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SUBMITTED BY
MUTEE ULLAH
ID: BETF14E025
INTERNSHIP REPORT
ON
Complete Process of Shakar Ganj Sugar Mill Bhone Pvt Ltd (Jhang)
SUBMITTED BY
MUTEE ULLAH
(ID: BETF14E025)
SUBMITTED TO
APPROVED BY
ACADEMIC ADVISOR
XYZ
HEAD OF DEPARTMENT
XYZ
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Department of Technical Education, University of Sargodha
Undergraduate Internship Report
Approval Letter
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Department of Technical Education, University of Sargodha
Undergraduate Internship Report
Acknowledgement
I thank Allah Almighty for giving me inspiration, time, patience and strength to
complete this work. With Allah will and mercy I have been able to achieve all this.
This report is the result of collective efforts of a number of important and valued
people who directly or indirectly supported and assisted me during my internship
period. To these people I owe my gratitude and thanks.
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Executive Summary
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Training Schedule
The following table contains my training schedule in XYZ Company Limited. My internship
started on 00 December, 2017 and ended on 11 May, 2018.
Date Division Time Instructor
26-12-11 Engr Arslan Shahid
Sugar Plant Operation 9am to 5pm
27-12-11 Foreman Mr.Khurram
Power Plant operations
to 9am to 5pm
28-12-11
Foreman Mr .Khurram
29-12-11 Foreman Mr.Yousaf
Distribution & Utilization
to 9am to 5pm
01-01-12
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List of Abbrevations
CT = Current Transformer
PT = Potential Transformer
CB = Circuit Breaker
MW = Mega Watt
LPT = Low pressure turbine
IPT = Intermediate pressure turbine
HPT = High pressure turbine
ONAN = Oil Natural Air Natural, without pumps and fans
ONAF = Oil Natural Air Forced, without pumps for oil, with fans for air
TG= Turbine Generator
OCB= Oil circuit Breaker
VCB= vacume circuit breaker
ACB= Air circuit Breaker
ID= induced Fan
FD=Forced draft Fan
SD = Secondary draft fan
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TABLE OF CONTENTS
INTRODUCTION .................................................................................................................................................................. 12
GENRATORS........................................................................................................................................................................... 30
TRANSFORMERS ................................................................................................................................................................... 31
ELICTRIC MOTRS .................................................................................................................................................................. 31
CIRCUIT BREAKERS ................................................................................................................................................ 36
MY ACHIEVEMENTS ............................................................................................................................................................ 54
RECOMMENDATIONS .......................................................................................................................................................... 54
DISCUSSION ........................................................................................................................................................................... 55
REFERENCES .......................................................................................................................................................................... 55
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LIST OF TABLE
Table 1-1: Generation details of APSCL .................................................................................................................. 13
Table 1-2: Financial performance of APSCL........................................................................................................... 14
Table 1-3: Salient feature of the 225MW future project ......................................................................................... 15
Table 1-4: Salient feature of the 450MW future project ........................................ Error! Bookmark not defined.15
Table 1-5: Salient feature of the 450MW (North) future project ........................................................................... 15
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List of Figures
Figure 2-1: Forced draft fan...................................................................................................................................... 16
Figure 2-2: Gas flow meter ........................................................................................................................................ 17
Figure 2-3: Water filter house ................................................................................................................................... 18
Figure 2-4: Burner room with water tube boiler ..................................................................................................... 20
Figure 2-5: Steam turbine ......................................................................................................................................... 22
Figure 3-1: Design diagram of CCPP in APSCL ..................................................................................................... 24
Figure 3-2: Combustion chamber in CCPP ............................................................................................................. 25
Figure 3-3: Diesel engine of CCPP ............................................................................................................................ 26
Figure 3-4: Fuel annex room in CCPP ..................................................................................................................... 27
Figure 3-5: Design of Steam Generation process in CCPP ..................................................................................... 29
Figure 4-1: A typical bus bar of APSCL .................................................................................................................. 30
Figure 4-2: A typical CT ............................................................................................................................................ 31
Figure 4-3: A typical PT ............................................................................................................................................ 31
Figure 4-4: Bushing of transformer .......................................................................................................................... 32
Figure 4-5: Silica gel in a cylinder ............................................................................................................................. 32
Figure 4-6: Insulator used in APSCL ....................................................................................................................... 33
Figure 4-7: Isolator used in APSCL .......................................................................................................................... 33
Figure 4-8: Double bus-bar arrangement ................................................................................................................. 34
Figure 4-9: Double bus bar transmission arrangement of APSCL ........................................................................ 35
Figure 4-10: SF6 circuit breaker ............................................................................................................................... 36
Figure 4-11: Oil circuit breaker ................................................................................................................................ 36
Figure 5-1: Generator in APSCL .............................................................................................................................. 38
Figure 5-2: Over current protection ......................................................................................................................... 39
Figure 5-3: Stator Winding Protection. .................................................................................................................... 40
Figure 5-4: Over current protection ......................................................................................................................... 41
Figure 5-5: Negative sequence protection ................................................................................................................ 42
Figure 5-6: Reverse power Protection use in APSCL .............................................................................................. 42
Figure 5-7: Minimum impedance and Distance protection..................................................................................... 44
Figure 5-8: Stator ground fault protection ............................................................................................................... 44
Figure 5-9: Earth fault protection of field circuit by potentiometer method & the relay used in APSCL .......... 45
Figure 6-1: Total output unit measure meter ........................................................................................................... 46
Figure 6-2: Control unit 1 &2 ................................................................................................................................... 46
Figure 6-3: Control unit 3 & 4 .................................................................................................................................. 47
Figure 6-4: Combine cycle control unit .................................................................................................................... 47
Figure 6-5: Feed water drum level control ............................................................................................................... 48
Figure 6-6: Safety valve used in APSCL ................................................................................................................... 49
Figure 6-7: Typical pressure gauge........................................................................................................................... 50
Figure 6-8: Flame detector. ....................................................................................................................................... 51
Figure 6-9: Junction box used in APSCL ................................................................................................................. 52
Figure 6-10: Fire alarm used in APSCL ................................................................................................................... 52
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CHAPTER – 1
Company Profile:
I did my internship at Shakar Ganj Sugar mill Bhone from 26th of December 2017 to 11th of
May 2018 and this internship report is the result of those 120 days attachment with the SML.
