Chapter - 1 Organisation Profile: "Environment Management", OHSAS 18001 For "Safety Management"
Chapter - 1 Organisation Profile: "Environment Management", OHSAS 18001 For "Safety Management"
ORGANISATION PROFILE
1.2 MINES – IA
Mine –IA is adjacent to the existing Mine-I block on the eastern side. The
project was commissioned in 2001. The total reserve in Mine-IA is 120
million tonnes in an area of 11.6 sq.km. The annual capacity of this mine is
3 million tonnes and lignite was first exposed in March 2003. This mine
feeds lignite to M/S ST-CMS, an independent Power project 250 MW and
NLC’s Thermal Power Station.
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1.3 THERMAL POWER STATION - I
The power generated from The Thermal Power Station is fed to the grid of
Tamilnadu Electricity Board, the sole beneficiary.
This Power Station consists of two units of 210 MW each. The first unit of
this Power Station was synchronized on 21.10.2002 and the second unit on
22.07.2003. The power generated from this Power Station is shared by
Tamilnadu, Kerela, Karnataka and Pondichery.
3
Some of the special features of this power station are:
1.5 MINES - II
4
1.6 THERMAL POWER STATION-II
The First Stage units are fully of foreign origin. Boilers are of M/s EVT
Germany design and manufactured, supplied and erected by M/S Traselectro
of Hungary. Turbines are of M/S Westing house U.S.A design and
manufactured, supplied and erected by the erstwhile M/S Franco Tosi of Italy
(now merged with M/S Ansaldo of Italy). Generator is of Ercole Marelli, Italy’s
supply. Stage-II units are fully of M/S BHEL’s supply even though the Boilers
are of M/S EVT Germany’s design, Turbines are of M/S KWU Germany’s (a
Siemens subsidiary) design and Generator is of Russian design. 9014.04
Million units of Electricity can be generated per annum from this power station
at 70% annual plant load factor; but the actual production figures in recent years
are much higher.
5
1.6.1 SWITCH YARD – TS II
The bus arrangements in switchyard are 2 Main bus and 1 transfer bus system.
There are 3 system buses in 230kV and 400kV yard namely First Bus, Second
Bus and Transfer Bus. Each bay is meant for each equipment to connect with
any one bus. The bay consists of first Bus isolator (89A), Second bus isolator
(89B), Line isolator (89C), Transfer Bus Isolator (89 D, Breaker, current
Transformer, Capacitance Voltage Transformer, Lightening arresters, Breaker
earth bus side (89E1), Breaker earth line side (89 E2), Line earth (89E3) etc.
Each bay has respective control panel and relay panel in control room. Wave
Traps are provided in transmission lines except mining feeders for PLCC
purpose.
6
Isolator is an off load device. It can be operated only without load since it is not
having arc quenching medium. Isolator is used to select any one of the bus
system to the element and also for perfect isolation of breaker.
Breaker is an on load device. It can be operated either with load or without load.
Through the breaker only the element is charged or isolated. The breaker is an
fast acting device During fault the protection relays senses the fault and trips the
breaker. The faulty equipment is isolated from the system by tripping of
respective breaker.
2 Nos. of Tie line (Tie Line 1 and Tie Line 2 ) feeder bays are inter
7
linking Thermal Power station 1 and Thermal Power Station 2
Station
Kadalangudy bay is to connect the TNEB sub station at
Kadalangudy
Puducherry feeder bay is to connect Villianur sub station in
Puducherry.
Bhahoor feeder bay is to connect Bhahoor sub station in Puducherry.
Inter connecting Transformer 1 and Interconnecting Transformer 2
any one bay main breaker to Bus Transfer breaker without supply
400kV SYSTEM
8
4 Nos. of Generator bays for stage 2 units.
9
The following projects are proposed to be taken up by NLC during the 11th
/12th Plan period :
Bithnok Lignite Mine-cum-Power Project ( 2.1 MTPA Lignite Mine
with linked 250 MW Power Plant)
Hadla Lignite Mine-cum-Power Project (Barsingsar Extension) ( 2.5
MTPA Lignite Mine with linked 250 MW Power Plant)
Jayamkondam Lignite Mine cum Power Project ( 13.5 MTPA Lignite
Mine with linked 1600 MW Power Plant)
Valia Lignite Mine cum Power Project at Gujarat ( 8 MTPA Lignite
Mine with linked 1000 MW Power Plant)
A 15 MTPA Coal Mine under Joint Venture with MCL and a 2000
MW Power Plant in Ib valley in Orissa.
