TRAINING REPORT

ON
OIL & NATURAL GAS CORPORATION
GAS PROCESSING PLANT
HAZIRA, SURAT (GUJARAT)

BY
ARPIT DIXIT
B.TECH (ELECTRICAL ENGINEERING) 2013-17
NIT, SRINAGAR

UNDER THE GUIDENCE OF :

Mr. B K GUPTA AND Mr. ROHIT SIR

OIL & NATURAL GAS CORPORATION
GAS PROCESSING PLANT
HAZIRA, SURAT (GUJARAT)

10/12/2015 - 08/01/2016
 AKNOWLEDGEMENT
I wish to thank OIL AND NATURAL GAS CORPORATION LIMITED
Hazira Plant for allowing me to attend the vocational training
programme at their premises and for providing all the needful
facilities required for the completion of the entire program. I
would also like to express our sincere gratitude towards
Mr.S.V.Acharya - Chief Engineer - In-charge Training Programme
for providing us with an opportunity to undergo training
programme in ONGC Hazira Plant.
I would also like to thank our mentor Mr. ROHIT SIR AND Mr. B K
GUPTA for their continuous guidance and for enlightening us with
his vital knowledge throughout the programme. Working under
their guidance has been an honor and a fruitful learning
experience.
I express my deepest gratitude to those who have helped and
encouraged me in various ways in carrying out this training
program. I would like to extend my thanks and would like to
acknowledge the ONGC personnel for sharing their valuable
knowledge.
INTRODUCTION TO HAZIRA PLANT
In recent past the natural gas acquired an increased importance by virtue of its
usage as the substitute of coal, petrol and diesel as fuel in the industrial boilers
and furnace. This natural gas being rich in propane and butane i.e., rich in
compounds such as C3 and C4 compounds gives straight run LPG .
Some of the gas fields in India are producing sour Natural gas which are required
to be subjected to special treatment for the removal of hydrogen supplied which
is very poisonous in nature. The isolated carbon condensate are also associated
with sour natural gas which when processed can yield sour LPG which is again
undesirable for usage so this requires an additional treatment for making it sweet
(free from H2S) marketable and safe for use.
This is all what is taken care off in HGPC( Hazira Gas Processing Complex) receives
the sour natural gas in varying amount through the subsea pipeline through the
subsea reservoir. The gas is received in the gas receiving stations, called the slug
catcher where the gas and the slug(containing hydrocarbon condensate ,moisture
such as corrosion inhibitors) are separated .The gas and the condensate are
routed through different streams for their further processing .The gas stream
after the removal of H2S and moisture yield dry and sweet gas which after dew
point depression is sent through the HBJ pipeline to the different receiving
stations. Where as the condensate after processing yields LPG and another
product called NGL.(Naphtha) which in turn produces kerosene and
ARN(Aromatic Rich Naphtha).
To carry out all these operation the major units which are installed in HGPC area
as ;
1. Gas Terminal .
2. Gas Sweetening Unit.
3.Gas Dehydration Unit.
4.Due Point Depression.
5.Sulphur Recovery Unit.
6.Condensate Fractionation Unit.
7.LPG recovery.
8.Kerosene Recovery Unit.
Hazira plant is self contained for all the utilities and offsite facilities such as
Cogeneration power, steam cycles water system, air system , inert gas system,
effluent treatment plants, product storage and dispatch etc. required for safe and
smooth facilities.

GAS RECIEPT TERMINAL:

The entire gas terminal after the first receiving valve the sour gas and condensate
are then routed through a set of pressure reduction control system. These control
valves maintain down stream pressure at a present value.(Normally set at 70
kg/cm2). In case the pressure exceeds the value, these valves try to close and
maintain the pressure. These control valves are operated normally in automatic
mode. The gas and condensate then passes through cyclone separators/filters
and further distributed to slug catchers.

GAS SWEETENING UNIT:

Sour gas from slug catcher is distributed to different GSU trains under the
pressure control and flow control. Sour gas is first preheated up to 40-45 D e.g.
sour condensate of gas from CFU also enters down stream of preheated under
flow control. The combine sour gas passes through knock out drum and enters
the bottom of high- pressure absorber column . The absorber is having valve type
trays. The amine solution(methyl di-ethanol amine of concentration 480 gm/lit) is
pumped from individual trains unit tank and is injected at the desired tray of the
column. The amine and gas flow in the column is counter current .The sweet gas
from the top of column is cooled and to GDU/LPG unit through a knock out drum.

GAS DEHYDRATION UNIT:

Sweetened from GSU trains enters inlet knock out drums of dehydration unit
where any entrained MDEA is knocked out. Gas then enters the absorber column
at its bottom, which has bubble cap type trays. Tri-ethylene glycol (TEG) is
injected at the top of the column .Dehydrated gas comes out from the column
and sent to dew point depression unit (DPD) via the outlet KOD under pressure
control. The rich TEG is taken out from bottom of column of column under level
control to a degassing drum where the hydrocarbons are removed and as fuel
gas.

DEWPOINT DEPRESSION :
The dehydrated gas from GDU trains first passes through gas-gas exchanger and
cooled to about 15-degree. This gas is further cooled to about 5-degree . In a
chiller with the help of propane refrigerant in closed circulation cycle. The chilling
temp. Control valve, which regulates the gas flow through chiller and operates at
a present temp. value in automatic mode. The cooled gas condensate at 5-degree.
goes to a filter separator where the liquid and gases are separated the
condensate is pumped to LPG plant surge drum(for condensate feed to
distillation column). The cooled gas from the top passes through gas-gas
exchangers where the chillness of the gas is exchanged with the incoming gas
from GDU. The gas then flows out to Gas Authority OF India (GAIL) for
transportation of sweet natural gas to Hazira-Bijapur-Jagdishpur.

SULPHUR RECOVERY UNIT:

Acid gas from GSU regenerator is brought to sulphur recovery unit to convert the
poisonous hydrogen sulphide gas into element sulphur by liquefied oxidation
catalytic process. Acid gas coming from GSU is taken to absorber/oxidiser vessel
via inlet KOD under flow control, which contains LOCAT SOLUTION. Hydrogen
sulphide is to oxidise to elemental sulphur by atm air in presence of the catalyst
.Carbon dioxide, oxygen ,nitrogen, water vapour and tresses of hydrogen sulphide
(within permissible limit set by pollution control board) are vented to the
atmospere .LOCAT solution returns back to oxidiser/absorber under pressure
control and molten sulphur thus separated is taken to a surge drum under level
control. Molten sulphur from surge drum is pumped by vertical pumps to
preconditioning unit for temperature conditioning with the help of thermal fluid
and then sent to Roto former. Here the molten sulphur is palletized and then
bagged in HDPF bags in the unit for final disposal (selling in the market).Sulphur
Recovery Unit has been installled as an environmental protection unit only.

KEROSENE RECOVERY UNIT:

NGL produced from CFU is the main feed for kerosene recovery unit. The NGL
flashed to 4.5 kg/cm2 and the vapor steam is taken to feed tray of naphtha
column . The liquid stream from the surge drum is passed through the preheater
and joining the vapor stream before entering the feed tray. NGL is fractioned to
produce Aromatic Rich naphtha (ARN). Passing through the air cooler and getting
accumulated in reflux drum condenses the top vapour of naphtha. The reflux
drum is pressurized with IG. The reflux liquid is pumped back to column top and
ARN tapped out from the discharge of the reflux pump. A part of naphtha column
bottom stream is vaporized through furnace and taken out to bottom of column.
This is passed through kerosene column bottom vs. Naphtha column bottom
exchanger and being vaporized by passing through furnace. The vapor is fed to
the bottom of column. Kerosene thus produced from top of column is cooled
before sending to storage tank.

LPG RECOVERY UNIT:

Sweet gas from GSU outlet and sweet condensate from DPD are taken as feed to
LPG recovery unit. Gas under flow and pressure control passes through a KOD for
separation of unwanted entrainment like MDEA. The gas is taken through gas
dryers and enters a cold box in which outgoing cold stream are passing for pre
cooling of incoming gas. The cold gas and liquid is taken to separator.The liquid
thus separated. The lean gas is then further compressed as per requirement of
down stream consumers. The liquid thus separated is taken out under level and
flow control and fed to lightened frationating column. Liquid from bottom of LEF
column is then fed to LPG column under level and flow control. In LPG column,
liquified petroleum gas is taken out from top and natural gas liquid is recovered
from bottom. The products coming out from distillation column are sent to
storage under level control.

CONDENSATE FRACTIONATION UNIT :

Sour condensate processing unit in Hazira Poject is called as condensate
fractionation unit(CFU). Associated sour gas condensate from slug catcher is
preheated and taken into a condensate surge drum operating at slightly lower
pressure than incoming pressure in CFU. Condensate, water and gas are
separated in the surge drum. Condensate from bottom of the drum is pumped to
a stripper column through coalesce filters under flow control. In stripper column
,H2S is stripped along with lighter hydrocarbons and taken out from surge drum,
and stripper top are jointly compressed by Off Gas compressor and feed to gas
sweetening train for elimination of H2S. The liquid from stripper bottom is re
boiled and fed to LPG column. LPG is taken out from the top through condenser
reflux drum and NGL from the bottom through NGL cooler, under level control to
storage area. It is being continuously monitored that LPG thus produced from CFU
is a sour and the same is sweetened through processing in caustic wash unit
before sending to LPG sphere.In case it is found that the LPG in sphere contains
more than 4ppm of H2S after sampling(as preparation for dispatch to consumers).
The bulk of LPG is re-routed through caustic wash unit to restrict the H2S level
below permissible limit.
 MAINTAINENCE OF ELECTRIC MOTORS
The electrical department of the ONGC plant consists of nearly about 750 motors in
operation which are a major asset to the plant to keep up the various processes to
keep operating without interruption . The motors used in the various stages of
processing are majorly poly-phase squirrel cage rotor induction motors which owing to
their extremely robust construction and high degree of load bearing capacity without
much faults showing up is the prime factor responsible for their selection in the plant .
The motors used are classified in 3 major categories according to the operating
voltage :
LT MOTORS (low stator voltages up to 230 volts)
MT MOTORS(medium level stator voltages up to 616 volts )
HT MOTORS(high level of stator voltages up to 11kv)

Three-Phase Induction Motor

Like any electric motor, a 3-phase induction motor has a stator and a rotor. The
stator carries a 3-phase winding (called stator winding) while the rotor carries a
short-circuited winding (called rotor winding). Only the stator winding is fed
from 3-phase supply. The rotor winding derives its voltage and power from the
externally energized stator winding through electromagnetic induction and
hence the name. The induction motor may be considered to be a transformer
with a rotating secondary and it can, therefore, be described as a transformer
type
AC machine in which electrical energy is converted into mechanical
energy.

Advantages

(I) It has simple and rugged construction.

(ii) It is relatively cheap.
(iii) It requires little maintenance.
(iv) It has high efficiency and reasonably good power factor.
(v) It has self starting torque.
Disadvantages
(i) It is essentially a constant speed motor and its speed cannot be changed
easily.
(ii) Its starting torque is inferior to d.c. shunt motor.

-
Construction

A 3-phase induction motor has two main parts (i) stator and (ii) rotor. The rotor
is separated from the stator by a small air-gap which ranges from 0.4 mm to 4
mm, depending on the power of the motor. The parts are as follows :

1. Stator

It encloses a hollow, cylindrical core made up of thin laminations of silicon steel to

reduce hysteresis and eddy current losses. A number of evenly spaced slots are
provided on the inner periphery of the laminations . The insulated connected to
form a balanced 3-phase star or delta connected circuit. The 3-phase stator
winding is wound for a definite number of poles as per requirement of speed.
Greater the number of poles, lesser is the speed of the motor and vice-versa.
When 3-phase supply is given to the stator winding, a rotating magnetic field (See
Sec. 8.3) of constant magnitude is produced. This rotating field induces currents in
the rotor by electromagnetic induction.

2. Rotor

The rotor, mounted on a shaft, is a hollow laminated core having slots on its
outer periphery. The winding placed in these slots (called rotor winding) may be
one of the following two types:
(i) Squirrel cage type
(ii) Wound type

SQUIRREL CAGE ROTOR

 It consists of a laminated cylindrical core having parallel slots on its outer
periphery. One copper or aluminum bar is placed in each slot. All these bars are
joined at each end by metal rings called end rings This forms a permanently short-
circuited winding which is indestructible. The entire construction (bars and end
rings) resembles a squirrel cage and hence the name. The rotor is not connected
electrically to the supply but has current induced in it by transformer action from
the stator. Those induction motors which employ squirrel cage rotor are called
squirrel cage induction motors. Most of 3-phase induction motors use squirrel
cage rotor as it has a remarkably simple and robust construction enabling it to
operate in the most adverse circumstances. However, it
suffers from the disadvantage of a low starting torque. It is because the
rotor bars are permanently short-circuited and it is not possible to add any
external resistance to the rotor circuit to have a large starting torque.