INTRODUCTION:
ABOUT SHAKARGANJ :
Shakarganj Limited is a Pakistani industrial company in the sugar, foods, and textiles industries established in 2005.
Sugar Mills
Bio Fuel
Particle Board
Food Products
Crescent Hadeed Limited
HISTORICAL BACKGROUND:
Shakarganj’s history dates back to2005. The company was incorporatedon 20
september with the object of setting up a sugar mill in district Jhang in district of
punjab. Commencement of business certificates was issued on 23 February 1970.A mill with a
design capacity of 8000 TCD was planned and ordered for supply of equipment was placed with
Messrs. Stork-Werkspoor sugar B.V., of Netherlands. Letter of credit was opened on 31
December 1969 and 10 January 1970. Construction of building started in March 1971.The
implementation of the project got delayed due to war in 1971 resulting in breakup of the country.
Some shipment of machinery was delayed. Insulation of equipment stated on 1st January 1972 and
project commenced trial operation on 7 January 1974. Public offer of shares was made on 21 may,
1979.Even since the team at shakarganj has never looked back. The sugar factory has been expanded
to a capacity of 10000 TCD extendable to 14000 TCD and has become the largest sugar factory in the
country. Shakarganj realized the need for research and setup shakarganj sugar research institute
in 1983. This was to strengthen research activities in sugar cane agriculture, sugar
manufacturing and engineering. Shakarganj has diversified into utilization of co-products, with the
addition of a distillery in 1986and particleboard plant in 1991.shakarganj took a major step in co-
generation of electricity for sale to the national grid in 1983.Balancing and modernization of sugar
plant was carried out between 1976 and 1980and plant capacity was upgraded to 2000 TCD.
By 1986 the capacity was increased to 5000TCD(total cane / day). The team at
shakarganj recognized technological advancements and kept constantly in step with the
latest innovation and development in sugar industry. A modern distillery based on Bio still technology
was added in 1986. The distillery unit went into production on 20 September, 1986 with an installed
capacity of 45000 liters of industrial alcohol per day. In 1990 a particle board plant with a daily
production capacity of 30 cubic meter was added to convert surplus bagasse into value added
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products. In 1991 work initiated on doubling the capacity of the plant with the provision to further
extend the capacity to 14000 TCD. Entire designing and engineering work was done in house by the
shakarganj team. The program was completed in 1992. It pushed the mill capacity to
10000TCD extendable to 14000 TCD. This made shakarganj, Pakistan’s largest sugar mill. Shakarganj
took a major step in co-generation of electricity for sale to national grid. Agreement with Water
and Power Development Authority (WAPDA) was signed on 25 July1993 at Lahore making
shakarganj the first private sector power supplier in Pakistan. Shakarganj took care of 12.86
percent of Jhang City’s power requirement during crushing season. Since 1995, 2 MW
electricity is being supplied to a neighboring textile company.
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Company Objective
i. To carry out the business of electric power generation
ii. To supply and sell electricity to SML Power Development Board through National
Grid.
iii. To undertake projects to increase the power generation of SML to meet the
growing demand of electric power in the country.
iv. To increase the net worth of the company.
Financial Performance
Despite adversities SML maintained a substantial progress during the year 2017-81, increase
revenue by 5.8% over the last year resulted increase the net profit ,before interest and tax to PKR
1408 million as against PKR 749 million of 2009-10 a 87% increase .The profit growth was at
a phenomenal rate of 146.49%. A comparative detail of financial result of 2009-10 is given
below:
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Future Project of SML
SML is a power generation company and its position is second in the country. It is SML
challenges to replace outlived inefficient plants. To cope up the growth of the demand and its
business. SML have under taken the following some important high efficient projects given
below: [3]
Power House:
Power House is established to provide electricity not only to Sugar production department
but also to all the departments of mill and it also supplies electricity to colony of mill. Power
house is under control of Electrical & Instrumentation Department (E&I) containing highly
qualified engineers. The house contains four HT and one LT turbo generators .A turbo
generator is a generator in which steam turbine is used to run the rotor. The MVA rating of
HT generators are 6MW each and MVA rating of LT generator is 2MW.
The two HT generators are condensing and other two are back pressure.LT generator is also
backpressure.
The total installed capacity of power house is 26 MW. There is also a new power plant (ETP)
whose installed capacity is 8 MW.ETP has 4 biogas generators. The rating of each generator is
2MW.
The main function of power house is to supply the power to different houses .Power
house also supplies power to ETP, Ujala and takes power from WAPDA which is used if
generators are switched off. The detail of each component used in power house is given
below. The rating of each turbine and generator is given under:
Generator # 03:
SOMER
• Rated Voltage 440 V
• Rated Current 351 A
• Power Factor 0.75
• Speed 1500 rpm
Condensing Turbine # 04,05
QINGDAO JIENENG STEAM TURBINE Co. Ltd
Model C6-2.40/0.392
• Rated Power 6 MW
• Rated Temperature 350 C
• Rated Speed 3000 rpm
• Inlet Pressure 2.40 Mpa
• Exhaust Pressure 0.392 Mpa
Generator# 04, 05
SICHUAN DONGFENG ELECTRICAL MACHINARY Co. Ltd.
• Rated power 6 MW
• Rated Voltage 11000V
• Rated Current 393.6 A
• Speed 3000 rpm
• Frequency 50 HZ
• Phase Number 03
• Rated Excitation Voltage 117 V
• Rated Excitation Current 251 A
• Power Factor 0.8
When a turbine is attached to the electric generator, the kinetic energy (i.e.
motion) of steam pushes against the fan-type blades of the turbine causing the
turbine and therefore the attached rotor of the electrical generator to spin and
produce electricity.
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Turbine
A steam turbine is a mechanical device that extracts thermal energy from pressurized and
converts it into rotary motion. The turbine mainly consists of nozzle and rotary and fixed blade
wheel. The steam is expanded from a high pressure to a low pressure either in nozzles or in the
blade where it is transformed into the mechanical work. The steam power plant of APSCL has a
casing around the blades that contains and controls the working fluid.
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2.19 Sections of steam turbine
The steam turbines used in Ashuganj Power Station Company Ltd (APSCL) are kept in three
different sections or chambers. The size and characteristics of the blades of the turbines in these
sections are different from each other.
i. High Pressure Turbine (HP): From the super heater the high speed steam first enters to
the high pressure turbine. The blades in the high pressure turbine are the smallest of all
turbine blades; this is because the incoming steam has very high energy and occupies a
low volume. The blades are fixed to a shaft and as the steam hits the blades it causes the
shaft to rotate.
