r Bharat Heavy Electricals Limited Bhopal A.C. Machines Engineering Division Three Phase Indu‘ n Motor Test Certi [Customer Praxair for Birla Copper MIC. S.No. 43032A421-11-01 [pes TTF 6542-4p Driven Equip. Compressor DOR From DE ANTICLOGKWISE (UVW-BYR)_6 Volts(V)___Current(A)_Output(Kiv)__Power Factor Spees(RPM) _Frea.(Hz) Duly 47000 470.0 7750 0.89) 1495.0 30.0, St [Construction No.of pes 4 Typecf enclosure CACWUPS5) Type of coming ICWSTAE1_ Saif Cooling.Closed circuit [Typ of Rotor ‘Squirrel Cage Rotor wth SC Rings. [sot Cooling Act. 2 Sided Cooling gore Water -2285LPM Siping Veniction Jssiorcomecton Star No.of teminals 6 Rotorcennection Cage No.of Sipaings lssortraneperts 1A ap 450m Insulalon Cass Sx F(Temp.riseB) RE INo.otsiprira rushes — nich size Bushiype No. oforichnedere [Tested According to 19: 325 Fi Insulation Resistance witt ‘SOV DC Slatorwig 17500110, Rotorwag > [2 High-valtage tests Stator wag. to frame - Phase to Phase with 232000 AC fort min Rotor wég to frame - Phase to Phase with VAC for imin [3 overspeed Test at mpm ie = timesrated speed for = min. Id Efficiency calculated by summation of losses Tea] 50%] | Calculated at 20°. [ouput kw 7750.0 | 5612.6] 3875] [Resistance Of [Stotor Current | yA 470.0 356.7] 2672] [Power factor [cose | 0.890 0.38] 0.85] 0.085680 JOnmctosses [Stator [KW 3855] 22.23] 10.68] lat 75% [Rotor kw 2592] 14221 6.17] o0Bs6Te [Coro & Friston loss [kW 23.12] 3.12) 63.12] [Contact toss at slipring [KW | =| = 2.005079, [adaitionalioss [0.50% _[kiV 375] 22.32 10.79] Hotatiosses [EP [kW 18638] 141.89] 110.69] ep [PaEP) few 7036.38] 5064.30] 3036.60] Efficiency _[PIPS2P | 97.65] 97.52| 97.22] [Guaranteed Eficiency —_[% 7.30] 97.2 26. [5H Toad Tex EW[Amps at_ 14020 KV 35.537 177.58 Tooker Ror Tes Short ckt_ current 470.10 A Short Lose 247.60 Kalvos 2607000 Js Resistancethermometers _[wa__7 [2 [3 [@ [s [6 [7 [8 [s wn ]o Resistance 100. ohmeat_O'C [autres [1 is fer foo _Jo1_los | —[—]—] —[—] = Bearing temperatures after 300 he. unnng = hein) 4470 NowDieeRd a wane 30S Bearing ype Sleeve Lubrication Type__Oil Cooling Forcedi10 lnm per Bearing) [Supprements [Remarks Frermminal Marking 4 Separation of No-Load Lose [Routine Tests. View from MiG Top 2 Annexure 1 Me : | : | NOE [Proparedby A Varstinay Checked by Date 28.03.2004DRG. NO. RDM5008/1 IF IN DOUBT ASK LIMITED ES. IMPEDANCE VOLTS % , SERIAL NO., YEAR OF MANUFACTURE WILL BE ENGRAVED AFTER TESTING ANO BEFORE DESPATCH & ® save no i (GByerenee” MALANPUR COPPER WOUND TRANSFORMER TO INDIAN STANDARD 2025-1977 Kwa 7250] TYPE oF COOLING ONAN VouTs AT .v [11000] FREQUENCY 30 HE No LOAD. Lv. 433, IMPEDANCE VOLTS. x HY, GORE AND WINDINGS Kg [7730 Maree Uv[16657—| WEIGHT OF ol Ko | 785 Hass 3 TOTAL WEIGHT Ky [ 4000, DIAGRAM ORG. NO. [ROWSODB7T) OlL 1 900, MAKER'S SERIAL No. [M5008 _| YEAR OF MANUFACTURE [CUSTOMER'S REF KO. GUARANTEED MAX. TEMP. RISE IN OIL 50,C,0F WOG. 5$C BY RESISTANCE OVER AN ANBIENT TEMPERATURE OF 45°C. GREA\ ALL INFORMATION IN THIS COCUMENT TS CONFIDENTIAL & SHOULO NOT BE USED WITHOUT PRIOR CONSENT OF CROMPTON ‘swircn | switch | WH VOLTAGE ACROSS | LOW VOLTAGE ACROSS Posinion| conmects | wy vw | 20 avo No. VOUS AMPS” OUTS: AMPS T |S =s) 180 2_[s —7| 11975 [840 37 — +] 11000 | asa 2 [ee 0795 [ars 3s — $0050 [68:1 2 3 2 mu aw ‘BIL_OF_WINDINGS ‘ p . WA Ly. 7s ace [Ac z ae a 45} Mess 5 1 oo] >| ee 1 kw Hy. - 2 i 2NN2D OCW gy w v ei Byatt Law 1 1 1 CONNECTION SYMBOL lous tz 2 2 WILGT: 1066 /2A, 7.5VA, $5%RE Lv, GONNEGTION DIAGRAM NET : 300/54, 10VA, C1510. IMPORTANT I SCONN: FORMER FROM a @ BEFORE CHANGING SWITCH POSITION D 140 [70] 160 GENTOL. [MATL : STAINLESS STEEL] THIRD ANGLE PROJECTION CUSRANTEED (270 ALL DIMENSIONS IN MM sue! 15 TOLERANCE SPEC._MS-107 Scale FINSH RATING & DIAGRAM PLT. INITIALS 1250KVA,_11kV/433V_ (TR-01) BIRLA COPPER — 1960 LP RN. : a GI Crompton) ste | Greaves ICUSTONER CONNENTS 29-07 SWALIOR| ARE. INCORPORATED Ravi [APPD. MALANPUR : ZONE REVISION DATE | DATE — 2/7172005 ORG. NO. RDM5008/1BIRLA COPPER, DAHEJ 2 Rev T-960 LP OXYGEN PLANT ——— Sheet | 4 of 8 ELECTRICAL SYSTEM DESIGN BASIS > Doc No 2213-EL-BASIS | [Pate | June 2003 ~ KW will be 725 amps only. The