A Report On Eletrical Maintenance in HPCL
A Report On Eletrical Maintenance in HPCL
A Report On Eletrical Maintenance in HPCL
HPCL Vishakh refinery was established in 1957 and was subsequently merged with ESSO which was multinational oil company of USA, which was setup in Mumbai and came with a new origin Hindustan Petroleum Corporation of India Limited (HPCL) in 1998. Electrical maintenance is one of the most crucial aspects in the refinery to ensure good productivity, reliability and safety against fire hazards. The industry thus employs one of the most advanced forms of maintenance techniques, i.e., IR Thermography, Vibration Health Analysis, etc This report of the project shows an overview of the employed maintenance techniques.
BACHELOR OF ENGINEERING
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ACKNOWLEDGEMENT
We would like to thank Mr. S.K.Mishra, Sr. Manager-Training, for accepting our request for industrial training at HPCL, Visakh Refinery.
We express our deep sense of gratitude and respect to Mr. N.Rajarao, Chief Manager, and Maintenance Electrical.
We heartily thank B.Jayanth Rao senior Manager, Planning Electrical for giving us enthusiastic support and guidance. We express our thanks to Mr. B.J.Benhar Babu, Manager Maintenance, Mr.Rama Chadra Rao Deputy Manager, Mr.nikki Agarwal Deputy manager, Mr. Pritam Majamder Engineer for guiding us with great attention, care and providing vital support at HOCK, Visakh refinery.
About HPCL
HPCL is a fortune 500 company, with annual turnover of Rs 1,16,428 crores and sales/income from operations Rs 1,31,802 crores ( US $25,618M) during FY 2008-09, having about 20% marketing share in India and is strong market infrastructure. Corresponding figures for FY 2007-08 are is to turnover of Rs 1,03,837 Crores and sales/ income fr4om operations of Rs 1,12,098 Crores ( US $ 25,142M).HPCL operates two major refineries producing a wide variety of petroleum fuels and specialties, one in Mumbai (West coast) of 6.5 million metric tons per annum (MMTPA) capacity and the other in Vishakhapatnam, (East coast) with a capacity of 7.5 MMTPA. HPCL holds an equity state of 16.95% in Mangalore refinery and p0etro chemicals limited, in state-of-the-art refinery at Mangalore with a capacity of 9 MMTPA. In addition, HPCL is constructing a refinery at Bhatinda, in state of Punjab. HPCL also owns and operates the largest lube refinery in the country producing lube based oils of international standards, with a capacity of 335 TMT. This lube refinery accounts for over 40% of Indias total lube base oil production. Presently HPCL produces over 300+ grades of lube, specialties and greases.HOCK s vast marketing network consists of 13 zonal offices in major cities and 90 regional offices facilitated by a supply and distributio0n infrastructure compressing terminals, aviation service station, LPG bottling plants, and an inland relay depots and retail outlets, lube and LPG distributorships . HOCK, over the years has moved from strength to strength on all fronts the refining capacity sturdily increased from 5.5 MMTPA in 1984/85 to 13 MMTPA presently. On the financial fronts, the turnover grew from RS 2687 Crores in 1984-85 to an impressive Rs. 1, 16,428 crores in FY 2008-09. HPCL has an Excellent performance for fifteen consecutive years up to 2005-06, since signing of the first MOU with the ministry of petroleum and natural gas. HPCL won the prestigious MOU award for the year 2007-08 for excellent overall performance.