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Intermediate Pressure Turbine (IP): From the boiler re-heater the steam enter into the
intermediate pressure turbine. The steam has expanded and has less energy when it enters this
section, so here the turbine blades are bigger than those in the high pressure turbine. The blades
are fixed to a shaft and as the steam hits the blades it causes the shaft to rotate. From here the
steam goes straight to the next section of turbine set.
ii. Low Pressure Turbine (LP): From the intermediate pressure turbine steam enters into
the low pressure turbine and continues its expansion. The blades of the turbine of this
section are larger than the previous two sections but the energy of steam is lesser than the
previous two sections.
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Mill House:
Mill house contains crushers. Weighing of cane, its crushing is done here .Crushers
Milling Machine
separate the bagasse and juice.
In mill house, it is first unloaded from
trolleys and is send to Dump-in carrier,
where further process takes place. Electric
hoist is driven by back type motor.
Then cane is passed through leveler, it
maintains the quantity of cane. After that,
it passed through cane fiberizer that
fiberize the cane .Next step in mill house
is then top pass the cane through
magnetic bar which separates the magnetic Magnetic Bar
pieces. Magnetic bar contains transformer
that magnetizes and attract the iron pieces.
After that juice is extracted from cane. Mill
house has its separate control unit. Here all
the motors are controlled. Control room
contains a transformer of 2500 KVA which
transforms 11KV/440V. There is also
another supply of 440V which is used in
shutdown when generators are switched off.
When juice is extracted from cane then the baggase is carried out with the help of this carrier.
It takes the baggase to boilers where it is used as fuel to run the boilers. Baggase is also used in
making boards.
Mill house contains high horse power induction motors i.e. squirrel cage and wound rotor. One
line& process diagram of mill house is given as.
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Process House:
After extraction of cane juice from cane (stored in storage tank, last
stage of cane processed in mill house) is further sent to process house where
this cane juice after passing through several processes is converted into sugar
with several waste extractions i.e. mud, molasses etc which are further sent to
their respective sections i.e. molasses to distillery plant.
From mill house juice comes into process house through juice pipe line. After
passing through juice line this juice is drained into primary heater. In primary
heater this juice is heated up to 65-70 C. The basic purpose to heat juice in
primary tank is to stop bacterial growth in juice. In primary heater juice is
heated with help of steam (usually exhaust steam from turbines). This clear
juice further flows towards evaporator. Evaporator section consists of vapor
cells and series of quads. The juice is entered into the vapor cell through
bottom and exhaust steam is treated on side of vapor cell to evaporate the
gases through juice. After various sub processes, juice starts crystallizing. And
residue is also obtained called molasses.
In process house, 3000KVA transformer is used to transform HT to LT.
An auxiliary supply LT supply is also given to process house which is used in
off season.
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Filter House:
From process house, sugar comes to filter house. Filter house contains
centrifuges. They filter the sugar from molasses. Molasses, also known as
treacle, is a dark brown viscous liquid obtained as a by-product in the
processing of cane sugar. It can be boiled again to crystallize out some of the
rich sucrose content of the liquid. This, however, is not economical. Three
types of motors are used in filter house i.e. DC motor, Induction-squirrel cage
and Induction-wound rotor. The motors used in centrifuge are of 220KW, in
which two motors are DC and one is AC, and these motors are controlled
through inverters. The transformer of filter control room is of 3000kva
Boiler House:
In boiler house, steam is made by burning bagaas in kiln. There are five
boilers in sugar mill. In each boiler, first water which is to be converted into
steam is filtered. After that it is boiled by burning bagaas in kiln. There are
three fans used in boiler house i.e. ID fan SD fan & FD fan.
ID fan is used as a exhaust fan to remove gases from kiln.
FD fan is used to blow bagaas in kiln. It supplies excess of air from bottom of
dumping grid for efficient combustion of bogaas. Through this fan positive
pressure is given.
Slipring induction motor is used in ID,FD& SD fans of rating 132KW and
219KW because it has high starting torque.
A transformer of 3000KVA is use in control room of boiler house which is
used for voltage transformation
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Generator:
In electricity generation, an electric generator
is a device that converts mechanical energy to
electrical energy. The reverse conversion of
electrical energy into mechanical energy is done
by a motor; motors and generators have many
similarities. A generator forces electrons in the
windings to flow through the external electrical
circuit. It is somewhat analogous to a water
pump, which creates a flow of water but does
not create the water inside. The source of
Turbo Generator
mechanical energy may be a reciprocating or
turbine steam engine, water falling through a turbine or waterwheel, an internal
combustion engine, a wind turbine, a hand crank, compressed air or any other source of
mechanical energy.
Like motor, a generator also has stator and rotor. Rotor winding is field winding
because main magnetic field is produced in Rotor and stator winding is armature because
main emf is induced in stator.
Working Principle:
Generator works on the principle of Faraday’s Law of Electromagnetic induction.
According to law, Supply is given to rotor which produces rotatory magnetic field. This field
induces emf in stator winding.
Synchronous Generator Construction:
A DC current is applied to the rotor winding, which then produces a rotor magnetic
field. The rotor is then turned by a prime mover (eg. Steam, water etc.) producing a
rotating magnetic field. This rotating magnetic field induces a 3-phase set of voltages
within the stator windings of the generator. “Field windings” applies to the windings that
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produce the main magnetic field in a machine, and “armature windings” applies to the
windings where the main voltage is induced. For synchronous machines, the field windings
are on the rotor, so the terms
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“rotor windings” and “field windings” are used interchangeably. Generally a synchronous
generator must have at least 2 components: a)Rotor Windings or Field Windings a.Salient
Pole b.Non Salient Pole b)Stator Windings or Armature Windings. The rotor of a
synchronous generator is a large electromagnet and the magnetic poles on the rotor can
either be salient or non salient construction. Non-salient pole rotors are normally used for
rotors with 2 or 4 poles rotor, while salient pole rotors are used for 4 or more poles rotor.
Excitation:
An electric generator or electric motor that uses field coils rather than permanent magnets
will require a current flow to be present in the field coils for the device to be able to work.
If the field coils are not powered, the rotor in a generator can spin without producing any
usable electrical energy, while the rotor of a motor may not spin at all. Thus a DC supply is
given to rotor to produce magnetic field. This method is called excitation.
