying 18
3.1.1 Schematic Diagram of Boiler 20
3.1.2 Picture of Bagasse fired Boiler 20
3.2.1 Picture of turbine 21
4.1.1 Flowchart of Both Sugar Plant &Cogeneration
Summary of Internship

1. Name of the Industry: Bilagi Sugar Mills Limited

2. Location:Girisagar road, Badagandi
3. Start Date: 17/7/2023
4. End Date: 12/8/2023
5. Total Duration of Internship(days): 24
6. Number of Working Hours/Day: 06
7. Internship Guide: Manjunath Meti
8. Contact Number of Guide: 9606458426

9. Title:Process of manufacturing sugar and generating electricity

10. Work Domain/Area:Generation and Distribution
Internship Certificate
Internship CIE Marks Sheet
 Contents Page No.
Acknowledgement
Abstract
List of Tables
List of Figures
Summary of Internship
Internship Certificate
Internship CIE Marks Sheet
1. Introduction

1.1 Introduction to company

1.2 About the Organization
1.3 Objectives of the Internship
1.4 Internship Schedule
2. Week-1 Activity Report

2.1 Overview of the Company

2.2 Process of manufacturing sugar
3. Week-2 Activity Report

3.1 Introduction to Boiler section

3.2 Brief Discussion about Turbine
4. Week-3 Activity Report

4.1 Cogeneration Plant

4.2 Introduction to Control Panel
5. Week-4 Activity Report

6. Internship Attendance Report

7.Outcomes of the Internship

Chapter 1
 Introduction

1.1 Introduction to Company

Bilagi Sugar mill Limited is promoted with keen and active interest taken by Shri. S.R. Patil,
Chairman, Bilagi Sugar Mill Limited (BSML), Badagandi and who is former minister and MLC
opposition leader in Karnataka Legislative Council and MLC in Karnataka Legislative Council
last 20 years in the government of Karnataka.

The M/s. Bilagi Sugar Mill Limited (BSML), setup at village Badagandi, TqBilagi, dist.
Bagalkot, State: Karnataka is an agro based company focused on the production of sugar
and generation of power which is supplied to state grid. BSML is committed to produce
quality sugar by adopting modern techniques and eco-friendly manufacturing practices.

BSML was incorporated on 19th November, 2001 under the companies Act, 1956. The
factory site is at a distance of 30Kms from Bagalkot city and about 4.7 Kms from Bilagi Town.
Now BSML is expanding its plant crushing capacity from present 3500 TCD to 12,500 TCD
and CO-Generation capacity from 8 MW to additional 30 MW (8 MW+30 MW=38 MW) and
plans are for further expansion to 60 MW in near future.

After expansion combined sugar and Co-generation plant will help to improve the overall
working of the company, which will enable them to make higher payment towards cane
price to farmers who supply cane to factory.

Also, from October onwards till May end state faces power shortage and factory can make
its contribution by giving power from their cogeneration unit to state grid. Government of
India and Govt of Karnataka has also recognized for cogeneration units. The biomass power
generation also helps in reduction of CO2 emission for cleaner environment.

Bilagi Sugar Mill LTD, Badagandi is a highly ambitious multipurpose company. The company
is producing plantation white sugar as a main product and molasses/press mud as by-
products along with co-generation of power
 INDUSTRY PROFILE

Fig. 1.1.1 Industry profile

Bilagi Sugar Mill Limited (BSML) is a Public Limited Company registered in the State of
Karnataka under the Companies Act, 1956 bearing Certificate of Incorporation Number (CIN)
U15429KA2001PLCO29788 dated 19-11-2001, with site located at Girisagar Road, Village
Badagandi, Taluk – Bilagi, Dist. Bagalkot, Karnataka.
1.2 About the Organisation
Company Profile:
Table. 1 Company Profile

Name of the company BILAGI SUGAR MILL LIMITED, BADAGANDI

Address At post: Badgandi, Tq: Bilagi,
Dist. Bagalkot, Karnataka
Year of established 19 November 2001
Business type Manufacturing
Chairman & Managing Shri Shivanagouda R Patil and Sureshgouda Patil
Director
Main product Sugar
Registered office K. H. B Colony Basavanagar Bagalkot -587101
Initial investment 120 crore
Land 100 acres
Phone no 9606458426
E-mail Id [email protected]