full load current of [250 KVA transformer is 1740 amps on 415V side. Accordingly incomer ACB and busbars are rated for 2000 amperes. ‘The plant will also generate about 300 KW power at 415V through an induetion generator coupled to the turbine in the cold box. Since the induction generator is used, no special components for paralleling are required and the induction generator will be provided with over current and earth fault protection. Heater Transformer The plant process includes nitrogen gas heaters and the heating is achieved normally by means of permanent steam heater. In addition, the plant will be providediwith 2 nos 860 KW electrical heaters. These electrical heaters will mostly function as standby heaters to the steam heaters and sometimes, will also be operated to supplement steam heaters in case of any operational problems in the steam heater, such as low steam supply pressure, ete ‘The standby heater load is isolated from the main auxiliary transformer and is fed from a dedicated 2500 KVA transformer. The capacity is sufficient to take care of some thyristor loads in the heater control panel, which may control about 50% of the total heater capacity. Single Line Diagrams Drawings 9-001-00-50 sheets 1 and 2 submitted separately show the single line diagrams for 11 KV and 415V Power distribution covering the loads enumerated above. The SLD’s outline the feeders of 11 KV switchgear, 41SV PMCC along with the metering and protection envisaged. 11 KY Switehgear The 11 KV panel will be provided with VCB’s having required 40KA/ 3sec short circuit rating. Incoming, transformer and motor feeders will be protected with numerical type protection relays (Siemens Type 7SJ series) and the power consumption will be monitored using Enercon EM3360 meters. Starting of 11 KV motors and voltage dip Following factors are considered to keep the voltage dip within acceptable values on the source side while starting the biggest 7750 KW motors. a) Motor Locked Rotor (Starting) Current limited to about 470» including tolerance. b) Motor will be stared at reduced voltage using autotransformer at 75% tap. Following calculation ives the voltage dip while starting the 7750 KW motor.Doc No 2213-EL-BASIS BIRLA COPPER, DAHEJ ——eerre ‘T-960 LP OXYGEN PLANT Rev 4 [Shest 5 of8 ELECTRICAL SYSTEM DESIGN BASIS | 5. une 2003) ‘System Minimum short circuit MVA (15 KA) $= 11 X 15 X 1.732 = 285 MVA Motor full load current 463 amps Motor Base MVA My = 11 X 0.465 X 1.732 =8.86 MVA Voltage Dip V. using autotransformer will be i T¥S7[M(a+Z yy) Where, a= Magnetizing inrush multiplier for auto transformer = 0.2 Z. = Tap position on auto transformer = 0.75 y= Starting Current multiplier = 4.7 Applying the appropriate values, Voltage Dip while starting 7750 KW motor = 1 / {1 + 285/ [8.86 * (0.2 +0.75°*4.7)}} 1/14(285/25.196) = 8.11% The autotransformers will be provided with additional tap at 80% and exact tap will be selected based on the plant voltage conditions at the time of commissioning. System power factor improvement The induction motors will have about 0.89 power factor at the estimated operating load of 5800 KW (75% of motor rating) as per data guaranteed by the supplier. 2 nos 11 KV, 750 KVAR capacitor banks are considered to get more than the desired 0.9 power factor as per the calculations below. Normal motor operating load: S800 KW Load power factor: 0.89 (75% load) & 0.90 (100% load) Desired improvement: 0.96 (To take care of negative tolerances) Capacitor factor (As per standard tables): 0.221 (0.89 to 0.96) and 0.193 (0.90 to 0.96) Preferred capacitor rating/motor 5800 X 0.221 = 1282 KVAR OR 0 X 0.193 = 1496 KVAR Further the capacitor rating shall be chosen based on the no load (magnetizing) current of the motor. The motor no load current is about 100 amps and limiting the capacitor current to about 90% of magnetizing current. the capacitor value shall be around 1700 KVAR. Accordingly 2 sets of 750 KVAR capacitor banks are chosen per motor and four sets of capacitor banks will be installed for the two motors. Each capacitor bank will be installed indoors with load break switch and fuse