There are three methods of excitation
Through slip Ring and brushes
Through Brushless Exciter
Through Pilot Exciter.
a. Through slip Ring and brushes:
In this method excitation is done by giving DC supply to rotor through brushes. In
rotor, a slip ring is mounted. DC supply is given to that slip ring through brushes.
Slip rings are metal rings completely encircling the shaft of a machine but insulated
from it. One end of the dc rotor winding is tied to each of the 2 slip rings on the shaft of the
synchronous machine, and a stationary brush rides on each slip ring.
A “brush” is a block of graphite like carbon compound that conducts electricity freely
but has very low friction; hence it doesn’t wear down the slip ring. If the positive end of a
dc voltage source is connected to one brush and the negative end is connected to the other,
then the same dc voltage will be applied to the field winding at all times regardless of the
angular position or speed of the rotor.
Small synchronous machines – use slip rings and brushes.
Some problems with slip rings and brushes:
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They increase the amount of maintenance required on the machine, since the
brushes must be checked for wear regularly.
Brush voltage drop can be the cause of significant power losses on machines with
larger field currents.
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used. A pilot exciter is a small ac generator with permanent magnets mounted on the
rotor shaft and a 3-phase winding on the stator. It produces the power for the field circuit
of the exciter, which in turn controls the field circuit of the main machine. If a pilot exciter
is included on the generator shaft, then no external electric power is required.
A brushless exciting scheme that includes a pilot exciter. The permanent magnet of
pilot exciter produces field current of exciter which intern produces field current of the
main machine.
Even though machines with
brushless exciters do not need slip
rings and brushes, they still include the
slip rings and brushes so that an
auxiliary source of dc field current is
available in emergencies.
The Speed of Rotation of a
Synchronous Generator:
Synchronous generators are by definition synchronous, meaning that the electrical
frequency produced is locked in or synchronized with the mechanical rate of rotation of the
generator. A synchronous generator’s rotor consists of an electromagnet to which direct
current is supplied. The rotor’s magnetic field points in the direction the rotor are turned.
Hence, the rate of rotation of the magnetic field in the
machine is related to the stator electrical frequency by:
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power will be a mechanical prime mover, e.g. diesel engine, steam turbine, water turbine or
anything similar. Regardless of the type of prime mover, the rotor velocity must remain
constant to maintain a stable system frequency. The power-flow diagram for a
synchronous generator is shown:
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field for a short-period. It is sufficient to rely on the control room attendant to disconnect
the faulty alternator manually from the system bus-bars. Therefore, it is a universal practice
not to provide automatic protection against this contingency.
c. Over current:
It occurs mainly due to partial breakdown of winding insulation or due to overload on
the supply system.
It can be overcome by designing high value of internal impedance alternator.
d. Over speed:
The chief cause of over speed is the sudden loss of all or the major part of load on
the alternator. Modern alternators are usually provided with mechanical centrifugal devices
mounted on their driving shafts to trip the main valve of the prime-mover when a
dangerous over speed occurs.
e. Over-voltage:
The field excitation system of modern alternators is so designed that over- voltage
conditions at normal running speeds cannot occur. However, overvoltage in an alternator
occurs when speed of the prime-mover increases due to sudden loss of the alternator load.
In case of steam turbine, control governors are very sensitive to speed variations. They
exercise a continuous check on over speed and thus prevent occurrence of overvoltage on
generating unit.
f. Unbalanced loading:
Unbalanced loading means that there are different phase currents in the alternator.
Unbalanced loading arises from faults to earth or faults between phases on the circuit
external to the alternator. The unbalanced currents, if allowed to persist, may either
severely burn the mechanical fixings of the rotor core or damage the field winding.
g. Stator winding faults:
These faults occur mainly due to the insulation failure of the stator windings. The
main types of stator winding faults, in order of importance are:
fault between phase and ground
fault between phases
inter-turn fault involving turns of the same phase winding
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Parallel Operation of AC
Generators:
Reasons for operating in
parallel:
Handling larger loads.
Maintenance can be done
without power disruption.
Increasing system
reliability.
Increased efficiency.
Conditions required for
Paralleling:
Conditions are as follows:
RMS line voltages must be equal.
The generators to be paralleled must have the same phase sequence.
Generator output phase angles must be the same.
The oncoming generator (the new generator) must have a slightly higher
operating frequency as compared to the system frequency.
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same direction each time, then the phase sequence is the same for both generators. If the
motor rotates in opposite directions, then the phase sequences differ, and 2 of the
conductors on the incoming generator must be reversed.
ii. Another way is using the 3 light bulb method, where the bulbs are stretched across
the open terminals of the switch connecting the generator to the system (as shown in the
figure above). As the phase changes between the 2 systems, the light bulbs first get bright
(large Phase difference) and then get dim (small phase difference). If all 3 bulbs get bright
and dark together, then the systems have the same phase sequence. If the bulbs brighten in
succession, then the systems have the opposite phase sequence, and one of the sequences
must be reversed.
iii. Using a Synchroscope – a meter that measures the difference in phase angles (it does
not check phase sequences only phase angles).
c. Check and verify generator frequency to be slightly higher than the system frequency.
This
is done by watching a frequency meter until the frequencies are close and then by
observing changes in phase between the systems.
d. Once the frequencies are nearly equal, the voltages in the 2 systems will change phase
with
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respect to each other very slowly. The phase changes are observed, and when the phase
angles are equal, the switch connecting the 2 systems is
LT Generator HT Generator
shut.
Generators Used in SML:
In SML, Turbo generators are being used. Turbo generators are those generators in
which stem turbine is used as a prime mover. There are four high tension and one low
tension generators. There is also one low tension diesel generator available which is used
at time of needed. There is also a biogas plant whose installed capacity is 9.248 MW. In ETP
eight biogas engine generators are installed and power rating of each generator is 1.156
MW.
The power rating of HT generator is 6MW and LT turbo generator is 2MW. The power
rating of Diesel generator 1641.2 KW.
The total installed capacity in SML is 36.848 MW.
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Step1:
Synchronizing Panel
Run turbine at 3000rpm.
Step2:
Place the selector switch on HWJT
excitation panel on following position.
Control Power Supply ON
Fan Control ON
Fan Power Supply Plant
DC Excitation Switch ON
Step3:
Press the “Button Exciting” on the
generator control panel and check the
following on HWJT.