WOUND ROTOR

It consists of a laminated cylindrical core and carries a 3-phase winding, similar to

the one on the stator The rotor winding is uniformly distributed in the slots and is
usually star-connected. The open ends of the rotor winding are brought out and
joined to three insulated slip rings mounted on the rotor shaft with one brush
resting on each slip ring. The three brushes are connected to a 3-phase star-
connected rheostat as shown in At starting, the external resistances are
included in the rotor circuit to give a large starting torque. These
resistances are gradually reduced to zero as the motor runs up to speed.
The external resistances are used during starting period only. When the motor
attains normal speed, the three brushes are short-circuited so that the wound
rotor runs like a squirrel cage rotor
STATOR AND ROTOR OF A SQUIRREL CAGE INDUCTION MOTOR

SELECTION OF INDUCTION MOTORS

All types of industries invariably required to install different electric motors as
prime movers for driving process equipment participating in different respective
production line ups. The continuous process of technical development has
resulted in highly diversified types of electrical induction motors .Hence an
utmost care must be taken in selection of most appropriate type of motor
considering number of Hence, an utmost care should be exercised in selection of
most appropriate type of motor considering number of technical factors for each
application, so that the motor would provide desired and optimum performance.
The characteristics of motors vary widely with the nature of their application and
the type of duty they are expected to perform. For example, the applications like
constant speed, constant torque, variable speed, continuous/intermittent duty,
steep/sudden starts, frequent start/stops, etc. should be taken into consideration
carefully when deciding for the type of a motor for that specific application. Like
one mentioned above need above, a number of other factors and design features
like weather conditions, stringent system conditions, abnormal surroundings,
hazardous area, duty cycle, motor efficiency, etc. should be considered while
deciding the rating and subsequently drawing out the technical specifications of
the motor.
The various parameters are :

Types of atmosphere :
Open
Dusty or closed
Gaseous/hazardous
Knowledge of atmosphere helps in correct selection of motor i.e. Weather proof
type, totally enclosed type, drip proof type or screen protected etc.

Site conditions and environment :

Ambient temperature : it is the temperature of the surrounding air in

which the motor has to work .it is very important in determining the rating
of motor. The life of a motor is directly dependent on the heat stresses to
which the insulation is subjected to in operation i.e. The maximum
temperatures permitted in the windings . The ambient temperature of 40
degrees is normally assumed .The maximum winding temperature a motor
can attain and still have long insulation life is the sum of ambient
temperature and maximum permissible temperature rise for particular
insulation class e.g. The maximum temperature rise for class B insulation is
90 degrees and that allowed for class F type insulation is 115 degrees. It
means the maximum winding temperature that can be allowed for class B
type is 130 degrees ad for F is 155 degrees.
 Elevation/Site Altitude: elevation should be below 1000 metres or 1000
metres above MSL. Above 1000 metres low reduction factors are to be
used because the thin air has less cooling capacity.

Duty cycle Rating (S1 to S7): It gives the measure and quick insight about
the operational time , characteristics of sudden or continuous loads being
attached to the shaft and lastly whether the motor will be operated with
normal start and stop calibrations or erratic start and stops.

Mounting and shaft orientation: generally motors are connected in 2

configurations
FOOT MOUNTED: Here the motor is mounted on side rails. If flat base
plates are used the motor should be raised by at least 13mm to allow free
passage of air underneath .
FLAGE MOUNTED: They are used to drive directly the drives where flexible
coupling is used.

Method of drives : there are various ways to drive the components

connected to the motor which are classified as :
Direct drive: solid and fixed coupling is used .
Belt drive
Chain drive
Gear drive

Temperature classification: another factor taken into consideration while

selecting a motor is whether the motor is used for operation in a flammable
atmosphere. The maximum surface temperature of any unprotected
surface of electrical equipment should not exceed the ignition temperature
of the gas or vapour. Temp classes are:

1. T1: 450 degrees

2. T2: 300 degrees
3. T3: 200 degrees
4. T4: 135 degrees
5. T5: 100 degrees
6. T6: 85 degrees
 Humidity :below 90 percent for totally enclosed types and 80 percent for
semi enclosed types.
INSTALLATION OF MOTORS :
For efficient installation of motors installation place should be well
ventilated and should have adequate space for heat dissipation and
maintenance .A minimum of 0.75m of working space around the motor is
recommended.
FOUDATION: foundation must be rigid and secure to provide adequate
support. There should be no vibration twisting or misalignment due to
inadequate foundation. A massive concrete foundation is preferred in order
to minimize the vibration ad stability is enhanced by proper plate and
foundation bolt.
ALIGNMENT: motor must be adequately aligned otherwise it can lead to
bearing failure, vibrations and shaft fracturing. The alignment should be
checked as soon as bearing failure or vibration is detected.
ELECTRICAL CONNECTIONS : check for:
1. Connection between motor lead cables and incoming power cables .
2. Direction of rotation of motor installed.
3. Connection of auxiliary devices like interval space heaters .
OPERATION OF MOTOR:
Ensure the connections are as per the diagram
All connections are properly insulated for voltage and temperature.
Ensure the capacity of fuses ,relays etc. are appropriate and contactors are
in good position .
Frame and terminal box are grounded and motor heaters are I off
condition.
MEASUREMENT OF IR VALUE: insulation resistance varies considerably for
different m/c size, operating voltage and atmospheric condition .For all
practical purposes the recommended minimum value can be calculated as
under:
Rw=pt(kv+1) mega ohm
Where pt is a constant dependent on the condition of winding and ambient
temperature at which the test is carried out and kv is the line voltage in kilo
volts.
 A minimum of 1.5 Mohm is required for a safe operation of an LT motor
operating at 415 volts where as for HT motor it should be 100 M ohm when
motor is new /repaired and 5M ohm after a long period of operation.

POLARIZATION INDEX: it is defined as the ratio of IR value after10 minutes

to IR value after 1 minute of operation. on a clean dry winding the
polarization index should not be less than 1.5. if it is less then drying out is
needed .In drying out the winding temperature is raised gradually to allow
any entrapped moisture to vapourise and escape without rupturing the
insulation. The entire heating cycle should be 15-20 hours .
WINDING RESISTANCE: it is measured to identify any shorting of the
winding.
Dry penetration test is conducted to check for the cracks in the joints
between rotor bars and short circuiting for SCIM.
Tan Delta Test is conducted to find out any deterioration of the insulation
due to contamination.

MAINTENANCE OF MOTORS IN THE PLANT :

As the number of installed motors in the plant is very large as all the
processing units need motors as prime movers for running large centrifugal
pumps of enormous capacities. So due to the large loads connected to the
motor shaft continually there is always a requirement of regular
maintenance not only for the rectification of the faults but even to ensure
timely action against the normal wear and tear of the machines parts over
the continual operation.
Generally maintenance in the ONGC Hazira plant is carried out In 2 classes:
1. Half yearly maintenance
2. Annual maintenance
Difference between half yearly maintenance and the annual one is that the
annual maintenance else than cleaning ,wiping ,greasing, check up of terminal box
,cleaning of cooling tubes and heaters (in case of large HT motors) also involves
conditional monitoring and calculation of Polarization index to determine the
value of winding resistance and the insulation strength which need not be
checked in half yearly maintenances.
Some important points which may require to be attended while periodical
maintenance is carried out are follows :
CLEANING AND BLOWING: -of the dust with moisture free compressed air
at a pressure of 4Kg/cm^2 (high pressure is avoided as it may damage the
insulations)
WIPING: Surface contamination on the winding can be removed by using a
soft , lint free wiping materials. If the contamination was oily the wiping
material can be moistened with safety type petroleum solvent.
TEFC motors require removal of any dirt accumulated on the surface as it
may lead to vibrations in the bearings which overtime lead to changes in
the air gap. The tube of air to air heat exchanger should be cleaned using a
tube brush with synthetic fibre brushes (not wire brushes).
CHECKING THE AIR GAP : excessive air gap indicates that bearing have
worn out . The air gap is measured by inserting a long steel feeler gauge
leaves. Four readings are taken around the periphery of the motor.
GREASING :- the ball bearings is done periodically without fail with the help
of a grease gun which fills in the grease in the specially designed grease
cups having a V shaped groove placed on both sides of the plate holding the
bearing which prevents grease from spilling all over the machine and
directs it only to the bearings.
ABNORMAL CONDITIONS EXPERIENCED BY MOTORS AND THEIR
VARYING EFFECTS :.
1. Abnormal System Conditions

1. Voltage
1. Undervoltage
2. Overvoltage
3. Unbalance in 3-phase
4. Single phasing
5. Voltage surges
2. Frequency
1. Low frequency
2. High frequency

2. Abnormal Operating conditions

 1. Locked rotor or stalled rotor
2. Reswitching/Frequent start-stops
3. Momentary interruption/Bus transfer
4. Overloading
5. Improper cable sizing

3. Environmental conditions

1. High/low ambient temperature

2. High altitude
3. High humidity
4. Corrosive atmosphere
5. Hazardous atmosphere/surroundings
6. Exposure to steam/salt-laden air/oil vapour

4. Mechanical problems

1. Seized bearings
2. Incorrect alignment/foundation levelling
3. Incorrect fixing of coupling
4. High vibration mounting
5. External shock due to load

5. Condition at location

1. Poor ventilation
2. Dirt accumulation
3. Exposure to direct sunlight

Though, above mentioned abnormalities may prevail for short or long

duration or may be transient in nature, major impact of the listed abnormal
conditions is overheating of the motor along with one or several of the other
effects as follows.
Change in the motor performance characteristics like drawl of more power and
consequent deterioration in motor efficiency, etc.

Increase in mechanical stresses leading to:

1. Shearing of shafts
 2. Damage to winding overhang
3. Bearing failures
4. Insulation failures

Increase in stator and rotor winding temperature leading to:

1. Premature failure of stator or rotor insulation (For wound rotor motor)

2. Increased fire hazard
3. Breakage of rotor bar and/or end ring (For squirrel cage motors)

All the motors encounter few or several of these abnormalities during the course
of their service lives. Consideration of listed abnormal conditions at design stage
greatly helps to minimize the effects of abnormal conditions to maintain a
consistent performance.

TROUBLESHOOTING:
ROTOR BAR CRACKS: cracked rotor bar develop more severe high
resistance connections .These high resistance connections require the
current to increase in the nearby bars to supply the torque required to start
up and operation of the motor. During the start up very high temperature is
developed around the crack or open bar causing potential damage to rotor
bar and stator insulation.
GROWLER TESTING is the most common method to analyse the rotor bars
of a SCIM .growler is a coil wrapped around a metal core with AC power
applied to the coil. The coil is placed next to the rotor .The magnetic field
generated by the coil induces a current In the rotor bar. A piece of this
metal is placed on the top of the rotor bar. If the bar is broken the
alternating voltage at the location of the break will cause the thin piece of
metal to vibrate.
VOLTAGE TESTING METHOD : approximately 25 percent of the operating
voltage is fed across a single phase of three phase motor. An ammeter is
placed in line with test circuit to indicate any current fluctuation while
turning the rotor manually . A broken rotor bar will cause an increase in the
stator winding impedance as it passes under the single energized phase.
This will decrease in the current seen on the ammeter for each rotation.A
 fluctuation of current of >5-10% in the current is generally considered
unacceptable.
ROTOR PROPOSITY: This is generally more common in cast rotor.it causes
imbalance In rotor fields which will develop into high vibration resulting
into bearing damage. Un-identified and un-corrected rotor will continue to
cause bearing failure over and over again.
ROTATION : Mostly the motors used are bi directional however ensure that
rotation is in conformity with the directional arrow marks shown on the
name plate or as required by driven equipment.
BEARING TEMPERATURE RISE AND SLEEVING: Bearing temperature should
be carefully monitored .If the temperature rise is excessive a thorough
investigation should be made before it is operated again. As detectors are
placed on the shaft of the rotor give the measure of the bearing
temperature which should be within the permissible limits and when the
rate of temperature rise is less than 1 degree per half an hour the bearing
temperature is considered to be stabilized. And if it exceeds 95 degrees the
motor should be stopped immediately.
Moisture protection is very important to be maintained by means of
external and internal heaters such that the temperature of motor is
maintained about 3 degree above dew point.
Any abnormal noise or vibration should be noted immediately with the
detectors and corrected accordingly. Increased vibration ca be indicative of
a change in balance due to mechanical failure of rotor part,stator winding
problem or a change in motor alignment