Vishakh refinery:
Rapid worldwide industrialization and scientific advancements has resulted in continuously raising energy requirements in all sectors e.g. industries, transport etc. petroleum being one of the major source of energy there is a pressing need for increasing the production of the crude oil as well as the desire fuel production. Concerted efforts are being made for maximizing the crude oil production from oil fields. As a result, quality of crude becomes heavier day by day. A simple distillation of crude oil is not sufficient and economical top meet the demand of the petroleum products esp due to the increasingly heavy nature of crude oil producing using the modern advanced
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method of crude production. Hence the refineries are required to adopt Bottom of Barrel Processing Concept for meeting the product demand. In the context, vishakh refinery was established in 1957 and was subsequently merged with ESSO which was multinational oil company of USA, which was setup in Mumbai and came with a new origin Hindustan Petroleum Corporation of India Limited (HOCK) in 1978. Over the year the capacity of the refinery was increased to 1.5 MMTPA by debottlenecking units. The major refinery capacity augmentation was taken up in 14985 by commissioning separate streams of 3.0 MMTPA crude distillation units ( CDU-2), fluidized catalytic cracking unit ( FCCU-2), crude oil receiving facilities at high seas ( Offshore tanker terminal ) and associated tankage and product dispatch facilities. Thus the installed capacity has increased to 4.5 MMTPA. The facilities came up in 1985 were the state-ofthe art control system for the better and efficient operation. An order to cater to the increased LPG consumption, the refinery works instrumental in developing first LPG import facilities on the eastern coast in 1987. As a step towards surmounting the frequent power distribution and improve reliability of utilizes a Captive Power Plant (CPP) of 14 MW capacity was widening its product range commissioned Propylene Recovery Unit (PRU) in 1992. In order to adhere to stringent environment norms the refinery had setup Effluent Treatment Plant (ETP) in 1993 and sulphur recovery unit (SRU) in 1994. With the second major expansion project VREP-2 completed in 1999 crude processing capacity increased from 4.5 MMTPA to 7.5 MMTPA and secondary capacity increased from 1.51.6 MMTPA. To meet the stringent diesel fuel specification, Diesel Hydro De Sulphurisation unit (DHDS) was also commissioned in 1999 /2000. To meet additional power requirement of these new units, CPP capacity was augmented by 40 MW in 1999, increasing total power generation capacity to 58 MW. It is a crude oil processing refinery having a capacity of 7.5 MMTPA. The processing units include crude units, fluidized catalytic cracking units, propylene recovery units and treating units like DHDS and SRU. The total load of the existing refinery is about 39 MW. This load is being met by the HPCL with the help of four gas turbine generators and heat recovery steam generators. The combined power and steam output of steam generating units and the HRSGs at fight conditioned is about 54 MW and 174 TPH of MP steam respectively. The HPCLs present power and steam requirements are met by following in-house GTGs and HRSGs. 2x9MW FRAME-3, GTG 1 and 2 with HRSGs installed in 1990 2x20MW FRAME-5, GTG 3-6 with HRSGs installed in 1999. Apart from the captive generators, HPCL has two AP TRANSCO grid incomers at 132 KV level. 11KV supply is derived by two numbers 16/20MVA, 132/KV grid transformers.
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The present contract demand with APTRANSCO in 13MVA at 0.9pf. HPCL is currently using grid as hot standby and the grid incomers are not paralleled with the GTGs under normal operating conditions. The refinery is located at latitude of 1741N and longitude of 8317 E on an area taken on a 99 years lease from Vishakhapatnam port trust.
Table of contents:
Introduction About HPCL 1 Chapter 1: Electrical Maintenance What is electrical maintenance? Types of electrical maintenance Breakdown maintenance Preventive maintenance Predictive maintenance Methods used in predictive maintenance thermography Motor current signature analysis Equipment health analysis Tan delta test Cable fault locating analysis y Surge generator Digital time domain reflectometer y Indicator Digipoint y Cable route tracer High potential test Chapter 2: captive power plant Introduction Step-up sequence of CPP CPP facilities Gas turbines 20 20
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4 5 5 6 6 7Infrared 7 8 9 11 12 13 13 15 15 17
19 19
Theory of GTG Generators Generator details Functional description Basic cycle Gas turbine equipments Air inlet equipment Compressor section 26 24
20 22 23
24 24 25 25
Rotor assembly Stator Fuel system Diesel system Naphtha valve Brushless generator- basics Automatic voltage regulator Heat recovery steam generator
26 28 29 29 29 30 31
Chapter 3: power distribution in HPCL Substations Switch gear Bus Power transformers Sub Motor control centre Power control centre Single line diagram of power distribution in HPCL Direct online starters in SS-50 Variable frequency drives 37 38
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32 33 34 35 36 36 36
Variable frequency motor Variable frequency controller Dynamic breaking Rectifier in VFD Bibliography 41
39 39 40 40
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11
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easier planning of maintenance and ordering spares, costs are distributed more evenly, No initial costs for instruments for supervision of equipment.