Number of employee 500

Board of Directors

Table. 2 Board of Directors

Name Designation Date of Appointment

S R PATIL Chairman 19 November 2001

Suresh gouda Patil Whole time director 01 February 2002
Laxman R Nirani Director 29 December 2008
Manjunath Aralikatti Director 01 July 2019
Naveen Badri Director 30 November 2021
Hanamanth gouda Patil Director 19 March 2014
1.3 Objectives of the Internship
The objectives of the internship are as follows:
 To understand corporative and managerial processes of an industries.
 To understand anoperational parameters of selected sugar cane mills in different
countries world-wide.
 To know the optimisation of bagasse for electricity generation and export to the grid.
 To know how the efficient use of bagasse for energy export to the grid will bring
additional revenue to the industry.
1.4 Internship Schedule
Table.3 Internship Schedule

Week Date Task Assigned

17/7/2023 Company overview, mill section, different section

1st Week to
in the factory, process of manufacturing sugar
22/7/2023
2ndWeek 24/7/2023 Overview of boiler section, specifications and
to
study of different boiler, working principle of
29/7/2023
steam turbine, components of steam turbine
3rd Week 31/7/2023 Explanation of Co-generation plant, benefits of
to
Co-generation, technologies used in Co-
05/8/2023
generation, introduction to control panel, study of
different control panels
4th Week 7/8/2023 Introduction to transformer, study of different
to
transformers, report making
12/8/2023

Chapter 2
Week -1 Activity Report
2.1 Overview of the company
 Fig. 2.1.1 Overview of the Sugar Industry

Cane weighment

Fig. 2.1.2 Cane Weighbridge

The vehicles carrying cane are weighed on the electronic weigh bridges. These weights are
printed on the weighment slips which also carry’s farmer’s details and net weight etc.

Cane unloading
 Fig. 2.1.3 Cane Unloading

The cane from the vehicles which are in bundles are unloaded with the help of cane
unloader on the feeder table. Feeder table cane is fed to cane carrier in required quantity.

Conveying cane

Fig. 2.1.4 conveying cane

The cane from the feeder table is then dumped to the main cane carrier, which conveys the
cane to the cane preparatory devices. The speed of the cane carrier will be controlled by
electronic devices depending on the cane crushing rate and level in the cane carrier, etc.

Milling
 Fig. 2.1.5 Overview of Mill Section

The prepared cane then passes through the milling tandem having three roller 3 to 5 mills
with necessary pressure feeding devices. The mills run at 3 to 5 RPM, driven through D.C.
/A.C motors, steam turbines or hydraulic drives. The hydraulic pressure is applied on top
roller to extract juice. The extracted juice is filtered in rotary juice screen and sent to boiling
house for further processing. The fibrous residue after juice extraction known as bagasse
from the last mill is conveyed through drag type steel conveyers to Boiler as a fuel.

Different sections of the mill

 Mill section
 Boiling house
 Production section (sugar house)
 Boiler section
 Turbine section
 Instrumentation section
 Cane section
 Account/Admin section

2.2 Process of manufacturing sugar

Sugarcane is the raw material for the manufacture of sugar. Juice from the canes is
extracted which is then processed to recover sugar. Bagasse, the left-out fibre material after
juice extraction is used as a fuel for boilers to produce steam. The steam from the boilers is
used in sugar plant for the recovery of sugar and in the power plant for generation of
captive electric power. A brief description of the sugar manufacturing process is given
below.

Crushing of Sugarcane:

Sugarcane is harvested in the fields, dressed in small bundles, stacked in lorries, tractor
trailers or bullock carts, brought to factory, weighed and crushed in a set of mills. Crushing
takes place mainly in two stages. Firstly, the preparation and then the milling. Milling takes
place after prepared the cane in leveller, cutter and fibrizer. The prepared cane is then
crushed by passing through four sets of mills. After crushing, the bagasse is separated and
used as fuel for boiler and the juice is sent for further processing.

Fig.2.2.1 Crushing of Sugarcane

Juice clarification:

The weighed quantity of juice is primarily heated to 70-75oC in juice heaters and then
treated with lime solution. The juice is heated again to 100-115 oC in another set of juice
heaters. The hot juice is then sent to clarifier. Clarified juice is the decanted out and sent for
evaporation through the Multiple Effect Evaporator bodies (MEE). The juice at 15% is
concentrated in the evaporators into syrup from 15% to 60% concentration.