Generator Voltage 100V
Exciting Transformer Voltage 170V
TG Voltage 11KV
Synchronizing Relay
TG Frequency 50Hz
Step4:
Operate net VCB and check
voltage/frequency on control signal screen
voltage /frequency.
Step5:
Mark corresponding switch
Power net voltage 11KV
Frequency 50Hz
Step6:
On the synchronous switch ISTK on
control signal screen to start “Compose
synchronous Meter” for voltage and
frequency matching power net.
Step7:
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Transformer:
A transformer is a device that transfers electrical energy from one circuit to
another through inductively coupled conductors—the transformer's coils.
A varying current in the first or primary winding creates a varying magnetic flux
in the transformer's core, and thus a varying magnetic field
through the secondary winding. This varying magnetic field
induces a varying electromotive force (EMF) or "voltage" in
the secondary winding. This effect is called mutual induction.
If a load is connected to the secondary, an electric
current will flow in the secondary winding and electrical
energy will be transferred from the primary circuit through
the transformer to the load. In an ideal transformer, the
induced voltage in the secondary winding (VS) is in proportion
to the primary voltage (VP), and is given by the ratio of the number of turns in the
secondary (NS) to the number of turns in the primary (NP) as follows:
.
Where:
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Where VS is the instantaneous voltage, NS is the number of turns in the secondary coil
and Φ equals the magnetic flux through one turn of the coil.
Basic Construction
An elementary transformer consists of a soft iron or silicon steel core and two
windings, placed on it. The windings are insulated from both the core and each other. The
core is built up of thin soft iron or low reluctance to the magnetic flux. The winding
connected to the magnetic flux. The winding connected to the supply main is called the
primary and the winding connected to the load circuit is called the secondary. Although in
the actual construction the two windings are usually
wound one over the other.
In case of three phase transformer three separate
cores are used and both primary and secondary
windings are done on same core for each phase.
Usually primary connection is in delta and secondary
connection is in star in case of three phase distribution
transformers. But in Case of transmission
Transformers, both primary and secondary is in delta. As we have discussed that both
primary and secondary winding are done on the same core, first LT winding is done and
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designed to have an accurately known transformation ratio in both magnitude and phase,
over a range of measuring circuit impedances. A voltage transformer is intended to present
a negligible load to the supply being measured. The low secondary voltage allows
protective relay equipment and measuring instruments to be operated at lower voltages.
PT used in SML has rating 11000/100,
b. Distribution Transformers:
These transformers are used for distribution. These transformers step down the
voltage. In SML 8 distribution transformers are used. One is of 4000KVA (11000v/440v,
209.94A/55564.82A) and others are of 3000 KVA (11000V/440V, 157.46A/3963.46A) and
2500KVA.
c. Excitation Transformer:
This transformer is step down transformer. This transformer is used in excitation of turbo
generator. Excitation transformer transforms 11000V AC in to 178V AC.
d. Neutral Grounding Transformer: NGR
This type of transformer is often called NGT. It is used to step down the turbo
generator fault current. When fault occur, current flows through NGT, it step down the
faulty current.
LT Distribution Panels:
Electricity distribution is the final stage in the delivery (before retail) of electricity to end
users. A distribution system's network carries electricity from the transmission system and
delivers it to consumers. Typically, the network would include medium-voltage (less than
50 kV) power lines, electrical substations and pole-mounted transformers, low-voltage
(less than 1 kV) distribution wiring and sometimes
electricity meters.
In SML, The 440v distribution supply for
different houses goes through distribution panels. A
distribution panel contains three phase bus bar
system. Supply is taken by connecting cables with
these busbars. The busbars rating of LT panel are
6300A.
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Electric motors:
An electric motor uses electrical energy to produce mechanical energy, very
typically through the interaction of magnetic fields and current-carrying conductors.
The reverse process, producing electrical energy from mechanical energy, is
accomplished by an alternator, generator or dynamo. Many types of electric motors can be
run as generators, and vice versa.
Electric motors are found in applications as diverse
as industrial fans, blowers and pumps, machine tools,
household appliances, power tools, and disk drives. They
may be
powered by LT Busbars
direct
current (e.g.,
a battery
powered
portable
device or
motor vehicle), or by alternating current from a central electrical distribution grid. The
smallest motors may be found in electric wristwatches. Medium-size motors of highly
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History:
The conversion of electrical energy into mechanical energy by electromagnetic
means was demonstrated by the British scientist Michael Faraday in 1821. The first electric
motors
The first commutator-type direct current electric motor capable of turning
machinery was invented by the British scientist William Sturgeon in 1832.
In 1888 Nikola Tesla invented the first practicable AC motor and with it the
polyphase power transmission system.
Application of electric motors revolutionized industry. Industrial processes were no longer
limited by power transmission using shaft, belts, compressed air or hydraulic pressure.
Instead every machine could be equipped with its own electric motor, providing easy
control at the point of use, and improving power transmission efficiency. Electric motors
applied in agriculture eliminated human and animal muscle power from such tasks as
handling grain or pumping water. Household uses of electric motors reduced heavy labor
in the home and made higher standards of convenience, comfort and safety possible. Today,
electric motors consume more than half of all electric energy produced.
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AC Motors:
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Synchronous electric
motor:
A synchronous electric motor is an AC
motor distinguished by a rotor spinning with
coils passing magnets at the same rate as the alternating current and resulting magnetic field
which drives it. Another way of saying this is that it has zero slip under usual operating
conditions. Contrast this with an induction motor,
which must slip to produce torque. A
synchronous motor is like an induction motor
except the rotor is excited by a DC field. Slip rings
and brushes are used to conduct current to rotor.
The rotor poles connect to each other and move
at the same speed hence the name synchronous
motor.
Asynchronous(Induction
motor):
An induction motor (IM) is a type of asynchronous AC motor where power is supplied to the
rotating device by means of electromagnetic induction.
Induction Motor Working Principle:
When 3 phase ac supply is given to the stator, it produces revolving magnetic field in the
stator winding, that induces voltage in the rotor winding(Faraday’s law of electromagnetic
induction) as a result of rotor current ,rotor magnetic field is produced that interacts with the
stator magnetic field and tries to chase it, in doing so rotor starts turning
Induction Motor is of two types.
Squirrel Cage
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It is becoming very popular the utilization of squirrel cage induction motors with
variable frequency drives (VFD's) in the Industry.