Disadvantages are:
less reliable than equipment with CBM More expensive due to more frequent parts change.
process control to determine at what point in the future maintenance activities will be appropriate. Most PdM inspections are performed while equipment is in service, thereby minimizing disruption of normal system operations. Adoption of PdM can result in substantial cost savings and higher system reliability. To evaluate equipment condition, predictive maintenance utilizes nondestructive testing technologies such as infrared, acoustic (partial discharge and airborne ultrasonic), corona detection in combination with measurement of process performance, measured by other devices, to trigger maintenance conditions. This is primarily available in Collaborative Process Automation Systems (CPAS). Site measurements are often supported by wireless sensor networks to reduce the wiring cost.
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AC Motors and Alternators IDC Motors and Generators Single and Three phase systems Eddy-Current drives Variable Frequency Drives Incoming power quality
machinery. Because of this technique Maintenance Partners offers a powerful tool for detecting damages in early stage.
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That prevents the device under test from damages during the tan delta test and guarantees damage-free measurement.
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Surge Generator:
Instrument has been primarily designed to produce high voltage surges for pre-location of underground cable fault in combination with inbuilt Reflectometer. LCD Screen for Reflectometer.
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faults including open, short and intermittent faults by way of ICM, Decay & ARM Method.
Indicator digipoint:
The DIGIPOINT is an easy to use, dual channel Digital Acoustic Fault Locator. It is used in conjunction with a Surge Generator to determine the exact position of faults in
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underground power cables. The instrument also indicates the cable by sensing and amplifying the electromagnetic signals produced at the time of surges.
Fig: Digiphone
The DIGIPOINT consists of two units the Acoustic transducer or pickup and the amplifier unit with head phones. The unique feature of DIGIPOINT provides a relative distance indicator with digital coincidence figure readout. This feature is very helpful for the operator in pinpointing the exact location of fault.
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Four modes of operation for accurate locates, even in congested areas: For cable path locating, the receiver uses one of four user selected locating modes dual peak, dual null, differential or special peak (which increases the sensitivity of the receiver for tracing over longer distances). The mode is selected depending on which is most effective under the locating conditions. The receiver includes four volume settings, including a special expander function that makes peaks and nulls more pronounced. The expander feature enhances the amplitude difference between two conductors carrying the same signal, making the unit extremely accurate, even in congested areas. A headphone jack is also included. The Advanced Cable Locator is easy to operate and requires very little training. Digital liquid crystal display (LCD) readout and push-button operation make the unit easy to understand, for more precise locates. A memory feature remembers operator set-up from previous use. The system consists of two basic components: Transmitter with built-in ohmmeter, which also senses and measures the presence of foreign voltage, and tests the continuity of the circuit. One-piece hand-held receiver with bar graph that indicates received signal and proximity to the cable. The cable locator uses four active trace frequencies - 577 Hz, 8 kHz, 33 kHz and 200 kHz which can be used individually or simultaneously to compensate for varying field conditions.
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required by safety agencies to be performed as a 100% production line test on all products before they leave the factory. Insulation Resistance Test This test is used to provide a quantifiable resistance value for all of a product's insulation. The test voltage is applied in the same fashion as a standard Hipot test, but is specified to be Direct Current (DC). The voltage and measured current value are used to calculate the resistance of the insulation.