CONDITION MONITORING
Rolling element bearings are critical components in induction motors and
monitoring their condition is important to avoid failures. Several condition
monitoring techniques for the bearings are available. Out of these, stator current
monitoring is a relatively new technique. Vibration, stator current . a common
mode of failure of an induction motor is the bearing failure followed by stator
winding and rotor bar failures. The bearing failure increases the rotational friction
of the rotor. Even under normal operating conditions of balanced load and good
alignment, fatigue failure begins with small fissures, located below the surfaces of
the raceway and rolling elements, which gradually propagate to the surface
generating detectable vibrations and increasing noise levels. Continued stressing
causes the fragments of the material to break loose producing localized fatigue
phenomena known as flaking or spalling. Electric pitting or cracks due to excessive
shock loading are common in induction machines when used for heavy loads.
The widespread application of rolling element bearings in both industry and
commercial life require advanced technologies to efficiently and effectively
monitor their health status. There are many condition monitoring methods used
for detection and diagnosis of rolling bearings.
In fact, large electrical machine systems are often equipped with mechanical
sensors, which are primarily vibration sensors such as proximity probes. However,
these are delicate and expensive. Various researchers have suggested that stator
current monitoring can provide the same indications without requiring access to
the motor. This technique utilises results of spectral analysis of the stator current
or supply current of an induction motor for the diagnosis [1].A detailed review of
different vibration and acoustic methods, such as vibration measurements in time
and frequency domains, sound measurement, the SPM and the AE technique for
condition monitoring of rolling bearings .
AE is the phenomena of transient elastic wave generation due to a rapid release
of strain energy caused by structural alteration in a solid material under
mechanical or thermal stresses. Generation and propagation of cracks are among
the primary sources of AE in metals. AE transducers are designed to detect the
very high frequency (450 kHz) stress waves that are generated when cracks
extend under load. The most commonly measured AE parameters are peak
amplitude, counts and events of the signal. Counts involve counting the number
of times the amplitude exceeds a preset voltage level in a given time and gives a
simple number characteristic of the signal. An event consists of a group of counts
and signifies a transient wave. The shock pulses caused by the impacts in the
bearings initiate damped oscillations in the transducer at its resonant frequency.
Measurement of the maximum value of the damped transient gives an indication
of the condition of rolling bearings. Low-frequency vibrations in the machine,
generated by sources other than rolling bearings, are electronically filtered out.
The maxim normalized shock value is a measure of the bearing condition. Shock
pulse meters are simple to use so that semiskilled personnel can operate them.
They give a single value indicating the condition of the bearing straightaway,
Instrumentation
Vibrations were measured with the help of a piezoelectric accelerometer Bruel
and Kjaer (B&K) type 4366having un damped natural frequency of 39 kHz. The
output of the accelerometer was fed to the B&K charge amplifier 2635 connected
to Ono Sokki CF 3200 portable fast Fourier transform analyzer. The schematic
diagram of the current sensor(working on Hall effect) in series with motor supply
line
The Hall element located in the air gap of the magnetic circuit converts the
magnetic field generated by the primary current into a proportional Hall voltage.
The magnetic field produced by the primary current generates a highly linear
magnetic flux in the air gap of the magnetic circuit, which in turn induces a
proportional Hall voltage in the Hall element. The voltage is then electronically
amplified resulting in an output voltage that is highly proportional to the primary
current up to the final value of the measuring range. The current sensor is
supplied with 715V from the power supply unit for 15min before taking the
measurements.
Measurement conditions
The measurements were carried out from no load to full load (27 kg) for the
induction motor bearing with an increment of 5 kg. The motor was run at
constant speed of 1440 rpm. Three healthy bearings were used to check the
repeatability of the measurements. Inner race defect was simulated by a circular
hole of diameter varying from 250 to 1500 mm in the outer race of the same
bearing (in steps of 250 mm successively after each measurement) by spark
erosion technique.
RESULTS AND DISCUSSIONS

3.1. Vibration velocity

Fig. 2 shows that the overall amplitudes of vibration velocity of three healthy
bearings are very much close to each other and their average overall level is also
shown. Fig. 3 shows that overall velocity values follow the same trend as that of
the good bearing with increase in load. The overall velocity value has increased
even for a small defect size of 250 mm. The overall velocity significantly increases
to 66% in case of a maximum defect size of 1500 mm with respect to healthy
bearing at 15 kg load.
The spectrum of the vibration velocity signal in the low-frequency range was
obtained to observe changes at the characteristic defect frequency of the bearing
outer race due to defects in it. The characteristic defect
where fr is the shaft rotational frequency, N is number of balls, bd and pd are the
ball diameter and pitch circle diameter ,respectively, and b is the contact angle of
the ball (with the races). For the shaft rotational frequency fr= 24 Hz and a test
bearing having nine balls of diameter 8.5mm and pitch circle diameter of 38.5mm
with contact angle =0, the characteristic inner race defect frequency fo is found
to be84.15 Hz.
Velocity spectrum of one of the healthy bearings in the low-frequency range of
500 Hz at 15 kg load is shown in Fig. 4.From the spectrum of velocity, it has been
observed that the peak occurs at fundamental frequency of shaft (i.e. at 24 Hz)
and at twice the supply frequency (i.e. at 100 Hz) in the spectral
Stator current signals
Fig. 6 shows the overall value of stator current amplitude comparison at 15 kg
load for 020 kHz range of three healthy bearings and also the average overall
stator current of three healthy bearings. From this chart also it is observed that
the overall amplitudes are very much close tone another for the three healthy
bearings. The overall stator current values were taken for all the defect sizes in
the inner race of the bearing. Fig. 7 shows that the overall stator current values
follow the same trend as that of the good bearing within crease in load. The
overall stator current value has increased slightly even for a small defect size of
250 mm. From 250 to 1250 mm, the amplitude of overall stator current values
increase continuously and the increase is much more for 1500 mm defect size.
literature, a defect in rolling element-bearing causes an increase in the overall
RMS value of stator current for a known frequency range. Hence, the results
obtained from the stator current correlates with the results reported in [4,15].
Thus, overall stator current has appreciably increased by 39.79% in case of
maximum defect size of 1500 mm with respect to healthy bearing at15 kg load.
The relationship of the bearing vibration to the stator current spectra can be
determined by remembering that any air gap eccentricity produces anomalies in
the air gap flux density [13]. Since ball bearings support the rotor, any bearing
defect will produce a radial motion between the rotor and stator of the machine.
The mechanical displacement resulting from damaged bearing causes the
machine air gap to vary in a manner that can be described by combinations of
rotating eccentricities moving in both directions [16]. Thus, bearing fault
simulated in the inner race of the bearing may also cause rotor eccentricity, which
is one of the common mechanical faults in the bearing. The rotor eccentricity in
induction motor takes two forms, i.e. static eccentricity (where the rotor is
displaced from the stator bore centre but still rotating upon its own axis) and
dynamic eccentricity (where the rotor is still turning upon the stator bore centre
but not on its own centre).Eccentricity causes a force on the rotor that tries to
pull the rotor even further from the stator bore centre. In the case of static
eccentricity this is a steady pull in one direction. This makes the unbalanced
magnetic pull(UMP) difficult to detect unless specialist experimental equipment is
utilized, which is not possible for motors in service. Dynamic eccentricity produces
a UMP, which acts on the rotor and rotates at rotor rotational velocity.
Both types of eccentricities cause excessive stressing of the machine and greatly
increase bearing wear due to uneven magnetic pull produced that leads to
variation of the sideband current magnitudes or predicted current harmonics in
relation to vibration velocity. Hence, any fault condition in the induction motor
causes the magnetic field in the air gap of the machine to be non-uniform. It has
been shown by Schoen [1] that these vibration frequencies reflect themselves in
the current spectrum as f bng=[fe mfv] (2)
where fe is the electrical supply frequency, m =1,2,3 is one of the characteristic
vibration frequencies. A current signal of a single phase of stator current of
induction motor and a vibration signal from a vibration sensor located at the
bearing housing of induction motor for three good bearings were obtained. The
corresponding current spectrum components in relation to vibrations for the
supply frequency fe of 50 Hz and at characteristic outer race defect vibration
frequency of 84.15 Hz are 34.15 and 134.15 Hz. Fig. 8 shows the acquired current
spectrum for the same low-frequency range of 500 Hz at 15 kg load as that of
vibration velocity spectrum to verify the relationship between stator current and
vibration velocity for healthy bearing. The spectrum of stator current in Fig. 8
indicates peak at supply frequency of 50 Hz in the current spectrum, whereas at
twice the supply frequency in the velocity spectrum (Fig. 4) indicating the UMP
even under normal operating condition. The corresponding current spectrum
components in relation to vibrations were not significant at
[ f e _ f o](i.e. at 34.15 Hz) and [ fe+fo] (i.e. at 134.15 Hz) .
The rest of the peak component other than at 50 Hz present in the current
spectrum occur at multiples of the supply frequency and these are caused due to
saturation, winding distribution and supply voltage. The stator current spectrum
of motor with the outer race defect of the bearing from 250 to 1500 mm in steps
of 250 mm were obtained in the low frequency of 500 Hz for 15 kg load and the
plot of 1500 mm is shown in Fig. 9. Predicted current harmonics for outer race of
the bearing relating vibration characteristic defect frequencies with the supply
current frequency are compared with those of healthy bearing. For minimum
defect size in the outer race of the bearing of motor, there was marginal increase
in the amplitude of the predicted current harmonics component at [ f e - f
o]=34:15 Hz and[ f e + f o]=134:15 Hz. However, significant increase in the
amplitude of predicted current harmonics or vibration sideband current
magnitudes is observed as the defect size increases as shown in Fig. 9. These
results are comparable with results reported in [5,13,17]for the outer race defect
in the bearing.

CO GENERATION PLANT
What is co generation ??
By definition, in lay mans language cogeneration is on site generation of 2
quantities and the most prevalent example of co-gen is generation of electric
power and heat as a byproduct simultaneously which is used up efficiently for
various processes going on in the hazira plant.
ROLE OF CO GENERATION PLANT
The role of co generation plant is to meet the energy requirements in the form of
electricity and steam. For meeting electricity needs ,power supply has been taken
from Gujarat electricity board at 66kv through 2 feeders each capable of meeting
the full load requirement .The importance of natural gas for petrochemical
industries ,fertilizers, and LPG for domestic cooking was for seen at that time and
it was this future outlook which led to this conception of own power generation
through CPP as reliable source of power .Since steam was one of the inputs used
for the processing of the gas idea of having 2 Gas Turbine based CPPs units along
with Heat Recovery Steam Generators was conceived and implemented .
With increase of processing capacity from 28 million cm^3 to 42 million cm^3
both steam as well as power demands went up and the third GT+ HRSG was
erected and commissioned .This has further added to the reliability of power to
the complex.

OPERATIONAL PHILOSOPHY:
Initially the system used to be connected with the grid till third GTG unit was
commissioned .But such a system had a serious draw back that our system too
used to collapse along with Gujarat electricity board (GEB) in case of grid faults
.After commissioning of third GTG ,our reliability has gone up and we started to
run the system in isolated mode ie. taking power from GEB when it was
absolutely necessary .We even reduced our contract demand from 8 MVA saving
cost on demand charges .Subsequently, 66kv protection systems was upgraded
using state of the art numeric control relays which operated within few cycles.
After this, the system used to isolate itself from the grid in case of grid faults
without affecting the operation of the plant .This gave us a shot in the arm and
we even started exporting surplus power to GEB . Today we are always connected
to the grid and exchanging power with the grid .A surplus power of 15.7 MVA is
being wheeled to sister ONGC plants thereby saving 4.5 crore rupees to the
corporation which would otherwise have been paid to GEB by mehsana asset
towards purchase of power. Still surplus power left is sold to GEB at a cost of rs
2.190 per unit as per their requirement.
Their is even a load shedding scheme which operates and sheds the load beyond
16 MW when either only one source is available or there is a severe fault leading
to predetermined high level of rate of change of frequency (df/dt). Such ascheme
saves the plant from complete black out situation, a thing of the past.