Induction motors are preferred in industries due to:
Speed variation can be achieved by invertors.
Rugged construction
Low manufacturing cost
Heavy load inertia starting.
High starting torque requirements.
Low starting current requirements.
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Whenever a big heavy electric motor is started, we need to start it slowly to prevent the
rotor overheating and drawing an enormous current(inrush current,5 to 10times the normal
motor current). When the windings of a 3-phase motor are connected in STAR the current is
reduced to only root three of the normal running current that is taken when it is connected in
DELTA. Once the motor picks up speed, with the help of timers, at set time, the connection is
changed to DELTA so that the motor runs at full
speed and torque from then on. It's a bit like using the
gears of an automobile. Star/delta starter figure is
given as
Starting Characteristics:
Starting current is approximately 30% of normal.
Starting torque is approximately 25-30% of normal.
Applications:
Where load torque during acceleration is very low.
May be used for partial acceleration.
Used more often for European motors.
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the duration of the acceleration. The initial applied frequency is very low, and the frequency is
gradually increased to the running speed desired.
Starting Characteristics:
Can be programmed similarly to the solid state starter to respond to current limits,
speed control, or internal ramping function. Current and torque are a function of the
programming.
Applications:
Usually used only when the inverter is necessary to supply variable frequency as a
speed control. Generally, is too expensive to use just for starting purposes, but may be
because it does have the very best starting characteristics relative to the burden it places on
the power system during acceleration.
d- Resistance Starters:
This process is normally used to control speed of slip ring induction motor. In this resistance
is connected with the rotor of motor by using carbon brushes. By varying speed of rheostat,
motor speed can be controlled.
e- Auto-Transformer:
In this method, an auto-transformer is placed in series with the motor during staring. The
transformer action reduces the voltage applied to the motor terminals. Because of the
transformer action, the line current is less than the motor current. For a given starting current
on the line side, the motor terminal voltage can be
higher than for other reduced voltage start
methods. Thus, this method gives the highest
motor torque per line ampere.
Starting Characteristics:
Motor terminal voltage less than line voltage
(by transformer ratio).
Motor current exceeds line current (by
inverse of transformer ratio).
Starting torque is reduced by the square of the terminal voltage.
Applications:
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DC Motors:
A DC motor is designed to run on DC electric power. The most common DC motor types
are the brushed and brushless types, which use internal and external commutation
respectively to create an oscillating AC current from the DC source—so they are not
purely DC machines in a strict sense.
Brushed DC Motors:
DC motor design generates an oscillating current in a wound rotor, or armature, with a
split ring commutator, and either a wound or permanent magnet stator. Carbon Brushes are
used to supply dc to commutator which is attached with rotor.
There are three types of brushed motors.
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A: shunt
B: series
C: compound
Brushless DC Motors:
Some of the problems of the brushed DC motor are eliminated in the brushless design. In
this motor, the mechanical "rotating switch" or commutator/brushgear assembly is replaced
by an external electronic switch synchronized to the rotor's position. Brushless motors are
typically 85-90% efficient or more (higher efficiency for a brushless electric motor of up to
96.5% were reported by researchers at the Tokai University in Japan in 2009),[17] whereas DC
motors with brush gear are typically 75-80% efficient.
They have several advantages over conventional motors:
The motor can be easily synchronized to an internal or external clock, leading to
precise speed control.
Brushless motors have no chance of sparking, unlike brushed motors, making them
better suited to environments with volatile chemicals and fuels. Also, sparking
generates ozone which can accumulate in poorly ventilated buildings risking harm to
occupants' health.
Brushless motors are usually used in small equipment such as computers and are
generally used to get rid of unwanted heat.
They are also very quiet motors which is an advantage if being used in equipment that
is affected by vibrations.
Modern DC brushless motors range in power from a fraction of a watt to many kilowatts.
Larger brushless motors up to about 100 kW rating are used in electric vehicles. They also
find significant use in high-performance electric model aircraft.
Uses:
Electric motors are used in many, if not most, modern machines. Obvious uses would be
in rotating machines such as fans, turbines, drills, the wheels on electric cars, locomotives and
conveyor belts. Also, in many vibrating or oscillating machines, an electric motor spins an
irregular figure with more area on one side of the axle than the other, causing it to appear to
be moving up and down.
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Electric motors are also popular in robotics. They are used to turn the wheels of vehicular
robots, and servo motors are used to turn arms and legs in humanoid robots. In flying robots,
along with helicopters, a motor causes a propeller or wide, flat blades to spin and create lift
force, allowing vertical motion.
Motors Used In SML:
In SML, three types of motors are used
Induction Motors
DC Motors
Tappered Rotor Motor
Induction Motors are widely used in SML. They are used in all houses of SML. All the
induction motors used have different purposes. Squirrel cage induction motors are widely
used in SML. The speed of this type induction motor is controlled by using inverters. And type
of starting of this type of motor is DOL and wye/delta.
Slip ring inductions motors are used in boiler house of SML .They are used because they
have high starting torque. In SML induction motors are of 132KW and 290KW.
Speed of Slip Ring motor is controlled here by connecting rheostat with the rotor of motor
Only two DC motors are used in SML. They are used in filter house and it is of 220KW.
Tappered motors are used to lift crane used in SML to lift heavy loads. Main specialty of this
motor is that rotor has breaks on it.
Power Factor:
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The power factor of an AC electric power system is defined as the ratio of the real
power flowing to the load to the apparent
power,[1][2] and is a dimensionless number
between 0 and 1 (frequently expressed as a
percentage, e.g. 0.5 pf = 50% pf). Real power is
the capacity of the circuit for performing work
in a particular time. Apparent power is the
product of the current and voltage of the circuit.
Due to energy stored in the load and returned to
the source, or due to a non-linear load that
distorts the wave shape of the current drawn
from the source, the apparent power will be
greater than the real power.
In an electric power system, a load with low power factor draws more current than a
load with a high power factor for the same amount of useful power transferred. The higher
currents increase the energy lost in the distribution system, and require larger wires and
other equipment. Because of the costs of larger equipment and wasted energy, electrical
utilities will usually charge a higher cost to industrial or commercial customers where there is
a low power factor.
It is the factor (%age)at which electric power is being consumed in the load..
A power factor of 0.8 means, 80% of generated power is being consumed in the load and 20%
of the generated power is continuously being bounces back & forth between the source & the
load. (Reactive power) & of no use.