Chapter 2
Captive power plant:
The power requirement of HPCLVR was earlier being met from APSEB. However frequent interruption in power supply were observed which causes crude through put loss, damage to equipment, fire hazard and unscheduled shutdown. With the above in view APSEB permitted HPCL, to install CPP. The CPP commissioned in 1991 is bussed on cogeneration of power and steam, leading to more energy efficient use of fuels as compared to a conventional power plant. The project step-up includes number of 9 MW Capacities (ISO) gas turbines generators (GTGs) along with two numbers heat recovery steam generators (HRSG) of 2.94 T/HR at 15 at 256 Centigrade in unfired condition at GTG base load. For that in view of VR expansion process from 4.5 MMTPA to 7.5 MMTPA and to meet the power requirement of refinery another set to GTGs of generating capacity to 25MW (ISO) each along with two number of HRSG of 60 T/HR at 15 at 280 centigrade in unfire3d condition at GTG base load another auxiliary equipment are installed on a part of VREP-H during 1999-2000 at a cost of RS.150 crore approximately.
y y y y
y y y y
The lock up- solenoid 20DA-2 energies and the DE speed is held constant at 1800 rpm. At 18% of HP speed, cranking status is displayed on mark-IV up to 25% of HP speed is cranking. Purging timer T2TVSC starts when cranking is displaced and times out after 60 seconds. Diesel stop value opens and firing timer T2F starts and time allow for flame detection in 60 seconds (if within 60secs. No flame is established machine go back to cranking). The turbine warms up for 60seconds (T2W). At about 52% HP speed jaw clutch disengages and LP shaft starts rotating. After 5mins diesel engine stops. From 80% HP and LP shaft speed exceeds HP.
CPP facilities:
The major facilities implemented in CPP are as follows
Gas turbines:
1&2
These are complete package units with enclosure for whether protection, thermal and acoustic insulation. The individual unit houses gas turbine, load gears box and electrical generator. The operating speed of a gas turbine is 6000rpm and the trip speed is 7150rpm.
3, 4, 5&6
The operating speed is 5100rpm. When the turbine starting system is actuated and the clutch is engaged, ambient air is drawn through the air inlet assembly, filtered aand compressed in 17 stage axial flow compressor. Compressed air from the compressor flows into the annular space surrounding ten combustion chambers, from which it flows into the space between the outer combustion gasing. In the combustion liners and enters the combustion zone through the metering poles in each of the combustion liners.
Theory of GTG:
Gasses passing through an ideal a gas turbine undergo three thermodynamic processes. These are isentropic compression, isobaric (constant
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pressure) combustion and isentropic expansion. Together these make up the Brayton cycle. In a practical gas turbine, gasses are first accelerated in either a centrifugal or radial compressor. These gasses are then slowed using a diverging nozzle known as a diffuser; these processes increase the pressure and temperature of the flow. In an ideal system this is isentropic. However, in practice energy is lost to heat, due to friction and turbulence. Gasses then pass from the diffuser to a combustion chamber, or similar device, where heat is added. In an ideal system this occurs at constant pressure (isobaric heat addition). As there is no change in pressure the specific volume of the gasses increases. In practical situations this process is usually accompanied by a slight loss in pressure, due to friction. Finally, this larger volume of gasses is expanded and accelerated by nozzle guide vanes before energy is extracted by a turbine. In an ideal system these are gasses expanded isentropically and leave the turbine at their original pressure. In practice this process is not isentropic as energy is once again lost to friction and turbulence. If the device has been designed to power to a shaft as with an industrial generator or a turboprop, the exit pressure will be as close to the entry pressure as possible. In practice it is necessary that some pressure remains at the outlet in order to fully expel the exhaust gasses. In the case of a jet engine only enough pressure and energy is extracted from the flow to drive the compressor and other components. The remaining high pressure gasses are accelerated to provide a jet that can, for example, be used to propel an aircraft.