Fig.2.2.2 Juice Clarifier

Crystallization:

The syrup is then sent to plant floor for further concentration in vacuum pans. The syrup
collected in supply tanks is taken to pans for boiling where the syrup concentrates and
attains super saturation stage. In such a condition, sugar grains are formed in the syrup. The
syrup mass with sugar particles is called massecuite. The massecuite is dropped in
crystallizers and cooled to complete the crystallization process.

Fig.2.2.3 Crystallization Fig.2.2.4 Crystallization of Sugar

Centrifuge:

The massecuite is then taken into the centrifugal machine. Sugar crystals are separated from
mother liquor in high-speed centrifuge. Sugar thus separated is sent to driers. Non
crystallisable matter from the syrup, called the molasses is drained out from the centrifuge.
The molasses is weighed and sent to storage tanks.

Fig.2.2.5 Centrifuge

Drying, Grading, and Bagging:

Sugar thus obtained is dried in the vibrating hopper and graded by passing through standard
sieves. The graded sugar is then bagged, weighed for 50Kg net, stitched, numbered and
stacked in the sugar go down.

Fig.2.2.6 Bagging Fig.2.2.7 Drying

 Chapter 3
Week -2 Activity Report

3.1 Introduction Boiler section

BOILER

Fig. 3.1.1 Schematic Diagram of Boiler

 The steam is the main energy source, used in the process of cane sugar production.
Steam is generated by burning bagasse.

 The advantage of using steam is, it is distributed and controlled easily. Another
special feature of steam production in sugar factories is the availability of renewable
bio-mass fuel-bagasse, a byproduct of cane after juice extraction.
 Modern boiler has one or two steam drums inter connected with water and steam tubes.
The bagasse is burnt in the furnace. Thus, the heat produced is passed through the
passage of boiler tubes which gives its heat energy to water inside to convert in to
steam.
 The final gases which after giving maximum heat energy for producing steam are
called flue gases which are let out through Chimney to atmosphere. Chimney outlet
gasses prior to their entry are passed through flue gas cleaning apparatus so that gases
let to atmosphere should not affect surrounding nature or human habitat.
 In a Sugar factory co-generation boiler pressure varies from 67 Kg/cm 2 to 110 Kg/cm2
and temp. of steam from 480°C to 540°C.

Fig. 3.1.2 picture of Bagasse fired Boiler

 Table 4 Details of existing Boilers at BSML

Steam Generators Capacity Pressure Temp. °C

Make T/Hr. kg/m2 (g)
Babcock & Wilcox * 416 125 545

Krupp I 250 125 490

Technical specification of Boiler

Maximum Continuous rating (MCR): 130 TPH
Super heater outlet pressure: 87 ata
Super heater outlet Temperature: 515°C+50°C
G.C.V. of bagasse: 2270 kcal /kg
Boiler thermal efficiency: 70-71.0% (on G.C.V.)
Instrumentation and control system based on DCS.
1. Specification of Boiler for 416 TPH (For 8MW Generator):

 Make: Thermax Babcock and Wilcox

 Reg no: KTK3225
 Type: Bi drum water tube
 Capacity:125 TPH
 Working pressure:85KG/cm^2
 Working temp:515°C

2. Specification of Boiler for 416 TPH (For 30MW Generator):

 Make: THERMAX LTD, PUNE

 Year of commissioning: 2015
 Reg No: KTK 4808
 Type: Single Drum, Bent water tube
 Working Pressure: 125 kg/cm²
 Design Pressure: 146 kg/cm²
 Hydraulic test: 219 kg/cm²
 Main steam temperature: 545 +/-5° Celsius
  Total heating surface area: 12057 m²

3.2 Brief discussion about TURBINE

Fig.3.2.1 Picture of turbine

Steam Turbine
Steam turbine is a device which converts pressure energy of the superheated steam into
useful work.

Working Principle of a Steam Turbine

The nozzles are stationary and the rotor blades are dynamic. When the high-pressure steam
through the nozzle hits the surface of blades, it creates a rotating motion due to the change
in the momentum of the blade. The resultant force on the blade results in the difference in
the momentum of entering and exiting of the different blades. The blades are attached to
the rotor shaft and convert change in momentum into rotating force.