Linear loads with low power factor (such as induction motors) can be corrected with a
passive network of capacitors or inductors. Non-linear loads, such as rectifiers, distort the
current drawn from the system. In such cases, active or passive power factor correction may
be used to counteract the distortion and raise the power factor.
Power Factor Improvement:
The improvement of power factor means to minimize the reactive component of power
which is not being used by the load..
this can be done by three methods
Use of capacitors bank
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Synchronous condensers.
Phase advancers
In SML, Both generation &
distribution levels power factor is
being improved by capacitor banks
operated by automatic power factor
relays.
Methods for Improving Power Factor:
There are three methods to improve the
power factor
Static Capacitors.
Synchronous Condensers.
Phase advancers.
a. Static Capacitors:
In this static capacitor is connected in parallel with the load. The purpose of connecting
static capacitor is to provide leading charging current that reduces the reactive power. If
reactive power is limited then due to this less current is draw and electric charges is reduced.
Fig shows the Static capacitors panels used in SML.
There is a power factor regulator is used. The purpose of power factor regulator is to connect
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b. Synchronous Condensers:
By using synchronous condensers, power factor can also be improved. A synchronous
condenser is basically a synchronous motor operating at no load and over exciting state.
To improve power factor, synchronous motor is connected parallel with the load. A
synchronous motor acts as a capacitor when it
is operating at no load. Thus it provides
leading charging current that reduces the
reactive power.
Synchronous condensers are used for high
power loads because it is uneconomical.
c. Phase Advancer:
Phase advancer is also another
technique used to improve the power factor
of induction motor. A phase advancer is an
AC exciter connected on the rotor shaft. A
phase advancer provides a leading current
that reduces the KVAr.
Switch Gear:
The apparatus used for switching, controlling and protecting the electrical circuits and
equipment such as switches, fuses, circuit breaker, relays, CT’s and PT’s etc, is named as
switch gear.
General Protection scheme:
Under normal operating conditions, the contacts remain closed and the circuit breaker
carries the full-load current continuously. In this condition, the e.m.f. in the secondary
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winding of current transformer (C.T.) is insufficient to operate the trip coil of the breaker but
the contacts can be opened (and hence the circuit can be opened) by manual or remote
control. When a fault occurs, the resulting over current in the C.T primary winding increases
the secondary e.m.f. This energizes the trip coil of the breaker and moving contacts are pulled
down, thus opening the contacts
Usually a switch gear contains following
devices.
Circuit Breaker
Protective Relays
Contactors (usually Magnetic)
Circuit Breaker:
A circuit breaker is an automatically-
operated electricalswitch designed to protect
an electrical circuit from damage caused by
overload or short circuit. Its basic function is
to detect a fault condition and, by interrupting continuity, to immediately discontinue
electrical flow. Unlike a fuse, which operates once and then has to be replaced, a circuit
breaker can be reset (either manually or automatically) to resume normal operation. Circuit
breakers are made in varying sizes, from small devices that protect an individual household
appliance up to large switchgear designed to protect high voltage circuits feeding an entire
city.
Operation:
Once a fault is detected, contacts within the circuit breaker must open to interrupt the
circuit; some mechanically-stored energy (using something such as springs or compressed
air) contained within the breaker is used to separate the contacts, although some of the
energy required may be obtained from the fault current itself. Small circuit breakers may be
manually operated; larger units have solenoids to trip the mechanism, and electric motors to
restore energy to the springs.
The circuit breaker contacts must carry the load current without excessive heating, and
must also withstand the heat of the arc produced when interrupting the circuit. When a
current is interrupted, an arc is generated. This arc must be contained, cooled, and
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extinguished in a controlled way, so that the gap between the contacts can again withstand
the voltage in the circuit. Different circuit breakers use vacuum, air, insulating gas, or oil as the
medium in which the arc forms. Different techniques are used to extinguish the arc .
Finally, once the fault condition has been cleared, the contacts must again be closed to restore
power to the interrupted circuit.
Types of Circuit Breaker:
Different types of circuit breakers are available in market. Some of them are following:
Air Circuit Breaker
Vacuum Circuit Breaker
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using arrays of induction disks, shaded-pole magnets, operating and restraint coils, solenoid-
type operators, telephone-relay style contacts, and phase-shifting networks.
Protective Relay is the most important part of switch gear. Different relays are used for
different operating functions. Protection relays respond to such conditions as over-current,
over-voltage, reverse power flow, over- and under- frequency, and even distance relays that
would trip for faults up to a certain distance away from a substation but not beyond that
point.
Some important relays used in common power station is given as.
Over Current Relay
VAJ Relay
MVAJ Relay
Distance Relay
Differential Relay
VAX, MVAX Relay
CTU Relay
CME Relay
Phase Discrepancy Relay
PT Fuse Failure Relay
Their details are given as.
a. Over Current Relay:
It operates in Phase-Phase or Phase-Ground fault and trip the circuit.
b. VAJ Relay:
It is like a contactor, it operates by receiving various signals from different relays. In
VAJ relay reset is necessary.
c. MVAJ Relay:
It is a magnetic contactor and reset is necessary in this.
d. Distance Relay:
It is being used in high transmission lines. There are various zones made on
transmission lines. It locates the distance of fault from the nearest zone.
e. Differential Relay:
This relay detects the fault between two CT. One CT is connected at HT and other at
LT side.
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Magnetic Contactors:
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Contactor is an electrically controlled switch (relay) used for switching a power circuit.
An electro magnetic contactor is a contactor driven by an electric control signal. A type of
contactor that is operated remotely through solenoid action.
Or
A type of starter for AC induction motors that combines a magnetic contactor and an
overload relay. Magnetic motor starters can be operated remotely.
Operating principle:
Unlike general-purpose relays, contactors
are designed to be directly connected to high-
current load devices. Relays tend to be of lower
capacity and are usually designed for both
normally closed and normally open applications.
Devices switching more than 15 amperes or in
circuits rated more than a few kilowatts are
usually called contactors. Apart from optional
auxiliary low current contacts, contactors are
almost exclusively fitted with normally open
contacts. Unlike relays, contactors are designed
with features to control and suppress the arc
produced when interrupting heavy motor
currents.