PLANTS AND EQUIPMENTS:

Cogeneration has 3 gas turbines having ISO rating of 25 MW each which
translates to a site rating of 20 MW each at an ambient temperature of 35
degrees. Each of these units is associated with dual HRSG boilers having capacity
of 18.5 tons each HP steam and 105 tons of LP steam per hour. In addition there is
an exclusive boiler having similar capacity . steam is required at three different
pressures :
LP steam: 9kg/cm^2
HP steam: 30kg/cm^2
MP steam: 18kg/cm^2
While HP and LP are produced by heat recovery steam generators (HRSG) , MP is
produced through exclusive boilers .There are 4 nos. of MP steam package water
tube boilers of 25 tons capacity each and a third 35 tons fire tube boiler . the
current requirement of different types of steam as under :
HP STEAM: 60 TONS
MP STEAM : 60 TONS
HP STEAM : 180 TONS
Power generated as well as received from the board is synchronized at 11 kv at
substation 1 from where it is distributed to 18 different sub stations. It may be
noted that our 11 kv bus was designed to handle 4 sources of power (2
GEB+2GTG) only. Hence while designing the synchronizing of the third unit along
with 2 sources of GEB , a reactor was added to the system to bring down the
system fault level within the design parameters . Cogeneration also has a DM
plant of capacity of 300 tons per hour , which de mineralizes water before it is
sent to boiler for making steam.
There is a vast network of steam headers for 3 different kinds of steam spread
across the plant from where different plants consume steam for process heating
.The steam after cooling converts into water called condensate which comes back
to the Cogeneration for recycling in the boilers. There is also a network of cooling
water, service water, fire water, plant air, instrument air and inert gas for purging
etc.
Cogeneration plant major equipments :
Three gas turbine driven generators
Three HRSGs (heat recovery steam generators)
Demineralization water plant
Two 66/11kv grid feeders and 66/11kv switchyard

MACHINE MADE BY YEAR FRAME RATING(MVA) SPEED(rpm)

NO.

GT-1 GE 1988 MS5001 21.12 5100

GT-2 GE 1988 MS5001 21.12 5100

GT-3 BHEL,HYDERABAD 1997 PG5371 19.2 5100

GAS TURBINE OPERATION :

The MS5001 is a single shaft gas turbine with ten-combustor reverse flow
combustion system working on the principle of Bray ton cycle which is a
thermodynamic cycle that describes the working of a constant pressure heat
engine . Although the brayton cycle is run as an open system, it is conventionally
assumed for the purpose of thermodynamic analysis that the exhaust gases are
reused in the intake, enabling analysis as a closed system . in the gas turbine
ambient air is drawn after passing through air filters at a pressure of 15kg/cm^2
into a CPD piston compressor where it is compressed to up to 8kg/cm^2 ideally
like an isentropic process. The compressed air is then made to run into a mixing
chamber where fuel is added ,an isobaric process. The pressurized air and fuel is
ignited in the combustion chamber and energy released by the expansion of the
air and the fuel mixture is used to drive a turbine which generally is made to
rotate at 5100 rpm and the flu gases are given out from the chimney at a
temperature around 427 degrees which are fed to the HRSGs connected , being at
a high temperature is sent to the different boilers to produce steam at three
different pressures of 30 ,18 and 8 kg/cm^2 which is used for heating in the
different processes in the plants . this is done because here the brayton cycle is
run at low pressure ratio and high temperature increase in the combustion
chamber, the exhaust gases might still might be hotter than the compressed inlet
gases . In that case , as per the methods to increase the overall efficiency from a
considerable low value of 25 % , a heat exchanger is used to transfer thermal
energy from the exhaust to the already compressed air , before it enters the CB.
The thermal energy transferred is effectively re-used , thus improving efficiency.
Hence, cogeneration systems make use of the waste heat from brayton cycles for
the production of steam which is used for other processes.

COMPONENTS OF A GAS TURBINE GENERATOR (GTG):

STARTING DEVICE: The gas turbines are required to operate from an
external source initially .This can be done by using a diesel engine , starter
motor or a turbo expander. here in hazira plant diesel engines are used as
starting devices .The turbine speed is brought to around 20% of its rated
speed when firing takes place in the combustion chamber . The starting
device remains connected till the turbine attains self sustaining speed
which is approx. 60% of its rated speed.

ACCESSORY GEAR : The accessory gear is used to connect the turbine shaft
at starting device to compressor end through hydraulic torque convertor
which is used when the GT is initially in the off mode and we need some
high initial torque to start it which is done with the help of synchronous
motors and gear box.

AIR INLET SYSTEM: inlet air enters the compartment and flows in the duct
with built in acoustical silencers and trash screen , to the inlet plenum
before entering the turbine compressor.

COMPRESSOR SECTION: There is an axial flow seventeen stage compressor

which consists of compressor rotor, casing, inlet guide vanes and two exit
guide vanes. The rotor blades supply the necessary force required for the
compression and stator blades guide the air to successive stages of
compressor. The compressed air discharges into the combustion chamber
through discharge casing . It may be noted that compressor itself consumes
about 60% of the power generated by the turbine.

COMBUSTION CHAMBER: The high pressure compressed air enters the

chamber through holes and louvers in the liner walls . it oxidizes the fuel
and makes it combustible . It also cools the metal parts and brings desired
 turbine inlet temperature . The combustion is initiated by spark plugs are
fired with flame from the fired chambers through cross fire tubes.

TURBINE: In the turbine section, the hot gases are converted into shaft
horse power .It is in two stages . In the first stage (high pressure) wheel and
the second (low pressure) wheel are bolted together to make up a single
unit. The first stage and the second stage nozzles direct the flow of hot
gases on the turbine blades .

REDUCTION GEAR BOX: It is a collection of gears used to couple the turbine

end to the generator shaft in a manner that the turbine speed is reduced to
an optimum value of 3000rpm from 5100 rpm in accordance with the
number of poles for which the alternator is designed to rotate and produce
electricity and the maximum vibration in the bearing is well within
15mm/sec.

EXHAUST SYSTEM : The exhaust system is that portion of the turbine in

which the gases used to power the turbine wheels are redirected and
released to atmosphere.

SUPPORT SYSTEM: The gas turbine incorporates a number of control

panels , protection and support systems associated with proper operation
,protection and control of the unit . The support system of the gas turbine
typically includes :
1. The lube oil system, is for furnishing normal lubrication and
absorbing the heat rejection of the gas turbine .
2. The trip oil system, which operates the devices for control.
3. The cooling water system, which cools the lube oil.
4. The starting system including the starting device and the required
logic sequence for starting the gas turbine and bringing it up to the
operating speed.
5. The venting and heating system provides ventilation of hot air from
compartments so that various devices in these compartments work
in the allowable compartment temperature .
6. The fire protection system provided to extinguish fires in the
compartments , in case any fire takes place .
 MODES OF OPERATION OF GAS TURBINES:
1. ISOCHRONOUS SPEED CONTROL MODE : In this mode the speed of
the rotor has to return to the original speed set point after a load has
been applied or rejected . However in parallel mode of operation
this would cause in stabilities . {HERE GT MAINTAINS RATED SPEED}

2. DROOP SPEED CONTROL MODE: In this mode the speed will

decrease by a fixed percentage when the generator is loaded from no
load to full load .This provides a stable working point for each load in
case of parallel operation . {HERE GT FOLLOWS THR GRID
FREQUENCY}. the droop slope is a fixed setting mostly between 3 and
5% .The speed set point can be adjusted to :
return to the rated frequency in the standalone operation.
change the generator active power in parallel operation.

There are 3 modes of operation for a generator :

STAND ALONE OPERATION: Here the generator is not connected to

other generators or the utility. As an isolated unit it supplies power to
all connected load.
FEATURES OF THIS MODE ARE AS FOLLOWS :
1. more/less fuel will raise/lower the frequency.
2. more/less excitation will raise /lower the voltage .
3. The total load determines the generator output.
4. Engine fuel control options : isochronous speed control, droop
speed control.
5. excitation current control options : constant voltage control,
droop voltage control.
6. control room is responsible to keep the bus frequency and
voltage constant if droop modes are active (else not necessary).

PARALLELED WITH THE GRID : Here the GTs need to be set in the droop
mode of operation and they are connected to each other in parallel
such that the utility grid will determine the generator frequency ,speed
and voltage .In cogeneration and in industries the GT can not change up
 its frequency but can slightly vary their terminal voltage . Its features
are as follows :
1. more/less fuel will raise /lower the generator active power.
2. more/less excitation will raise/lower the generator reactive
power.
3. Grid determines the frequency ,speed and voltage .
4. The difference between the total plant load and the generator
output power will be imported or exported .
5. engine fuel control options : droop speed control only.
6. excitation current control options: droop voltage control, VAR
control, PF control .
7. control room is responsible to keep the imported /exported
power or power factor constant.

PARALLELED WITHOUT THE GRID : HERE ,all the GTs are connected to
each other but not with the grid ,so one GT should be in isochronous
mode and (it will take care of the load variations and will maintain the
frequency at 50 Hz) and other GTs need to be in the droop mode .Its
features as follows :
1. more/less fuel will raise/lower the generator active power and the bus
frequency.
2. more/less excitation will raise /lower the generator reactive power and
the bus voltage .
3. The total plant load determines the sum of the power of all generators.
4. engine fuel control option: droop speed control .
5. power management system keeps the bus frequency and voltage
constant ,while sharing the load .

GENERATOR USED: In cogeneration plant of Hazira we have 3

generators which are cylindrical rotor ,rated at 3000 rpm, 2 pole machines
with brushless excitation system .

MACHINE MADE BY RATING

 G-1 AND G-2 BRUSH 31.25MVA, 11KV ,0.8
LAG,50 HZ

G-3 BHEL 31.25MVA, 11KV ,0.8

LAG,50 HZ

BOILERS:

In general , a boiler is a device used for generating :

1. Steam for heating purposes ,process use and mainly for power generation.
2. Hot water for heating purposes.

However ,according to Indian boiler act , a boiler is a closed pressure vessel

with capacity exceeding 22.75 liters used for generating steam under pressure
. It includes all the mountings fitted to such vessels which remain wholly or
partly under pressure when the steam is shut off. The form of energy , which is
generated in the cogeneration plant is electricity and steam without these the
processing cannot be done , thus how we can notice the importance of co
generation plant. The flue gases enter the boilers having a damper or a gate
 like arrangement for diverting the gases to the furnace or to the chimney to be
thrown out in case of no production of steam , it even has second level of gate
called bulletin gate which is to ensure no trace of gases leakage into the
furnace in case of maintenance in the boiler. Once the furnace is heated, it
heats the demineralized water ,free from all salts and at a ph level of 8 ,free
from oxygen is fed in the boiler for the production of steams at different
pressure depending upon the boiler and requirements of the processes.
The steam produced at different pressure is stored in separate drums The total
number of boilers in the cogeneration plant are 8 among which 3 are HRSGs
which can be operated in their respective 3 modes i.e. 1) GT mode 2) FD mode
3) GT+supplementary.

BOILER YEAR MADE BY: TYPE STEAM CAPACITY PRESSURE TEMPERATURE

TYPE: KG/CM^2

HRSG1&2 1987 BHEL,TIRCHY WATER HP 18.5T/HR 38 SATURATED

TUBE

HRSG1&2 1987 BHEL,TIRCHY WATER LP 105T/HR 9 SATURATED

TUBE

HRSG 3 1995 BHEL,TIRCHY WATER HP 50T/HR 38 SATURATED

TUBE

KTI
1986 BABCOK WATER HP 20T/HR 36.7 SATURATED
HITACHI,JAPAN TUBE
LP 105T/HR 8.2 SATURATED

IAEC- 1985 IAEC GAS MP 25T/HR 22 SATURATED

1,2&3 FIRE
FKJ THERMAX 2006 THERMAX WATER MP 35T/HR 22 SATURATED
TUBE

From the table it is very evident that there are 5 water tube boilers and 3 gas fire
boilers. The total high pressure steam capacity is 107T/HR ,total medium pressure
steam capacity is 110T/HRS and total low pressure steam capacity is 315T/HRS.
Out of the three HRSGs , HRSG3 is designed for only HP steam but it has a
provision of dumping from HP steam to MP steam and LP steam .

OPERATION OF HRSG:
Heat recovery and Steam Generators also known as HRSGs can be either
operated in GT+S mode , FD mode or only GT mode .GT+S mode is selected
when heat given out as an exhaust by GT is not enough to generate desired
quantity of steam at desired pressure .FD mode operation is selected only
when GT mode is not available due to maintenance or shut down. Diverter
damper diverts the GT exhaust to the boiler for GT+s mode or to the
atmosphere for open cycle operation. For safety of boiler protections of low
drum level, loss of flame, drum level to D/D close etc have been provided.
These protections are checked before taking the boiler into operation .
controls are done through PLC.