Because of the high pressures used in the steam circuits and the materials used, steam
turbines and their casings have high thermal inertia.When warming up a stream turbine for
use, the main steam, stops valves (after the boiler) have a bypass line to allow superheated
steam to supply bypass the valve and proceed to heat up the lines in the system along with
the steam turbine.Also,a turninggear is engaged when there is no steam to slowly rotate the
turbine to ensure even heating to prevent uneven expansion. After first rotating the turbine
by the turning gear, allowing time for the rotor to assume a straight plane (no bowing), then
the turning gear is disengaged and steam is admitted to the turbine, first to the astern
blades then to the ahead blades slowly rotating the turbine at 10–15 RPM(0.17–0.25 Hz) to
slowly warm the turbine. The warm-up procedure for large steam turbines may exceed ten
hours.

Components of the steam turbine

The design of steam turbine components is a complex task as it involves a three-dimensional

design of its parts. Numerous factors are to be considered while designing like heat,
pressure, impulsive force, sensitivity, stress, strain, vibrations, number of rotations,
efficiency, etc. Considering the design part there are various components of steam turbines
like rotor, shaft, blades, casing, bearings, valves, nozzle, seals, trip system, governor system,
casing etc. But here we will focus only on 5 main parts of the steam turbine.

1. Rotor

Steam turbines are fixed on a casing and a rotor attached with moving blades. The rotor is
fitted inside the casing which consists of rows of moving blades penetrating between the
rows of fixed blades. The high pressure steam flowing through the turbine passes through
the fixed and moving blades alternatively. The mechanism is such that the fixed blade
directs the steam at a right angle for entry into the moving blades. The utmost care has to
be taken so that the rotor and its casing withstands thermal stress and the moving blades
fitted with the rotor must securely withstand the high centrifugal forces.

2. Casing
Casing is required to protect the steam turbine from steam leakage.The ends of the casing
where the shaft of the rotor passes a seal is required to prevent steam leakages. Leakages
are not fully eliminated but can be controlled to minimal amount.

3.Speed regulator

The speed regulator regulates the overall turbine speed. The speed turbines are designed to
operate at a rated speed called synchronous speed and the turbine operating above the
synchronous speed can damage the machine. At synchronous speed the efficiency of the
turbine is
 Chapter 4

Week -3 Activity Report

4.1 Co-generation

Fig.4.1.1 Flowchart of both Sugar plant and Cogeneration

Cogeneration is a process that simultaneously produces two or more forms of useful energy,
such as electric power and steam. It harnesses the thermal and electrical energy that is
released as part of the production process in various industries. When a fuel is burnt to
generate heat, and that heat is exploited in a thermo dynamic cycle to produce electricity, a
great deal of energy is wasted. This wasted energy (which can be up to two-thirds of the
energy content of the fuel) emerges as heat. If that heat can be utilized for space heating,
for making hot water or in a manufacturing process, it could reduce the amount of
additional energy needed for those purposes. This makes the economics of cogeneration
extremely favourable.
Technologies of Cogeneration:
Cogeneration can be implemented in many ways. Small diesel engines, gas turbine plants
with waste heat boilers, combined cycle cogeneration stations, biomass-based plants can be
used to provide heat as well as generate electricity. There are two types of cogeneration
plants. Topping cycle: Primary fuel is used to produce electricity, and thermal energy which
is the byproduct is then used for process heating. Bottoming cycle: Primary fuel is used to
produce heat which is required for the process at high temperatures and hence, power is
generated through a suitable waste heat recovery system.

Standards to generate power in sugar mill by using bagasse:

As per the industrial records, some of the standard values are mentioned below,

 If one tonne of bagasse is burnt 2.2 tonne of steam is produced.

 If one tonne of coal is burnt 4 tonne of steam is produced as per the calorific value of
coal.
 To generate 1MW of power 4 tonne of steam is required.
 To generate 20MW of power 80 tonne of steam is required.
 The boiler used for steam production is Thermal Babcock and Wilcox Boiler with an
operating capacity of 80 TPH, the pressure of 67 ATA, the temperature of 487±50C.
 If one tonne of a cane is crushed 300Kg of bagasse is produced.
 In a day to generate 20MW of power 50 tonne of de-mineralized water is used.
 To generate 1MW of power 6.55 tonne of water is required. To generate 20MW of
power 131 tonne of water is required.
 The moisture content in the bagasse must be from 490 to 550C.

4.2 Introduction to the control panel

An electrical control panel is an enclosure, typically a metal box or plastic moulding which
contains important electrical components that control and monitor a number of mechanical
processes. They are energised systems that require maintenance, with planned preventative
maintenance and condition-based monitoring being the most effective methods. Electrical
personnel will need to gain access within control panels for fault finding, adjustments, and
electrical safety testing. Operators will interact with the controls of the panel to operate and
control the plant and process.