When current passes through the electromagnet,
a magnetic field is produced, this attracts the
moving core of the contactor. The electromagnet
coil draws more current initially, until its
inductance increases when the metal core enters the coil. The moving contact is propelled by
the moving core; the force developed by the electromagnet holds the moving and fixed
contacts together. When the contactor coil is de-energized, gravity or a spring returns the
electromagnet core to its initial position and opens the contacts.
Most motor control contactors at low voltages (600 volts and less) are air break
contactors; i.e., ordinary air surrounds the contacts and extinguishes the arc when
interrupting the circuit. Modern medium-voltage motor controllers use vacuum contactors.
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Motor control contactors can be fitted with short-circuit protection (fuses or circuit breakers),
disconnecting means, overload relays and an enclosure to make a combination starter.
Applications:
Lighting control:
Contactors are often used to provide central control of
large lighting installations, such as an office building or retail
building. To reduce power consumption in the contactor coils, latching contactors are used,
which have two operating coils. One coil, momentarily energized, closes the power circuit
contacts, which are then mechanically held closed; the second coil opens the contacts.
Magnetic starter
A magnetic starter is a contactor designed to provide power to electric motors. The
magnetic starter has an overload relay, which will open the control voltage to the starter coil
if it detects an overload on a motor. Overload relays may rely on heat produced by the motor
current to operate a bimetal contact or release a contact held closed by a low-melting-point
alloy. The overload relay opens a set of contacts that are wired in series with the supply to the
contactor feeding the motor. The characteristics of the heaters can be matched to the motor so
that the motor is protected against overload. Recently, microprocessor-controlled motor
protection relays offer more comprehensive protection of motors.
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In SML, Overhead transmission is used to supply power to Crescent Ujala from Power
House and through ETP.
Crescent Ujala is both connected with SML Power House and ETP.
Figure2 shows the transmission tower of SML. There is Wapda incoming and Ujala
outgoing.
Figure1 shows the transmission cables of Ujala feeder and ETP feeder.
Here 11KV transmission line is used for transmission. There is also incoming transmission
line for ETP which is used to supply auxiliary supply if ETP generation has been cut off.
Insulator used in this line is of porcelain.
There is also an underground transmission line of 11KV for Ujala.
Multicore Cables
Introduction:
Electric power can be transmitted or distributed either by overhead system or by
underground cables. The underground cables have several advantages such as less liable to
damage through storms or lightning, low maintenance cost, less chance of faults, smaller
voltage drop and better general appearance. However, their major drawback is that they
have greater installation cost and introduce insulation problems at high voltages compared
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Underground Cables:
An underground cableessentially consists of one or more conductors covered with suitable
insulation and surrounded by a protecting cover.
Construction of Cables:
Figure shows the general construction of a 3-conductor cable. The various parts are:
a. Cores or Conductors:
A cable may have one or more than one core (conductor) depending upon the type of
service for which it is intended. For instance, the 3-conductor cable shown in Fig. 11.1 is used
for 3-phase service. The conductors are made of tinned copper or aluminium and are usually
stranded in order to provide flexibility to the cable.
b. Insulation:
Each core or conductor is provided with a suitable thickness of insulation, the thickness
of layer depending upon the voltage to be withstood by the cable. The commonly used
materials for insulation are impregnated paper, varnished cambric or rubber mineral
compound.
c. Metallic sheath:
In order to pro- tect the cable
from moisture, gases or other
damaging liquids (acids or alkalis) in
the soil and atmosphere, a metallic
sheath of lead or aluminum is
provided over the insulation as
shown in Fig. 11.1
d. Bedding:
Over the metallic sheath is
applied a layer of bedding which
consists of a fibrous material like
jute or hessian tape. The purpose
of bedding is to protect the metallic sheath against corrosion and from mechanical injury
due to armoring.
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e. Armouring:
Over the bedding, armoring is provided which consists of one or two layers of
galvanized steel wire or steel tape. Its purpose is to protect the cable from mechanical injury
while laying it and during the course of handling. Armoring may not be done in the case of
some cables.
f. Serving:
In order to protect armouring from atmospheric conditions, a layer of fibrous
material (like jute) similar to bedding is provided over the armouring. This is known as
serving.
It may not be out of place to mention here that
bedding, armouring and serving are only
applied to the cables for the protection of
conductor insulation and to protect the
metallic sheath from mechanical injury.
Classification of Cables:
Cables for underground service may be
classified in two ways according to
The type of insulating material used in
their manufacture
The voltage for which they are
manufactured. However, the latter
method of classification is generally
preferred, according to which cables
can be divided into the following
groups:
Low-tension (L.T.) cables — upto
1000 V
High-tension (H.T.) cables — upto 11,000 V
Super-tension (S.T.) cables — from 22 kV to 33 kV
Extra high-tension (E.H.T.) cables — from 33 kV to 66 kV
Extra super voltage cables — beyond 132 kV
A cable may have one or more than one core depending upon the type of service for
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which it is intended. It may be single-core, two-core, three-core, four-core etc. For a 3-phase
service, either 3-single-core cables or three-core cable can be used depending upon the
operating voltage and load demand.
In SML, Low tension and high tension cables are used. In high tension lines three core
armoured cable is used and in low tension lines multi core cable is used.
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This method of laying underground cables is (Direct lying) simple and cheap and is
much favoured in modern practice. In this method, a trench of about 1·5 metres deep and 45
cm wide is dug. The trench is
covered with a layer of fine sand (of
about 10 cm thickness) and the
cable is laid over this sand bed. After
the cable has been laid in the
trench, it is covered with
another layer of sand of about 10 cm
thickness.
The trench is then covered with
bricks and other (Draw-in System) materials in order
to protect the cable from
mechanical injury.
It is a simple and less costly method. It is a clean and safe method as the cable is invisible
and free from external disturbances .It cannot be used in congested areas where excavation is
expensive and inconvenient. This method of laying cables is used in open areas where
excavation can be done conveniently
Draw-in system:
In this method, conduit or duct of glazed stone or cast iron or concrete are laid in the ground
with manholes at suitable positions along the cable route. The cables are then pulled into
position from manholes. Figure shows section through four-way underground duct line.
Repairs, alterations or additions to the cable network can be made without opening the
ground.
Solid system:
In this method of lying, the cable is laid in open pipes or troughs dug out in earth along the
cable route. The troughing is of cast iron, stoneware, asphalt or treated wood. After the cable
is laid in position, the troughing is filled with a bituminous and covered over. Cables laid in this
manner are usually plain lead covered because troughing affords good mechanical protection.
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References:
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