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ceramic, or other materials that make up the engine to withstand high temperatures and stresses. To combat this many turbines feature complex blade cooling systems. As a general rule, the smaller the engine the higher the rotation rate of the shaft(s) must be to maintain tip speed. Blade tip speed determines the maximum pressure ratios that can be obtained by the turbine and the compressor. This in turn limits the maximum power and efficiency that can be obtained by the engine. In order for tip speed to remain constant, if the diameter of a rotor is reduced by half, the rotational speed must double. For example large Jet engines operate around 10,000 rpm, while micro turbines spin as fast as 500,000 rpm. Mechanically, gas turbines can be considerably less complex than internal combustion piston engines. Simple turbines might have one moving part: the shaft/compressor/turbine/alternative-rotor assembly (see image above), not counting the fuel system. However, the required precision manufacturing for components and temperature resistant alloys necessary for high efficiency often makes the construction of a simple turbine more complicated than piston engines. More sophisticated turbines (such as those found in modern jet engines) may have multiple shafts (spools), hundreds of turbine blades, movable stator blades, and a vast system of complex piping, combustors and heat exchangers. Thrust bearings and journal bearings are a critical part of design. Traditionally, they have been hydrodynamic oil bearings, or oil-cooled ball bearings. These bearings are being surpassed by foil bearings, which have been successfully used in micro turbines and auxiliary power units.
1&2: Generators which converts mechanical energy is rated for 11.2MVA at 0.8,11kv,3phase ,50hz , 4-pole machine which runs at a speed of 1500rpm . the generator is coupled with the gas turbine through the load gear box which reduces gas turbine of 6500rpmto 1500rpm. Dc excitation current is fed to generator rotor winding Using brushless excitation system. Automatic voltage regulation keeps the output voltage constant. The generator is protected by appropriated relays against over current, short-circuits and earth faults etc. the generator winding is cooled externally using forced air cooling system. the generator is enclosed within a metal using forced air cooling systems . the generator is enclosed within a metal enclosure which is protected by co2 extinguishing system against possible electrical fires. 3, 4, 5&6: The generator is rated at 27.388mva at 0.8pf, 11kv, 3-phase, 50 Hz. The generator is 2pole machine running at a synchronous speed of3000rpm. The turbine speed is reduced from 5100rpm to 3000rpm through a load gear box. The generators is provided with open air ventilation system consisting of air filter unit by 2 axial flow fans located on the rotor aft one at either end. The generator rotor is supported on 2 journal bearings lubricants by the turbine oil system
1. 2. 3. 4. 5. 6.
Make output rating rated frequency full load current P.F rated speed
The generators are provided with a brushless excitation which eliminates the provision of slip rings and brushes.
Functional Description:
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Definition of gas turbine: A gas turbine is machine or engine in which mechanical power in the form of shaft is produced when a steam of air rushes on the blades r by buckets of a wheel it turn round .
Basic Cycle:
A gas turbine operates by y y y y Continuously drawing in fresh air . Compressing thin air through a higher pressure Adding and burning fuel in the compressed air to increase its energy level. Directing the high pressure and temperature air to an expansion turbine converts the gas energy to mechanical energy of a rotating shaft. The resulting low pressure, low temperature gases are discharged to atmosphere
Compressor section:
The axial flow 15 stage compressor section consists of compressor rotor casing, and to exit guide vanes. In the compressor the air is confined to the space between the rotor
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and the stator blades where it is compressed in stages by an alternate series of rotting blades which supply the force needed to compress the air in each stage and the stator blades guide the air so that it enters the following rotor stage at proper angle. The compressed air exists through the compressor discharge casing through the combustion chamber. Air is also extracted from the compressor for the turbine cooling and for lube oil sealing at the bearings of the turbine.
Rotor assembly:
The compressor rotor is an assembly of 15 wheels two stub shafts assemblies, tie bolts and the compressor rotor blades and shafts are assembled by mating rabbets and secured by 12 tie bolts arranged concentrically around the rotor axis. The forward stub shaft contains the journal and the thrust number for the number one runner and the thrust bearing assembly, sealing surfaces for the bearing oil deflectors and compressor flow pressure air deflectors. The aft stub shaft contains for no.2 journal and thrust bearing assembly, the sealing surfaces for the bearing oil deflectors compressor highpressure air seal. The shaft wheel portion of the stub haft contains the first stage compressor rotor blades. The compressor rotor assembly is dynamically balanced before it is assembled to the unbalanced turbine rotor assembly. This complete assembly is then dynamically balanced.