Different types of control panel used in BILAGI SUGAR MILL LIMITED, BADAGANDI are as
given below
 Transformer Panels
 Metering Panels
 Electro-Static Precipitator(ESP)
 Generator Relay Panels
 Turbine Relay Panels
 KPTCL Interface Panel
 Boiler Control Panels
 Synchronisation Panel
 PCC panel
 MCC Panels
 LAVT panel
Power Control Centre (PCC) panel:

These are used as power distribution board to control the power supply to HT Motors,MCC
Panels and Transformers. Manufacture of these centres is under supervision of the expert
professionals using a superior grade of materials and components. The power control centre
is available in different customised specifications as per the requirements of the industrial
customers.

Features:

● Single operated type audible front operated type

● Integrated with all necessary productions to meet all safety standards
● High efficiency
● Precision engineered
● Robust designer
● Hassle free operation
● Maintenance free.
PCC Panels in SPSCL Industry are:
 1. HT PANEL(PCC/01)
2. LT PANEL (PCC/02)
Motor Control Centre (MCC):
Panels switch govern (take control) of motors is called motor control centre. MCC used for
controlling the process equipments hence, PCC will be acting as an incomer end for MCC.

A. APFC panel
B. DRAW OUT panel
 Chapter 5
Week -4 Activity Report
5.1 Introduction to Transformer
A transformer is a static electrical device transformer is one of the most common devices
found in electrical system that links the circuits which are operating at different voltages.
These are commonly used in applications where there is a need of AC voltage conversion
from one voltage level to another.

It is possible either to decrease or increase the voltage and currents by the use of
transformer in AC circuits based on the requirements of the electrical equipment or device
or load. Various applications use wide variety of transformers including power,
instrumentation and pulse transformers.

In a broad, transformers are categorized into two types, namely, electronic transformers
and power transformers. Electronic transformers operating voltages are very low and are
rated at low power levels. These are used in consumer electronic equipment like televisions,
personal computers, CD/DVD players, and other devices.

The term power transformer is referred to the transformers with high power and voltage
ratings. These are extensively used in power generation, transmission, distribution and
utility systems to increase or decrease the voltage levels. However, the operation involved
in these two types of transformers is same.
 Fig. 2.2. Schematic Diagram of transformer

5.2 Different Transformers Existed at Industry

 Current Transformer
 Potential Transformer
 Power Transformer
 Distribution Transformer
 Converter transformer
 NGT transformer

Current Transformer

Fig 2.2.1: Current Transformer

The current transformer shall be cast-resin insulated type of adequate capacity and proper
characteristics on secondary as specified. The current density should not be more than 1000
amps/sq. Inch. CTs shall withstand stresses originated from short circuit. They shall have
ratios, output and accuracy as specified in the drawings. All CTs to be of single core type in
generator, tie and Spare-1 feeders and the CTs required for bus bar protection. Other CTs
may be of multicore type. CTs should preferably of bar primary type. They shall be mounted
on the switchboard stationary part. The secondary CT leads from all panels should be
terminated on the front of the board on easily accessible shorting type terminal connectors
so that operation and maintenance can be carried out when the panels are in service CTs
shall be suitable for continuous loading of 120% of rated current. CTs shall be subjected to
heat run test.

Specification of Current Transformer:

 Make: MEHRU
 Ratio:500/11A
 Reg no: IS 270S/1892
 Type: Outdoor Oil Cooled
 Standards: IEC60076-1, IEC60076-2, IEC60076-3, ANSI,IEEE,AS
 Highest System Voltage:145KV
 Insulation Level:275/650KV
 Accuracy Class:1-0.2

Potential Transformer

Fig2.2.2: Potential Transformer

The potential transformer shall be cast-resin insulated type. It shall be draw out type and
easily accessible so that the same can be attended to or replaced when the panels are in
service condition. The potential transformers shall be protected through HRC fuses on
primary side and MCBs on secondary side. They shall have ratios, outputs and accuracies
specified. The draw out mechanism shall disconnect the primary connection before the PT
or its primary fuses become accessible. All PTs shall be single phase type. They shall have
voltage factor of 1.2 times continuous and 1.9 times for 8 hours.