NLC’s New Thermal Power Project at Neyveli ( 2 X 500MW ) in lieu
of TPS-I.
Mine – III linked with TPS – III ( 8 MTPA Lignite Mine and 1000
MW Power Plant) at Neyveli.
Coal based power project at Madhya Pradesh (1000 MW Power Plant)
Coal based power project at Jharkand (1000 MW Power Plant)
Coal based power project at Uttar Pradesh (2000 MW Power Plant)
Fund requirement of the above projects will be met from internal accruals and
borrowings. Upon successful completion of the above projects, NLC’s mining
capacity will be increased to 79.70 MTPA, ( both Lignite and Coal ) and power
generation capacity will be raised to 14740 MW.
CHAPTER 2
CONTROL AND INTERLOCKS
2.1 ISOLATORS AND INTERLOCKS
10
2.1 i INTRODUCTION
The Isolators are OFF LOAD electrical device in the 230 KV and 400 KV
Switchyard. There are 3 different types of isolators available in the switchyard. All
the isolators both bus and line in 230Kv side are of Double break center operated.
All the bus isolators in 400Kv side are of Pantograph type. The line isolators in
400Kv side are of center break type. All the isolators are motor operated. All the
power contactors, switches, fuses, limit switches, aux. contacts, motor with gear
assembly etc. are housed in the Motor Operated Mechanism (MOM) box.
The motor operated isolators can be operated remotely from control room or from
the local MOM box electrically by selecting the local / remote accordingly only
when certain interlocks (conditions) are satisfied.. Normally this switch is set for
remote operation only. In case of failure of remote operation or for test purposes
local operation is done. A fly back control switch is provided in the control panel
for operating the isolators. The green lamp in the control panel will glow indicating
that the isolator is open. A red lamp would indicate the closed condition of the
isolator.
11
normally act as stopper for the insertion of manual operation handle.
The manual operation handle can now be inserted through the opening provided
for and turned, to close or open the isolator. After the manual operation is carried
out the castle key is to be put back in position and turned in the clockwise direction
restoring the condition needed for remote/local operation by electrically.
The interlocks are implemented for safe guarding the equipments and for personal
safety. The isolator can be closed / opened electrically, only when certain interlocks
(conditions) are satisfied.
For 230Kv bus isolator 89A i.e. I bus isolator can be opened eclectically
from remote if the following conditions are satisfied.
a. KIMC (Key interlock main coil) key i.e. isolator manual operation
key shall be in the front panel of the MOM box and turned 'ON'.
The I bus isolator (89A) can be closed electrically from remote if the following
conditions are satisfied along with the above mentioned conditions (a to f). (If the
element is being taken in to service from shutdown).
charged condition.
If the element is already in service on transfer bus then 89A can be opened if
transfer bus isolator (89D) is in closed condition, bus transfer isolator (89TrA) in
closed condition along with the above mentioned conditions ‘a to e’. If the element
is already in service on transfer bus then 89A can be closed if transfer bus isolator
(89D) is in closed condition, bus transfer isolator(89TrA) in closed condition and
the above mentioned conditions ‘a to e’ and “g&h’.
For both the opening and closing operations 3phase AC and 220V DC switches
shall be in ON condition along with fuses. Fuse rating for 220V DC is 2A and for 3
phase AC is 4A. As soon as closing command is given from remote, Bus Bar
Protection CT switching relay 89AX (In CTMK) will pickup and extend DC
supply to the closing contact in MOM box.
The open indication of 89A will vanish immediately as soon as command is given
provided all the above interlocks are satisfied. Close indication is in series with
89A aux. Contact (NO) and 89AX(NO). When aux. contacts have changed while
closing, 89AY relay will pick up (In relay panel).
The open indication will come when the aux. Contacts are changed and 89AX is
reset. The open indication is in series with aux. contact (NC) and 89AX (NC).