MAJOR PARTS OF HRSG :

DIVERTER DAMPER: The flue gasses coming out of the gas turbine ducts
has two paths for coming out , one is from bypass stack and another one
is through HRSG . The path of flue gasses is decided by the position of
diverter damper ,if diverter damper blocks bypass stack then flue gasses
path is via HRSG otherwise vice versa.

PRESSURE DIFFERENTIAL CONTROLLER: Pressure differential controller

has a role depending upon the type of mode of mode of HRSG ,likewise
when the HRSG is under the GT mode. PDC is fully open in position and
during the GT+S supplementary mode the PDC is opened such that the
pressure of the furnace is maintained.
 DE-AERATOR: The water in the DE aerator has a ph of around 8 .The
water is added from the makeup tank after passing from the makeup
heater .After the addition of return condensate in the de-aerator ,the ph
value increases to around 9,it is further increased to 10 by means of
dosing which is done directly in the drums. The dosing includes sulphate
and phosphate dosing . The water from the de-aerator is fed into the
drums. Prior entering to the LP drum the water is passed through
economizer tubes. The exhaust gases after passing over the HP ,LP,
economizer and make up heater tubes is liberated into the chimney.

POWER DISTRIBUTION: Power from all the 3 GTs and grid is fed into
the main 11kv substation-1 . From substation-1 power is distributed to 18
different substations. Power is consumed at 11 kv, 6.6 kv and 415 volts
depending on the capacity of the drive . the total production of all the GTs is
60 Mega Watts out of which 32 mega watts is consumed in the plant itself in
feeding the different processing sections and the rest 28 mega watts of power
is exported to the Gujarat Electricity Board and to the sister ongc plants
depending upon the requirement. The distribution of power within the various
sub stations will be discussed in the sub stations category .
 SUBSTATION

Presently ,ONGC Hazira plant consists of 18 substations from SS-1 to SS-18 with
substation 17 under the process of reconstruction . The power distribution to
various process units depending upon the operating voltage of the equipments
is done through these substations through adequate protections with the help
of power fuses , circuit breakers and protective relays for the various
abnormalities that can sprout up under the process of continuous operation
and environmental disturbances. As per the single line diagram it is evident
that power after generation from the co generation plant from the 5 sources
(3 GTs and 2 supply lines from GEBs ) where power from GEB is provided
through a 66kv bus line which is stepped down to 11kv with the help of step
down transformers TR-101 and TR-102 , is sent to firstly at substation 1 from
where further distribution for reduced voltages of 6.6kv and 415v bus lines is
supplied through transformers that reduce it from 11 to various ranges of
voltages for operating the equipments .Depending upon the voltages , not all
the substations have same voltage bus line feeding the loads connected to
them instead substations 2, 3,4 ,16,18 have 6.6kv bus bars , substation 14 has
both 11kv and 6.6kv bus bars and all of them come under the category of HT
 substations .LT substations include 5,6,7,8,9,10,11,12,13,15,17(reconstruction)
as they have bus bars at working voltage of 415volts . These transformers are
known as incomers and feed the bus line of the corresponding substation
which is not a single line instead consists of 2 or 3 parts joined together with
the help of bus couplers which help to shut down particular section of loads
connected to the bus and even help to supply the part of the loads connected
to the failed incomer and even provides facility for the maintenance of a
particular part of the bus and prevents disruptions in continuous operation of
the plant
Substations have varying installations of breakers (HT or LT) , bus couplers ,
direct online starters , battery chargers , relays , fuses and contactors for the
efficient supply of power from source to the equipments and continuous
supervision and monitoring of the various equipments installed in the field as
in case of any abnormalities the relays attached to the motors send a signal to
the control room from where a signal is sent to the sub station which cut off
the supply to that very equipment until the repair work has been done .Hence
sub stations in ONGC Hazira plant gives a deep insight in the switchgear and
protection section of the power system analysis and implementation.

WHAT IS SWITCHGEAR AND PROTECTION

????
A switchgear is a generic term which includes all the switching devices
associated mainly with the power system protection . It also includes devices
used for control, metering and regulating of power system. Assembling of such
devices in a logical manner forms a switchgear .
We all are familiar with low voltage switches and re-wire able fuses at our
homes. The switch is used to manually open and close the electrical circuit in
our home and electrical fuses are used to protect our household electric
circuits from short circuit faults and over current. In same way every electric
circuit including high voltage power systems needs switching and protecting
devices . But in high voltage and extra high voltage system, these switching
and protecting devices becomes complicated one for high fault current
interruption in safe and secure way. In addition to that from commercial point
of view every electric power system needs measuring , controlling and
 regulating arrangements . Collectively the whole system is called switchgear
and protection of power system.
Switchgear protection plays a vital role in modern power system network ,
right from generation through transmission to distribution end. The current
interruption device or switching device is called circuit breaker in switchgear
protection system. The circuit breaker can be operated manually as when
required and it also operated during over current and short circuit or any other
faults in the system by sensing the abnormality in the system. The circuit
breaker senses the faulty condition of system through protection relay and this
relay is again actuated by a faulty signal normally comes from current
transformers or voltage transformers .
A switchgear has to perform the function of carrying , making and breaking the
normal load current like a switch and it has to perform the function of clearing
the fault in addition to that it also has provision of metering and regulating
various parameters of electrical power system.
The various components of switchgear and protection implemented in the
various sub stations are as follows :
Electrical fuses
Circuit breakers
Protective relays
Contactor
Bus Coupler
Instrument Transformer (CT and PT)
Electrical Isolators
Step Down Transformers and their accessories
Battery Charger
direct Online Starters for LT motors

DOL(direct online ) Starters :

A direct online starter is used to start the electric motors by applying the full
line voltage to the motor terminals .This is the most rudimentary type of
starters implemented for induction motors which being self starting in theory
but practically due to the large inertia of the rotor and the rotating magnetic
field keeps on changing the poles as a result the rotor keeps vibrating in its
own position hence an additional magnetic field is produced which locks the
rotor in the direction of the rotating magnetic field produced by the stator
poles as a result the rotor is driven in the direction of magnetic field with an
increased value of torque acting on it . DOL starters also contain protection
devices and in some cases condition monitoring . smaller sizes of DOL starters
are manually operated ; larger sizes DOL use electromechanical contactors to
switch the motor circuit .A small motor can be started by simply plugging it
into an electrical receptacle or by using a switch or circuit breaker. A larger
motor requires a specialized switching unit called a motor starter or motor
contactor.
When energized, a direct on line (DOL) starter immediately connects the motor
terminals directly to the power supply. Reduced-voltage, star-delta or soft
starters connect the motor to the power supply through a voltage reduction
device and increases the applied voltage gradually or in steps. In smaller sizes a
motor starter is a manually operated switch; larger motors, or those requiring
remote or automatic control, use magnetic contactors. Very large motors
 running on medium voltage power supplies (thousands of volts) may use
power circuit breakers as switching elements.

A direct on line (DOL) or across the line starter applies the full line voltage to the
motor terminals, the starters or cubicle locations, can usually be found on an ELO
drawing. This is the simplest type of motor starter. A DOL motor starter also
contains protection devices, and in some cases, condition monitoring. Smaller
sizes of direct on-line starters are manually operated; larger sizes use an
electromechanical contactor (relay) to switch the motor circuit. Solid-state direct
on line starters also exist. A direct on line starter can be used if the high inrush
current of the motor does not cause excessive voltage drop in the supply circuit.
The maximum size of a motor allowed on a direct on line starter may be limited
by the supply utility for this reason. For example, a utility may require rural
customers to use reduced-voltage starters for motors larger than 10 kW.

DOL starting is sometimes used to start small water pumps, compressors, fans
and conveyor belts. In the case of an asynchronous motor, such as the 3-phase
squirrel-cage motor, the motor will draw a high starting current until it has run up
to full speed. This starting current is typically 6-7 times greater than the full load
current. To reduce the inrush current, larger motors will have reduced-voltage
starters or variable speed drives in order to minimize voltage dips to the power
supply. A starter contains two DOL circuitsone for clockwise operation and the
other for reversing starter can connect the motor for rotation in either direction.
Such a counter-clockwise operation, with mechanical and electrical interlocks to
prevent simultaneous closure. For three phase motors, this is achieved by
swapping the wires connecting any two phases. Single phase AC motors and
direct-current motors require additional devices for reversing rotation.

A DOL can be used if the high inrush current of the motor does not cause does not
cause excessive voltage drop in the supply circuit . The maximum size of the
motor allowed on a DOL starter may be limited by the supply utility for this
reason. for example, a utility may require rural customers to use reduced voltage
starters for motors larger than 10kw .
It is generally used only for small motors otherwise it needs more protection
devices to be incorporated due to the high values of the operating voltages
involved. Contactors and bi metallic relays are two main components of a DOL
starter. In contactor there is an electromagnet where a current is passed through
the coil around the electromagnet such that it gets magnetized and the plunger is
pulled and the contacts are restored . Now to quench the spark produced due to
contact a long path is provided so that the arc length is increased and the spark
gets quenched . In BMR two different metals having different heat capacities are
used .So at same temperature their expansions are different and hence works as a
relay for the DOL.

CONTACTOR :

It is an electrically controlled switch used for switching an electric power circuit

similar to a relay but with higher current ratings . A contactor is controlled by a
circuit which has a much lower power level than the switched circuit .
contactors come in various forms of capacities and features . Unlike a circuit
breaker , a contactor is not intended to interrupt a short circuit current .
Contactors range from those having a breaking current of several amperes to
thousand of amperes and 24v dc to many kilovolts .

CONSTRUCTION:
 A contactor has three components. The contacts are the current carrying part
of the contactor. This includes power contacts, auxiliary contacts, and contact
springs. The electromagnet (or "coil") provides the driving force to close the
contacts. The enclosure is a frame housing the contact and the electromagnet.
Enclosures are made of insulating materials like Bakelite, Nylon 6, and
thermosetting plastics to protect and insulate the contacts and to provide some
measure of protection against personnel touching the contacts. Open-frame
contactors may have a further enclosure to protect against dust, oil, explosion
hazards and weather.

Magnetic blowouts use blowout coils to lengthen and move the electric arc. These
are especially useful in DC power circuits. AC arcs have periods of low current,
during which the arc can be extinguished with relative ease, but DC arcs have
continuous high current, so blowing them out requires the arc to be stretched
further than an AC arc of the same current. The magnetic blowouts in the
pictured Albright contactor (which is designed for DC currents) more than double
the current it can break, increasing it from 600 A to 1,500 A.

Sometimes an economizer circuit is also installed to reduce the power required

to keep a contactor closed; an auxiliary contact reduces coil current after the
contactor closes. A somewhat greater amount of power is required to initially
close a contactor than is required to keep it closed. Such a circuit can save a
substantial amount of power and allow the energized coil to stay cooler.
Economizer circuits are nearly always applied on direct-current contactor coils
and on large alternating current contactor coils.

A basic contactor will have a coil input (which may be driven by either an AC or DC
supply depending on the contactor design). The coil may be energized at the
same voltage as a motor the contactor is controlling, or may be separately
controlled with a lower coil voltage better suited to control by programmable
controllers and lower-voltage pilot devices. Certain contactors have series coils
connected in the motor circuit; these are used, for example, for automatic
acceleration control, where the next stage of resistance is not cut out until the
motor current has dropped.

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 ("form A") 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,

which 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.
For contactors energized with alternating current, a small part of the core is
surrounded with a shading coil, which slightly delays the magnetic flux in the core.
The effect is to average out the alternating pull of the magnetic field and so
prevent the core from buzzing at twice line frequency.

Because arcing and consequent damage occurs just as the contacts are opening or
closing, contactors are designed to open and close very rapidly; there is often an
internal tipping point mechanism to ensure rapid action.

Rapid closing can, however, lead to increase contact bounce which causes
additional unwanted open-close cycles. One solution is to have bifurcated
contacts to minimize contact bounce; two contacts designed to close
simultaneously, but bounce at different times so the circuit will not be briefly
disconnected and cause an arc.

A slight variant has multiple contacts designed to engage in rapid succession. The
first to make contact and last to break will experience the greatest contact wear
and will form a high-resistance connection that would cause excessive heating
inside the contactor. However, in doing so, it will protect the primary contact
from arcing, so a low contact resistance will be established a millisecond later.
Another technique for improving the life of contactors is contact wipe; the
contacts move past each other after initial contact in order to wipe off any
contamination.

ARC SUPPRESSION:
Without adequate contact protection, the occurrence of electric current arcing
causes significant degradation of the contacts, which suffer significant damage.
An electrical arc occurs between the two contact points (electrodes) when they
transition from a closed to an open (break arc) or from an open to a closed (make
arc). The break arc is typically more energetic and thus more destructive.