Specification of Potential Transformer:

 Make: MEHRU
 Ratio:110/1.73KV
 Reg no: IS 270S/1892
 Type: Outdoor Oil Cooled
 Standards: IEC60076-1, IEC60076-2, IEC60076-3,ANSIIEEE,AS
 Highest System Voltage:123KV
 Insulation Level:230/550KV
 Accuracy Class:1-0.2 2-0.2
 Quantity:3 no

Power Transformer

SI.No Cable size Power Voltage Current Total Total Core

In mm^2 In HV LV HV LV weight Oiling &winding
MVA
1. 4R*3C*30 16 110KV 11KV 840A 84A 44325 11780 21000
 0
2. 7R*3C*30 31.5 110KV 11KV 1650A 165A 62100 10200 29800
0

Distribution Transformer
A distribution transformer which provides final voltage transformation in the electric power
distribution system, stepping down the voltage used in the distribution lines to level used by
the customer. And distribution transformer consists of two primary components that are
core and coil.

Construction of Distribution Transformer:

Fig.2.3.Distribution Transformer

Transformer tank shall be of welded sheet steel construction and provided with gaskets
Steel cover plates. Base shall be suitably reinforced to prevent any distortion during lifting.
Base channels shall be provided with skids and pulling eyes to facilitate handling.
All covers and seals shall be oil and air tight and shall not be affected by mineral oil or
Synthetic oil action. Detachable radiators equipped with air vent drain plug and lifting lugs
shall be provided with cut off valves to permit removal of any radiator unit without
emptying the tank. Radiators shall be securely braced to prevent undue vibration.
- All fasteners and bolts etc. shall be galvanized or zinc passivity. All surfaces to be painted
shall be thoroughly cleaned, decaled, made free from rust and given a priming coat of rust
resisting paint followed by two finishing coats of approved shade. Paint shall be suitable to
SI.N Cable size Power Voltage Current
o In mm^2 In
HV LV HV in A LV
MVA
1. 1R*3C*240 2.5 11KV 433KV 131.2 3333
2. 1R*3C*240 3 11KV 433KV 157.46 4000.12
3. 1R*3C*240 3.5 11KV 433KV 183.7 4666.8
withstand specified atmospheric conditions
Four distribution transformers are used in sugar mills.

CONVERTER TRANSFORMERS:
 Fig.2.3.1: Converter Transformer

Converter Transformer are specially designed for dedicated electronic converter circuits (i.e.
for VFDS and DC drives) used for motors, It has two secondary windings star and delta with
suitable voltages as output (i.e. 660V or 690V) and it is mainly used for reduction of
harmonics produced by drive elements.

 AC to AC converter transformers
 AC to DC converter transformers

SI.N Cable size Power Voltage Current

o In mm^2 In KVA
HV LV1 LV2 HV LV1 LV2

1. 1R*3C*240 2500 11KV 690V 690V 131.22 1045.92A 1045.92A

A
2. 1R*3C*240 2500 11KV 660V 660V 131.22 1093.5A 1093.5A
A
3. 1R*3C*240 2500 11KV 660V 660V 131.22 1093.5A 1093.5A
A
4. 1R*3C*240 1600 11KV 690V 690V 83.98 669.37A 669.37A

Neutral transformer
 Fig.2.4Neutral Transformer

 The Earthing or neutral grounding transformer may be two winding with a zig- zag
connected primary and a star connected secondary or a single winding three phase
auto-transformer with windings interconnected star or zig-zag. Earthing transformer
is a three limbed core type transformer having two equally balanced windings on
each core. One set of windings is connected in stare to provide the neutral point. The
others ends of this set of windings are connected to the second set of windings. It is
transformer used to collect lightening/surge in voltage and current produced from
distribution transformers (Delta end transformers).

Specification:
 Serial No: JN6913
 Cable size: 1RX3CX240SQMM
 Company: KIRLOSKAR
 Frequency: 50Hz
 Phase: HV-Three Star
 KV Ratings: HV-11KV
 Current Ratings:
 Rated short time current-100A
 Zero phase sequence (ohm/ph) = 20.175
 Cooling: ONAN (Oil Natural and Air Natural)
 Commission of year: 200
 Chapter 6
Internship Attendance Report
 Chapter 7
Outcomes of the Internship
 It was a good experience towards Industry.
 Capability to acquire and apply fundamental principle.
 Technique for producing heat and electricity in one process that can save
considerable amount of energy.
 Came to knew how the mechanism of power generation and electrical field involved
in it.
 To know how Co-generation plant works in sugar factory and what are different fuels
can be supplied for boiler and etc.
 It was a grateful experience to take up internship training in the industry.
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