When aux. contacts have changed while opening, 89AY relay will reset. This 89AY
relay is used for isolator contact multiplication purpose. A typical control circuit
for a 1st bus isolator is shown in fig 1.1.1
13
89A ISOLATOR CONTROL CIRCUIT
+ve -ve
220V DC SUPPLY
J 23
4A K23
2A
89BY K537 89BCX K549
K49 89AX
K551 O NC 89A
LR K51
RC
OC LSC
K31 CC K33 OC K43 K47
K45
CC
89E1 K571 89CVTA K531 K63
89AX-
MSC
K35
PBC O NC
CC
K539 K541 89AX
L R
K547
FS J FS29
J6
8
2A 4A
L253
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2.2 BREAKER CONTROL CIRCUIT
There are two types of breakers available in the 230/400 Kv yard; one is gang
operated and another is individual pole operated. In the gang operated type all the
three poles are controlled by a single operating mechanism. In the individual pole
type, each pole will have its own operating mechanism. At switchyard three
different types of operating mechanisms are available. One is Spring Charging
mechanism, another is Hydraulic mechanism (oil) and the third one is Pneumatic
(air) mechanism.
Each breaker irrespective of the type will have one number Closing coil (CC) and
two numbers of Tripping coils(TC1 & TC2). Since opening of the breaker in case
of a fault in the system is more important as a redundancy two nos. of Trip coils
are provided. Each TC will be monitored for its healthiness by Trip coil
supervision relays (95,195). When the breaker is in open condition two relays will
monitor the TC healthiness via breaker NC aux. Contact. When in service one
relay will monitor the TC healthiness via breaker NO aux. Contact. When there is
any problem in the TC then its circuit supervision relay will sense and give alarm.
These trip coil supervision relays contacts are used in the closing circuit interlock
of the breaker. If any TC is unhealthy then the breaker will not close.
Breaker can be closed from the remote when the following interlocks are satisfied.
2. All the trip relays 86, including the Bus Bar protection relay 96 are in reset
condition.
If any protection relay senses the fault and initiates a tripping via trip relay contacts
then the breaker TC1 & TC2 will pickup and breaker will open. If the breaker fails
to open even after receiving tripping signal then the fault will not get cleared and
lead to unwanted damages to other related equipments. To avoid such things one
backup protection for the breaker is available which is called Local Breaker
Backup protection (LBB) .
When the element is in service all the three phases current will be passing thro’ the
LBB relay. As soon as the trip relay picks up one of its contact will extend DC
supply to the trip coils. Simultaneously one more contact of the trip relay will
extend the DC supply to the LBB relay. As soon as DC supply is extended to the
LBB relay, the LBB relay will pickup and initiates a timer 2/50Z, which starts
counting 200ms. The TC1&TC2 will pickup as soon as DC supply was extended to
them and breaker will open. When the breaker opens the current thro’ the LBB
relay will become zero and the timer 2/50Z resets. But if the breaker did not open
then the current in that pole will be flowing thro’ LBB relay and after 200ms time
was lapsed the timer 2/50Z will pickup and initiates a contact in the Bus Bar
Protection DC circuit which in turn trips all the elements connected that bus where
the faulty breaker was connected. When all the elements connected to the bus
including the Bus coupler opens then the corresponding bus will become dead the
fault will be cleared. Maintenance personnel can access the breaker, which was not
opened and can start working.
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2.3 FEEDERS DISTANCE PROTECTION
2.4 i INTRODUCTION
BBP is provided for bus faults like flashover at the isolators, at the circuit breaker
bushings, CT and PT faults. A large proportion of bus bar faults results from
human error rather than a switchgear components failure. It also covers the failure
of insulators of isolators and breakers during operation and mal-operation of earth
switches.
Whenever an element is connected to the 1st bus or 2nd bus or Transfer bus
accordingly CT switching relays 89Ax or 89BX or 89Dx housed in the CT
Marshalling Kiosk of the respective bay in outdoor yard will pickup. CT secondary
of the BBP core 4 will be connected to the Main Zone differential relay circuits
Zone A, Zone B or Zone C through the 89Ax or 89BX or 89DX relay contacts.
BBP Core 5 will be directly connected to the Check Zone Differential relay
circuits. This check zone is to ensure that the fault has really occurred in the bus.