The heat developed by the resulting electrical arc is very high, ultimately causing
the metal on the contact to migrate with the current. The extremely high
temperature of the arc (tens of thousands of degrees Celsius) cracks the
surrounding gas molecules creating ozone, carbon monoxide, and other
compounds. The arc energy slowly destroys the contact metal, causing some
material to escape into the air as fine particulate matter. This activity causes the
material in the contacts to degrade over time, ultimately resulting in device
failure. For example, a properly applied contactor will have a life span of 10,000
to 100,000 operations when run under power; which is significantly less than the
mechanical (non-powered) life of the same device which can be in excess of 20
million operations.

Most motor control contactors at low voltages (600 volts and less) are air break
contactors; air at atmospheric pressure surrounds the contacts and extinguishes
the arc when interrupting the circuit. Modern medium-voltage AC motor
controllers use vacuum contactors. High voltage AC contactors (greater than 1000
volts) may use vacuum or an inert gas around the contacts. High Voltage DC
contactors (greater than 600V) still rely on air within specially designed arc-chutes
to break the arc energy. High-voltage electric locomotives may be isolated from
their overhead supply by roof-mounted circuit breakers actuated by compressed
air; the same air supply may be used to "blow out" any arc that forms.

BUS COUPLER :
A bus coupler is a device meant to help users switch between two or more
computer buses on the fly. Unlike other bus switching methods, in which the
computers must be shut off to avoid electrical problems, a bus coupler allows
users to change buses without going through this process. There are two main
types of bus couplers, in-line and box; while each can be used in most systems, all
are meant for slightly different applications. This device is useful for networks, or
computers with multiple buses, because users sometimes will need different
buses for processing certain problems or functions.

The primary task of a bus coupler is to help users switch between different buses
on a network. This task normally takes a relatively long time, because the power
has to be turned off, the other bus has to be confirmed as safe, the computer has
to start back up and the buses have to power up. With a coupler, this switch is
made within seconds, without having to go through all the other steps.

When a bus coupler is used, it also makes bus switching safer. If the bus is
improperly switched, even if users go through the longer process, then there is a
chance that an arc will be made and the resulting electricity can damage the
systems or injure users. A coupler is able to balance this, and the bus switch
occurs without any change in power.

Bus couplers come in two builds: in-line and box. Both bus coupler types are
similarly connected to buses, and they can be used with most systems. The
difference is that the box type tends to be heavier and bigger, but make it simpler
to find problems with the electricity; in-line couplers are lighter but tend to offer
fewer connections and cannot withstand much force without breaking. Unless
weight or size is an issue, there should be no problems using one coupler in place
of another.

Aside from making bus switching safer, a bus coupler helps users function quickly
with networks. One bus system usually will have different hardware
configurations that make it better for one function over another, and being able
to switch between different configurations quickly can help increase processing
time. Networks normally will only need this device or computers set up with
several bus configurations, because consumer computers commonly have just
one bus configuration, making this device useless with them.
FUSES :
In electronics and electrical engineering, a fuse is a type of low resistance resistor
that acts as a sacrificial device to provide overcurrent protection, of either the
load or source circuit. It s essential component is a metal wire or strip that melts
when too much current flows through it, interrupting the circuit that it connects.
Short circuits, overloading, mismatched loads, or device failure are the prime
reasons for excessive current. Fuses can be alternative to circuit breakers.

A fuse interrupts an excessive current ("operates") so that further damage by

overheating or fire is prevented. Wiring regulations often define a maximum fuse
current rating for particular circuits. Overcurrent protection devices are essential
in electrical systems to limit threats to human life and property damage. The time
and current operating characteristics of fuses are chosen to provide adequate
protection without needless interruption. Slow blow fuses are designed to allow
harmless short term currents over their rating while still interrupting a sustained
overload. Fuses are manufactured in a wide range of current and voltage ratings
to protect wiring systems and electrical equipment. Self-resetting fuses
automatically restore the circuit after the overload has cleared, and are useful in
environments where a human replacing a blown fuse would be difficult or
impossible, for example in aerospace or nuclear applications.

CONSTRUCTION OF FUSES :

A fuse consists of a metal strip or wire fuse element, of small cross-section

compared to the circuit conductors, mounted between a pair of electrical
terminals, and (usually) enclosed by a non-combustible housing. The fuse is
arranged in series to carry all the current passing through the protected circuit.
The resistance of the element generates heat due to the current flow. The size
and construction of the element is (empirically) determined so that the heat
produced for a normal current does not cause the element to attain a high
temperature. If too high a current flows, the element rises to a higher
temperature and either directly melts, or else melts a soldered joint within the
fuse, opening the circuit.

The fuse element is made of zinc, copper, silver, aluminum or alloys to provide
stable and predictable characteristics. The fuse ideally would carry its rated
current indefinitely, and melt quickly on a small excess. The element must not be
damaged by minor harmless surges of current, and must not oxidize or change its
behavior after possibly years of service.

The fuse elements may be shaped to increase heating effect. In large fuses,
current may be divided between multiple strips of metal. A dual-element fuse
may contain a metal strip that melts instantly on a short-circuit, and also contain a
low-melting solder joint that responds to long-term overload of low values
compared to a short-circuit. Fuse elements may be supported by steel or
nichrome wires, so that no strain is placed on the element, but a spring may be
included to increase the speed of parting of the element fragments.

The fuse element may be surrounded by air, or by materials intended to speed

the quenching of the arc. Silica sand or non-conducting liquids may be used.

FUSE WIRE RATING:

The melting point and specific resistance of different metals used for fuse wire

Metal Melting point Specific Resistance

Aluminum 240oF 2.86 - cm

Copper 2000oF 1.72 - cm

Lead 624oF 21.0 - cm

Silver 1830oF 1.64 - cm

Tin 463oF 11.3 - cm

Zinc 787oF 6.1 - cm

SOME IMPORTANT FACTS PERTAINING TO FUSES :

1. Fuse
2. Fuse wire
3. Minimum Fusing Current : It is minimum value of current due to
which fuse melts.
 4. Current Rating of Fuse : It is maximum value of current due to which
fuse does not get melt.
5. Fusing Factor : This is the ratio of minimum fusing current and current
rating of fuse.
6. Therefore, fusing factor = Minimum fusing current / current rating of
fuse.
7. The value of fusing factor is always more than 1.
8. Prospective Current in Fuse: Before melting, the fuse element has to
carry the short circuit current through it. The prospective current is
defined as the value of current which would flow through the fuse
immediately after a short circuit occurs in the network.
9. Melting Time of Fuse or Pre-arcing Time of Fuse: This is the time taken
by an fuse wire to be broken by melting. It is counted from the instant,
the over current starts to flow through fuse, to the instant when fuse
wire is just broken by melting.
10.Arcing Time of Fuse: After breaking of fuse wire there will be an arcing
between both melted tips of the wire which will be extinguished at the
current zero. The time accounted from the instant of arc initiated to
the instant of arc being extinguished is known as arcing time of fuse.

11. Operating Time of Fuse : When ever over rated current starts to flow
through a fuse wire, it takes a time to be melted and disconnected, and
just after that the arcing stars between the melted tips of the fuse wire,
which is finally extinguished. The operating time of fuse is the time gap
between the instant when the over rated current just starts to flow
through the fuse and the instant when the arc in fuse finally
extinguished. That means operating time of fuse = melting time + arcing
time of fuse.

CURRENT CARRYING CAPACITY OF FUSE WIRE :

Current carrying capacity of a fuse wire depends upon numbers of factors like,
what material used for it, what are the dimension of it, i.e. diameter and length,
size and shape of terminals used to connect it, and the surrounding.
FUSE LAW :
Fuse law determines the current carrying capacity of a fuse wire. The law can be
established in the following way. At steady state condition that is when fuse carry
normal current without increasing its temperature to the melting limit. That
means at this steady state condition, heat generated due to current through fuse
wire is equal to heat dissipated from it.
HIGH RUPTURING CAPACITY (HRC) FUSES :

high rupturing capacity (HRC) fuses are short-circuit current limiting with low
rated minimum breaking current ,low switching over voltages . HRC high voltage
fuses are used to protect transformers, capacitor banks, cable networks and
overhead lines against short-circuits. ABB HRC HV fuses protect switchgears from
thermal and electromagnetic effects of heavy short-circuit currents by limiting the
peak current values (cut-off characteristics) and interrupting the currents in
several milliseconds. HRC fuse or high rupturing capacity fuse- In that type of
fuse, the fuse wire or element can carry short circuit heavy current for a known
time period. During this time if the fault is removed, then it does not blow off.

The enclosure of HRC fuse is either of glass or some other chemical compound.
This enclosure is fully air tight to avoid the effect of atmosphere on the fuse
materials. The ceramic enclosure having metal end cap at both heads, to which
fusible silver wire is welded. The space within the enclosure, surrounding the fuse
wire or fuse element is completely packed with a filling powder. This type of fuse
is reliable and has inverse time characteristic, that means if the fault current is
high then rupture time is less and if fault current is not so high then rupture time
is long.

CIRCUIT BREAKER :
A circuit breaker is an automatically operated electrical switch designed to
protect an electrical circuit from damage caused by overload or short circuit. Its
basic function is to detect a fault condition and interrupt current flow. Unlike a
fuse, which operates once and then must 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:
All circuit breaker systems have common features in their operation. Although
details vary substantially depending on the voltage class, current rating and type
of the circuit breaker.

The circuit breaker must detect a fault condition; in low voltage circuit breakers
this is usually done within the breaker enclosure. Circuit breakers for large
currents or high voltages are usually arranged with protective relay pilot devices
to sense a fault condition and to operate the trip opening mechanism. The trip
solenoid that releases the latch is usually energized by a separate battery,
although some high-voltage circuit breakers are self-contained with current
transformers, protective relays and an internal control power source.

Once a fault is detected, the circuit breaker contacts 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
(opening) the circuit. Contacts are made of copper or copper alloys, silver alloys
and other highly conductive materials. Service life of the contacts is limited by the
erosion of contact material due to arcing while interrupting the current.
Miniature and molded-case circuit breakers are usually discarded when the
contacts have worn, but power circuit breakers and high-voltage circuit breakers
have replaceable contacts.

When a current is interrupted, an arc is generated. This arc must be contained,

cooled and 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 the arc forms in.

DIFFERENT TYPES OF HIGH VOLTAGE CIRCUIT BREAKERS INSTALLED IN

THE PLANT ARE AS FOLLOWS :
The different types of circuit breakers used in the ONGC plant are :
 Air blast circuit breaker(LT SUB STATIONS)
Minimum oil circuit breaker(LT SUB STATION)
Vacuum circuit breaker (HT SUB STATION)
Sulphur hexafluoride circuit breaker(HT SUB STATION)

AIR BLAST CIRCUIT BREAKER : This type of circuit breakers, is

those kind of circuit breaker which operates in air at atmospheric pressure. After
development of oil circuit breaker, the medium voltage air circuit breaker (ACB) is
replaced completely by oil circuit breaker in different countries. But in countries
like France and Italy, ACBs are still preferable choice up to voltage 15 KV. It is also
good choice to avoid the risk of oil fire, in case of oil circuit breaker. In America
ACBs were exclusively used for the system up to 15 KV until the development of
new vacuum and SF6 circuit breakers.
WORKING PRINCIPLE OF AIR CIRCUIT BREAKER :
The working principle of this breaker is rather different from those in any other
types of circuit breakers. The main aim of all kind of circuit breaker is to prevent
the reestablishment of arcing after current zero by creating a situation where in
the contact gap will withstand the system recovery voltage. The air circuit
breaker does the same but in different manner. For interrupting arc it creates an
arc voltage in excess of the supply voltage. Arc voltage is defined as the minimum
voltage required maintaining the arc. This circuit breaker increases the arc voltage
by mainly three different ways,
It may increase the arc voltage by cooling the arc plasma. As the temperature of
arc plasma is decreased, the mobility of the particle in arc plasma is reduced,
hence more voltage gradient is required to maintain the arc.
It may increase the arc voltage by lengthening the arc path. As the length of arc
path is increased, the resistance of the path is increased, and hence to maintain
the same arc current more voltage is required to be applied across the arc path.
That means arc voltage is increased.
Splitting up the arc into a number of series arcs also increases the arc voltage

MINIMUM OIL CIRCUIT BREAKER : Mineral oil has better

insulating property than air. In oil circuit breaker the fixed contact and moving
contact are immerged inside the insulating oil. Whenever there is a separation of
current carrying contacts in the oil, the arc in circuit breaker is initialized at the
moment of separation of contacts, and due to this arc the oil is vaporized and
decomposed in mostly hydrogen gas and ultimately creates a hydrogen bubble
around the arc. This highly compressed gas bubble around the arc prevents re-
striking of the arc after current reaches zero crossing of the cycle. The oil circuit
breaker is the one of the oldest type of circuit breakers.