For bus coupler Breaker tripping, the BBP core of the B/C CT on the 1 st bus side
of the breaker will be connected to Zone-B and the BBP core of the B/C CT on the
2nd bus side of the breaker will be connected to Zone-A. For the transfer bus main
zone core is connected to zone-A or zone-B through 89TRAx or 89TRBx and core
2 is connected to zone-C.
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2.4 iv OPERATION OF BBP
During normal operation secondary current will circulate in the zone and there will
not be any differential current passing thro' differential relay 87. In case of fault
the differential current flow thro' the respective relays which will initiate in case of
open circuit of any one of the CTs or when the unbalance current increases due to
the saturation of the any of the CTs differential current will flow thro' differential
relays which will initiate unnecessary tripping. To avoid mal operation like this
BBP supervisory relays 95A,B,C and CH are provided. These relays are connected
parallel to the differential relay 87. For low differential current flow thro' 87 & 95,
95 relay picks up earlier than 87 relays which will short the differential relay 87
after a time delay. An annunciation “Bus Bar Protection Zone A/ B /C Faulty “ will
come. Immediately the concerned element has to be checked and problem shall be
corrected otherwise till 95 relay is in picked up condition Busbar Protection of that
zone will be out of service. But when actual fault comes the diff.current flow will
be high and 87 picks up faster than 95. The diff. Relay 87 picks up instantaneously
before 95 relay shorts this relay. The connections of the BBP circuits are shown in
the fig.2.4.1 to 2.4.3.
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In case LBB operates for anyone of the elements 2/50z and 50z will initiate BBP.
87 CH check zone differential relay which get energized from separate CT core to
ensure that really a fault has occurred and BBP should not act for false pick up of
the main zone 87A, 87B, 87C differential relays. If the 87C Check Zone relay is
not available then for any false pick up of the Zone A,B,C differential relays
87A,87B or 87C the BBP will act.
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TYPICAL TYPICAL
UNIT BUS I FEEDER BUS I
BUS II BUS II
TRANSFER BUS TRANSFER BUS
52 52
TTB2 TTB2
89C
TTB1
TTB1
89AX 89AX
ZONE 1 BUS B
WIRES
C
89BX 89BX
A
ZONE 2 BUS
WIRES B
89DX 89DX
A
ZONE 3 BUS B
WIRES
C
B
CHECK ZONE
BUS WIRES C
Fig : 2.4.1 BBP ZONE 1,2,3 & CHECK ZONE CT CONNECTION DIAGRAM
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A B11 A B15 A B21
ZONE I
Z O N E II
B B31 B41
W IR E S
B B35 ZONE III B
WIRES
C B51 C B55 WIRES C B61
N B81 N B81 N B81
95CAX 95CBX 95CCX
9
9 9
5 5
5
25-325V C C
25-325V C 25-325V
87 87 87 B 87 87 87 C
87 87 87 A
AC BA BB BC CA CB CC
AA AB
IN OUT IN OUT
IN OUT
A
B
Check Zone wires C
N B81
95CX
10-70V
9
5
25-325V C
87B
87A
CH
87C H
CH CH
IN OUT
- Ve
P11
P13
P15
TRANSFER BUS
COUPLER
CC
CC
CC
96
96
96
2/50Z
96
ABC
50Z 2/50Z
89TRBX 96 96 96
AB AB AB
89TRAX 96
C
89DX TYPICAL ICT.
50Z 2/50ZX
89BX 96 96 96
89AX 96
C
89DX
TYPICAL G.T
50Z 2/50ZX
89BX 96 96 96
89AX
97
C
89DX
96
X
I II B/T 50Z
TYPICAL
89BX FEEDER
96 96 96
+ve
89AX
96 96 96
B B B
C C C
2/50Z
B B B
50Z
2/50Z
96 96 96
B B B P2
C C C
A A A
OUT
P15
P13
P11
Zone C
IN
87CC
OUT
87CB
P9
Zone B
87CA
IN
OUT
CHECK
87BC
P7
P3
IN
OUT
87BB
Zone C
87BA
IN
P1
87AC
P5
87CHC
P3
87CHB 87AB
87CHA 87AA
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