OPERATION OF OIL CIRCUIT BREAKER :

The operation of oil circuit breaker is quite simple lets have a discussion. When
the current carrying contacts in the oil are separated an arc is established in
between the separated contacts.
Actually, when separation of contacts has just started, distance between the
current contacts is small as a result the voltage gradient between contacts
becomes high. This high voltage gradient between the contacts ionized the oil and
consequently initiates arcing between the contacts. This arc will produce a large
amount of heat in surrounding oil and vaporizes the oil and decomposes the oil in
mostly hydrogen and a small amount of methane, ethylene and acetylene. The
hydrogen gas cannot remain in molecular form and its is broken into its atomic
form releasing lot of heat. The arc temperature may reach up to 5000 K. Due to
this high temperature the gas is liberated surround the arc very rapidly and forms
an excessively fast growing gas bubble around the arc. It is found that the mixture
of gases occupies a volume about one thousand times that of the oil decomposed.
From this figure we can assume how fast the gas bubble around the arc will grow
in size. If this growing gas bubble around the arc is compressed by any means
then rate of de ionization process of ionized gaseous media in between the
contacts will accelerate which rapidly increase the dielectric strength between the
contacts and consequently the arc will be quenched at zero crossing of the
current cycle. This is the basic operation of oil circuit breaker. In addition to that
cooling effect of hydrogen gas surround the arc path also helps, the quick arc
quenching in oil circuit breaker.

VACUUM CIRCUIT BREAKER : A vacuum circuit breaker is such

kind of circuit breaker where the arc quenching takes place in vacuum. The
technology is suitable for mainly medium voltage application. For higher voltage
vacuum technology has been developed but not commercially viable. The
operation of opening and closing of current carrying contacts and associated arc
interruption take place in a vacuum chamber in the breaker which is called
vacuum interrupter. The vacuum interrupter consists of a steel arc chamber in the
centre symmetrically arranged ceramic insulators. The vacuum pressure inside a
vacuum interrupter is normally maintained at 10 - 6 bar.

OPERATION OF VACUUM CIRCUIT BREAKER:

The main aim of any circuit breaker is to quench arc during current zero crossing,
by establishing high dielectric strength in between the contacts so that
reestablishment of arc after current zero becomes impossible. The dielectric
strength of vacuum is eight times greater than that of air and four times greater
than that of SF6 gas. This high dielectric strength makes it possible to quench a
vacuum arc within very small contact gap. For short contact gap, low contact mass
and no compression of medium the drive energy required in vacuum circuit
breaker is minimum. When two face to face contact areas are just being
separated to each other, they do not be separated instantly, contact area on the
contact face is being reduced and ultimately comes to a point and then they are
finally de-touched. Although this happens in a fraction of micro second but it is
the fact. At this instant of de-touching of contacts in a vacuum, the current
through the contacts concentrated on that last contact point on the contact
surface and makes a hot spot. As it is vacuum, the metal on the contact surface is
easily vaporized due to that hot spot and create a conducting media for arc path.
Then the arc will be initiated and continued until the next current zero. At current
zero this

vacuum arc is extinguished and the conducting

metal vapor is re-condensed on the contact surface. At this point, the contacts are
already separated hence there is no question of re-vaporization of contact
surface, for next cycle of current. That means, the arc cannot be reestablished
again. In this way vacuum circuit breaker prevents the reestablishment of arc by
producing high dielectric strength in the contact gap after current zero.
There are two types of arc shapes. For interrupting current up to 10 kA, the arc
remains diffused and the form of vapor discharge and cover the entire contact
surface. Above 10 kA the diffused arc is constricted considerably by its own
magnetic field and it contracts. The phenomenon gives rise over heating of
contact at its center. In order to prevent this, the design of the contacts should be
such that the arc does not remain stationary but keeps travelling by its own
magnetic field. Specially designed contact shape of vacuum circuit breaker make
the constricted stationary arc travel along the surface of the contacts, thereby
causing minimum and uniform contact erosion.

SULPHUR HEXAFLOURIDE CIRCUIT BREAKER :

A circuit breaker in which the current carrying contacts operate in sulphur

hexafluoride or SF6 gas is known as an SF6 circuit breaker. SF6 has excellent
insulating property. SF6 has high electro-negativity. That means it has high affinity
of absorbing free electron. Whenever a free electron collides with the SF6 gas
molecule, it is absorbed by that gas molecule and forms a negative ion.
The attachment of electron with SF6 gas molecules may occur in two different
ways,
These negative ions obviously much heavier than a free electron and therefore
over all mobility of the charged particle in the SF6 gas is much less as compared
other common gases. We know that mobility of charged particle is majorly
responsible for conducting current through a gas. Hence, for heavier and less
mobile charged particles in SF6 gas, it acquires very high dielectric strength. Not
only the gas has a good dielectric strength but also it has the unique property of
fast recombination after the source energizing the spark is removed. The gas has
also very good heat transfer property. Due to its low gaseous viscosity (because of
less molecular mobility) SF6 gas can efficiently transfer heat by convection. So
due to its high dielectric strength and high cooling effect SF6 gas is approximately
100 times more effective arc quenching media than air. Due to these unique
properties of this gas SF6 circuit breaker is used in complete range of medium
voltage and high voltage electrical power system. These circuit breakers are
available for the voltage ranges from 33KV to 800KV and even more.
WORKING OF SULPHUR HEXAFLOURIDE CIRCUIT BREAKER :
The working of SF6 CB of first generation was quite simple it is some extent similar
to air blast circuit breaker. Here SF6 gas was compressed and stored in a high
pressure reservoir. During operation of SF6 circuit breaker this highly compressed
gas is released through the arc in breaker and collected to relatively low pressure
reservoir and then it pumped back to the high pressure reservoir for re utilize.
The working of SF6 circuit breaker is little bit different in modern time. Innovation
of puffer type design makes operation of SF6 CB much easier. In buffer type
design, the arc energy is utilized to develop pressure in the arcing chamber for arc
quenching.
Here the breaker is filled with SF6 gas at rated pressure. There are two fixed
contact fitted with a specific contact gap. A sliding cylinder bridges these to fixed
contacts. The cylinder can axially slide upward and downward along the contacts.
There is one stationary piston inside the cylinder which is fixed with other
stationary parts of the SF6 circuit breaker, in such a way that it can not change its
position during the movement of the cylinder. As the piston is fixed and cylinder is
movable or sliding, the internal volume of the cylinder changes when the cylinder
slides.
Here the breaker is filled with SF6 gas at rated pressure. There are two fixed
contact fitted with a specific contact gap. A sliding cylinder bridges these to fixed
contacts. The cylinder can axially slide upward and downward along the contacts.
There is one stationary piston inside the cylinder which is fixed with other
stationary parts of the SF6 circuit breaker, in such a way that it can not change its
position during the movement of the cylinder. As the piston is fixed and cylinder is
movable or sliding, the internal volume of the cylinder changes when the cylinder
slides.
During opening of the breaker the cylinder moves downwards against position of
the fixed piston hence the volume inside the cylinder is reduced which produces
compressed SF6 gas inside the cylinder. The cylinder has numbers of side vents
which were blocked by upper fixed contact body during closed position. As the
cylinder move further downwards, these vent openings cross the upper fixed
contact, and become unblocked and then compressed SF6 gas inside the cylinder
will come out through this vents in high speed towards the arc and passes
through the axial hole of the both fixed contacts. The arc is quenched during this
flow of SF6 gas.

INSTRUMENT TRANSFORMERS :
How will you measure AC currents and voltages of very high magnitude? You will
need the measuring instruments having higher range, which literally mean huge
instruments. Or there's another way, using the transformation property of AC
currents and voltages. You can transform the voltage or current down with a
transformer whose turns ratio is accurately known, then measuring the stepped
down magnitude with a normal range instrument. The original magnitude can be
determined by just multiplying the result with the transformation ratio. Such
specially constructed transformers with accurate turns ratio are called as
Instrument transformers. These instruments transformers are of two types - (i)
Current Transformers (CT) and (ii) Potential Transformers (PT).
Current Transformers (CT):
Current transformers are generally used to measure currents of high magnitude.
These transformers step down the current to be measured, so that it can be
measured with a normal range ammeter. A Current transformer has only one or
very few number of primary turns. The primary winding may be just a conductor
or a bus bar placed in a hollow core (as shown in the figure). The secondary
winding has large number turns accurately wound for a specific turns ratio. Thus
the current transformer steps up (increases) the voltage while stepping down
(lowering) the current.
 Now, the secondary current is measured with the help of an AC ammeter. The
turns ratio of a transformer is NP / NS = IS / IP

One of the common application of a current transformer is in a 'Digital Clamp

Meter'.
Generally, current transformers are expressed in their primary to secondary
current ratio. A 100:5 CT would mean the secondary current of 5 amperes when
primary current is 100 amperes. The secondary current rating is generally 5
amperes or 1 ampere, which is compatible with standard measuring instruments.

Potential Transformer (PT) :

Potential transformers are also known as voltage transformers and they are
basically step down transformers with extremely accurate turns ratio. Potential
transformers step down the voltage of high magnitude to a lower voltage which
can be measured with standard measuring instrument. These transformers have
large number of primary turns and smaller number of secondary turns.
A potential transformer is typically expressed in primary to secondary voltage
ratio. For example, a 600:120 PT would mean the voltage across secondary is 120
volts when primary voltage is 600 volts.
PROTECTIVE RELAYS:

A relay is a device which is operated by a variation in its electrical or physical

conditions to effect the operation of other devices in an electric circuit. A
protective relay is a relay, the principal function of which is to protect service
from interruption or to prevent or limit damage to apparatus. In electrical
engineering, a protective relay is a device designed to trip a circuit breaker when
a fault is detected.[2] The first protective relays were electromagnetic devices,
relying on coils operating on moving parts to provide detection of abnormal
operating conditions such as over-current, over-voltage, reverse power flow,
over- and under- frequency. Microprocessor-based digital protection relays now
emulate the original devices, as well as providing types of protection and
supervision impractical with electromechanical relays. Electromechanical relays
provide only rudimentary indications of involved phase and zone targets. In many
cases a single microprocessor relay provides functions that would take two or
more electromechanical devices. By combining several functions in one case,
numerical relays also save capital cost and maintenance cost over
electromechanical relays. However, due to their very long life span, tens of
thousands of these "silent sentinels" are still protecting transmission lines and
electrical apparatus all over the world. An important transmission line or
generator unit will have cubicles dedicated to protection, with many individual
electromechanical devices, or one or two microprocessor relays.
OPERATION PRINCIPLE :
Electromechanical protective relays operate by either magnetic attraction, or
magnetic induction. Unlike switching type electromechanical relays with fixed and
usually ill-defined operating voltage thresholds and operating times, protective
relays have well-established, selectable and adjustable time/current (or other
operating parameter) operating characteristics. Protection relays may use arrays
of induction disks, shaded-pole. magnets, operating and restraint coils, solenoid-
type operators, telephone-relay contacts, and phase-shifting networks.
Protective relays can also be classified by the type of measurement they make. A
protective relay may respond to the magnitude of a quantity such as voltage or
current. Induction types of relay can respond to the product of two quantities in
two field coils, which could for example represent the power in a circuit. Although
an electromechanical relay calculating the ratio of two quantities is not practical,
the same effect can be obtained by a balance between two operating coils, which
can be arranged to effectively give the same result.
Several operating coils can be used to provide "bias" to the relay, allowing the
sensitivity of response in one circuit to be controlled by another. Various
combinations of "operate torque" and "restraint torque" can be produced in the
relay.
By use of a permanent magnet in the magnetic circuit, a relay can be made to
respond to current in one direction differently from in another. Such polarized
relays are used on direct-current circuits to detect, for example, reverse current
into a generator. These relays can be made bistable, maintaining a contact closed
with no coil current and requiring reverse current to reset. For AC circuits, the
principle is extended with a polarizing winding connected to a reference voltage
source.
Light weight contacts make for sensitive relays that operate quickly, but small
contacts can't carry or break heavy currents. Often the measuring relay will
trigger auxiliary telephone-type armature relays.
In a large installation of electromechanical relays, it would be difficult to
determine which device originated the signal that tripped the circuit. This
information is useful to operating personnel to determine the likely cause of the
fault and to prevent its re-occurrence. Relays may be fitted with a "target" or
"flag" unit, which is released when the relay operates, to display a distinctive
colored signal when the relay has tripped
ELECTROMECHANICAL PROTECTIVE RELAY :

Electromechanical relays can be classified into several different types as follows:

attracted armature Induction mechanical
moving coil motor operated thermal

"Armature"-type relays have a pivoted lever supported on a hinge or knife-edge

pivot, which carries a moving contact. These relays may work on either
alternating or direct current, but for alternating current, a shading coil on the pole
is used to maintain contact force throughout the alternating current cycle.
Because the air gap between the fixed coil and the moving armature becomes
much smaller when the relay has operated, the current required to maintain the
relay closed is much smaller than the current to first operate it. The "returning
ratio" or "differential" is the measure of how much the current must be reduced
to reset the relay.
A variant application of the attraction principle is the plunger-type or solenoid
operator. A reed relay is another example of the attraction principle.
"Moving coil" meters use a loop of wire turns in a stationary magnet, similar to a
galvanometer but with a contact lever instead of a pointer. These can be made
with very high sensitivity. Another type of moving coil suspends the coil from two
conductive ligaments, allowing very long travel of the coil.
STATIC PROTECTIVE RELAY :
Application of electronic amplifiers to protective relays was described as early as
1928, using vacuum tube amplifiers. Devices using electron tubes were studied
but never applied as commercial products, because of the limitations of vacuum
tube amplifiers. A relatively large standby current is required to maintain the tube
filament temperature; inconvenient high voltages are required for the circuits,
and vacuum tube amplifiers had difficulty with incorrect operation due to noise
disturbances.
Static relays with no or few moving parts became practical with the introduction
of the transistor. Static relays offer the advantage of higher sensitivity than purely
electromechanical relays, because power to operate output contacts is derived
from a separate supply, not from the signal circuits. Static relays eliminated or
reduced contact bounce, and could provide fast operation, long life and low
maintenance.
DIGITAL PROTECTIVE RELAY :
The functions of electromechanical protection systems are now being replaced by
microprocessor-based digital protective relays, sometimes called "numeric
relays".
A microprocessor-based digital protection relay can replace the functions of many
discrete electromechanical instruments
These convert voltage and currents to digital form and process the resulting
measurements using a microprocessor. The digital relay can emulate functions of
many discrete electromechanical relays in one device, simplifying protection
design and maintenance. Each digital relay can run self-test routines to confirm its
readiness and alarm if a fault is detected. Numeric relays can also provide
functions such as communications (SCADA) interface, monitoring of contact
inputs, metering, waveform analysis, and other useful features. Digital relays can,
for example, store two sets of protection parameters, which allows the behavior
of the relay to be changed during maintenance of attached equipment. Digital
relays also can provide protection strategies impossible to synthesize with
electromechanical relays, and offer benefits in self-testing and communication to
supervisory control systems.
NUMERICALPROTECTIVE RELAY :
The distinction between digital and numerical relay rests on points of fine
technical detail, and is rarely found in areas other than Protection. They can be
viewed as natural developments of digital relays as a result of advances in
technology. Typically, they use a specialized digital signal processor (DSP) as the
computational hardware, together with the associated software tools. The input
analogue signals are converted into a digital representation and processed
according to the appropriate mathematical algorithm. Processing is carried out
using a specialized microprocessor that is optimized for signal processing
applications, known as a digital signal processor or DSP for short. Digital
processing of signals in real time requires a very high power microprocessor. Most
numerical relays are also multifunctional.
ISOLATORS : An isolator switch is used to ensure that an electrical
circuit is completely de-energized for service or maintenance. Such switches are
often found in electrical distribution and industrial applications, where machinery
must have its source of driving power removed for adjustment or repair. High-
voltage isolation switches are used in electrical substations to allow isolation of
apparatus such as circuit breakers, transformers, and transmission lines, for
maintenance. The disconnector is usually not intended for normal control of the
circuit, but only for safety isolation. Disconnector can be operated either
manually or automatically (motorized disconnector).
 Disconnector for medium voltage
Unlike load break switches and circuit breakers, disconnectors lack a mechanism
for suppression of electric arc, which occurs when conductors carrying high
currents are electrically interrupted. Thus, they are off-load devices, intended to
be opened only after current has been interrupted by some other control device.
Safety regulations of the utility must prevent any attempt to open the
disconnector while it supplies a circuit. Standards in some countries for safety
may require either local motor isolators or lockable overloads (which can be
padlocked).
Disconnector have provisions for a padlock so that inadvertent operation is not
possible (lockout-tag out). In high-voltage or complex systems, these padlocks
may be part of a trapped-key interlock system to ensure proper sequence of
operation. In some designs, the isolator switch has the additional ability to earth
the isolated circuit thereby providing additional safety. Such an arrangement
would apply to circuits which inter-connect power distribution systems where
both ends of the circuit need to be isolated.

BATTERY CHARGER :
A battery charger comprises of rectifier and a tapped transformer ,DC supply
required for charging is obtained from the battery charger .Along with this service
rectifier feeding the load where control DC supply is required for control system .
connect the positive terminal of the charger to positive terminal of the battery
and same for the negative. During the normal use current leaves the positive
terminal and enters through negative terminal while during the charging mode
current enters through positive terminal and leaves from negative terminal .In
generating substation , the DC auxiliary power sources is required for protecting
systems and for control systems. This supply is usually 110 v DC or 220v DC and
obtained from storage battery system.
The batteries are placed in a well ventilated battery room .The battery cells are
placed on the raised wooden rocks. The DC busses are generally supported on the
ceiling or the side walls on the epoxy insulator support .The dc busses are flat
copper sections. The connections are made by soldering by flame of gas. The bus
bars from battery rooms are brought out to DC board by means of asbestos
cement slabs. The lead acid batteries in the room should be kept on the trickle
charge by means of the battery charger kept connected to the dc bus bars.
SPECIFICATIONS OF A STEP DOWN TRANSFORMER
:

STEP DOWN TRANSFORMER ACCESSORIES :

The details of various accessories fitted on the transformer and their functions are
as follows :
Buchholz relay
conservator
silica gel breather
oil temperature indicator
winding temperature indicator
double diaphragm explosion vent
magnetic oil level indicator
BUCHHOLZ RELAY : Buchholz relay is a very sensitive , gas and oil operated
instrument which safely defects formation of gas or development of sudden
pressure inside the oil transformer. It is connected to various protection circuits
to give an early audible alarm in case of gas collection and to disconnect the
transformer from supply in case of severe fault inside the transformer.
CONSERVATOR: conservator is used in the transformer for providing adequate
space for expansion of oil when transformer is loaded or when ambient
temperature changes substantially . It also conserves the insulating property of oil
from deterioration and protects the transformer failure on account of oil.
SILICA GEL BREATHER : Whenever there is a change in the ambient temperature
or in the load of an oil immersed transformer , there is a change in the volume of
oil. This change therefore forces the air above the oil level in the conservator to
be either pushed out or breathed in from outside atmosphere .Whenever the air
is breathed in there is a possibility of moisture and dust from atmosphere to be
sucked in . This is dangerous to the insulating properties of oil. Silica gel breather
are provided to prevent this and to ensure that dry air is breathed in and out
through the breather.
Dry silica crystals , which are dark blue in color , have a very good capacity to
absorb moisture. When the air from outside is breathed in the conservator , it
passes through the crystals and the moisture in the air is absorbed . Thus the air
that reaches the conservator is dry. Dust particles are partly trapped in the oil seal
and partly trapped by the crystal of the silica gel .
OIL TEMPERATURE INDICATOR: It is used to monitor the temperature of
transformer oil. It consists of :
1. Bourdon tube with a pointer mounted in a case with a reading dial and a
glass cover.
2. The temperature sensing bulb.
3. Armored capillary tubing connecting the Bourdon tube and the bulb.
The vapor inside the bulb in contact with the hot oil in the thermometer pocket
expands and the pressure of the vapour inside the system increases . This
increase in pressure results in movement to the pointer, which indicates the
temperature on the dial of the thermometer.
WINDING TEMPERATURE INDICATOR: The use of a winding temperature
indicator permits the winding temperature to be constantly monitored and
harmful overloads can be avoided by restricting the loads which leads to
temperature rise beyond permissible limits .
An oil pot containing a heating coil is mounted on the cover of the transformer
tank. The sensing bulb of the dial thermometer is inserted inside the heating coil.
The terminals of the heating coil are connected to the secondary of a ring type
current transformer , which is fitted on the bushing lead under the transformer
tank cover . A current proportional to the main transformer current flows through
the secondary of the CT and the heating coil .It is provided with a maximum
reading pointer and one set of alarm contacts and one set of trip contacts.
DOUBLE DIAPHRAGM EXPLOSION VENT : The purpose of explosion vent is to
prevent damage to the transformer tank by releasing any excess pressure that
may be generated inside the tank .
Explosion vent consists of a bent pipe with aluminum diaphragm at both ends. A
protective wire mesh is fitted on the opening of the transformer to prevent the
pieces of ruptured diaphragm from entering the tank. Wire mesh is also provided
at upper end to protect upper diaphragm from mechanical damage .
Neat the lower end of the vent there is a small oil level indicator .When the lower
diaphragm ruptures , transformer oil rise in the vent pipe and is visible through
the indicator , indicating the failure of lower diaphragm . In case the pressure
developed is not reduced to safe value after the bursting of the lower diaphragm ,
upper diaphragm also gives way throwing the gas and oil outside and thus
protecting the transformer tank from mechanical damage.

BREAKDOWN VOLTAGE OF TRANSFORMER OIL : BDV of

transformer oil is that minimum voltage at which conduction in the oil takes
.transformer oil is used in the transformer for the cooling of transformer core . Its
breakdown voltage should be more than a certain value so that conduction does
not takes place . Normally BDV of transformer oil is more than 60kv. But due to
mixing of some dust particles and moisture its BDV is decreased . For a HV
transformer the minimum value of transformer oil BDV should be 30kv. If BDV is
less than this particular value then this oil is filtered and reused in the
transformer.
OIL FILTERING : Main purpose of oil filtering is to increase its BDV value . BDV
value of the oil is decreased mainly due to the moisture and dust particles in the
oil . So in oil filtering mainly these two things are removed .Dust particle is
removed by filtering and moisture is removed by heating the oil of the
transformer by heater. The oil filtering unit filters 6000 liters oil per hour . Around
five to six round of filtering is done through filtration . There is two terminals of
the pipe in the filtering unit one works as input and other works as output .intake
of oil having low BDV is taken from the transformer and outlet of oil having high
BDV is fed into the transformer simultaneously.

TRANSFORMER MAINTENANCE REPORT COPIES

COMPONENTS OF UPS:
RECTIFIER : Rectifier represents the input stage and transforms the alternating
voltage of the power line in continuous voltage .The functions carried out by
rectifier are the following :
powering the inverter with direct supply
charging the battery automatically
MICROPROCESSOR: controls the entire system.
BATTERY: Provides the reserve energy for powering the load when there is no
power input to the UPS .For different versions it may be housed inside the UPS in
a compartment at the side or in a supplementary cabinet.
INVERTER : This is the output stage .Converts direct voltage from the rectifier or
battery into stabilized sinusoidal alternating voltage. It is always in operation and
the load connected to the output of the UPS is always powered .
BYPASS: The bypass device allows synchronized ,automatic or manual passage in
zero time of the power of the protected line load (inverter output) to unprotected
line(by-pass-line).
SWMB: Non automatic switch for maintenance .Closing SWMB and opening all
the other switches allows maintenance operations inside the unit safely while
keeping the load powered .There is no power inside the equipment .
EMI FILTERS : One filter is connected before rectifier and one after inverter . The
filter connected in rectifier does not allow high frequency components in rectifier
, other does not allow up and down fluctuations.
 CONCLUSION
India is one of the fastest growing economies in the world and is all set to become
a major economic as well as technical super power of this century. The industrial
and process industries of India face stiff competition from their international
counterparts . to meet this ever growing challenge , India needs to boost its fuel
and power supplies and its effective and productive utilization .
Hazira plant at present generates approximately 60 MW of electric power ,out of
which 32 MW is consumed within the plant for the various processes to keep
going without interruption and the remaining 28 MW of power is supplied to GEB
.It also processes the sour gas recieved from south bassein gas fields to produce
LPG, Naphtha, super kerosene oil, ATF, sulphur etc. These useful fuels and
chemicals are then supplied to various industries . This plant is also strategically
placed at Surat , major industrial port near Arabian Sea. Its proximity to Bombay
High and many neighbouring industries plays a major role in making this plant key
element in development of Indian Industries.