Stator:
The stator (compressor casing) enclosed the compressor portion of the rotor and is divided into 4 sections; inlet casing, forward compressor, aft compressor and discharge casing. The inner section, which directs the flow of outside air from the inlet equipment
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to the compressor blades, contains no 1 bearing assembly and low pressure air seals. The forward section of the compressor casing is downstream of the inlet section contains the stator for stages 0 through 3. the aft section downstream of the forward section contains the stator blades for stages 4 through 9.
Combustion section:
The combustion section consists of 10 combustion chambers, fuel nozzles, cross fire tubes and transition pieces. The combustion chambers are arranged concentrically around the axial fuel compressor and are bolted to the compressor discharge section bulkhead. Air for combustion is supplied directly to the compressor to the combustion chambers. This arrangement is called a reverse flow system since the compressor discharge air flows forward around the liners and then enters and flow back towards the turbine. Fuel is fed into the chambers of the turbine section.
Turbine section:
In the turbine, high temperatures gases from the combustion section are converted shaft horse power. This section comprises of the following components
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1. 2. 3. 4. 5. 6. 7.
Turbine casing First stage nozzle Second stage nozzle First stage turbine wheel(hp turbine) Second stage turbine wheel(lp turbine) Diaphragm assembly Inter stage gas parts
Diesel engine:
The diesel engine starting motor (10hp, 125v dc) starts the diesel engine during startup procedures. The diesel engine lube oil pressure should be sufficient enough for startup. Diesel engine minimum speed sensed by pressure switch accelerating solenoid .The accelerating speed of the engine is nearly 2100rpm. The cooling for this engine is provided by CWM line.
Fuel system:
The turbine can use a variety of liquid and gaseous fuels, which may vary substantially in hydrocarbon composition, physical properties and levels of contamination. High pressure fuel pumps how dividers have substantially improved the reliability of these critical fuels. Naphtha fuel to the GTGs is from the two fixed cum floating roof tanks 183 A and 183 B each approximately. 2600KJL diesel system is from tanks 181, 182A each of approx 300KL. The fuel is pumped from the tank by fuel forwarding pumps. A
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pneumatic control bypass valve is provided in discharge of the pump for recirculation of fuel back to maintain discharge pressure. The fuel travels to the pressure controller where the pressure is controlled by pressure control valve (5.5-6 Kg/sqcm) with bypass valve from where it goes to the filter skid
Diesel System:
From the 25 micron dual filter skid, diesel goes through the trip oil operated stop value to reach main fuel pump. The servo controlled bypass value in the discharge line of the main fuel pump enters a 0.5 micron filter and then goes through the filter. The flow divided as six output ports each connected to a combustion chamber. The flow divider which is driven by input pressure itself distributes diesel at equal pressure to all combustion chambers through check values calibrated at 7kg/sqcm pop pressure.
Naphtha Valve:
The fuel from control valve travels two stages. Filtration consists of 25 microns and 6micron dual filter skid. Accumulated pressurized with nitrogen are provided upstream of a Naphtha control valve to take care of the pressure fluctuations in the system . Naphtha passes through the three way transfer valve and reached the PFD skid before naphtha change out takes place, diesel has to enter or pass through naphtha skid to chamber. the fuel after six micro naphtha filters enters naphtha PFD consists of a trip oil operated stop valve a screw pump with discharge of which is controlled by a servo operated by pass valve.
Brushless Generator-Basics:
The permanent magnet generator (PMG) is coupled to shaft of the generator. The PMG has a permanent magnet on its rotor. The stator has winding after star up of the turbine; the PMG is also rotating at the same speed as that of generator. The permanent magnet causes a magnetic flux in the air gap between stator and rotor in the PMG. The stator windings cut in this flux (on rotation) and thus an emf is reduced in the stator windings. This is at 220v, 75 Hz.
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The variable dc current output of the AVR is brought to the stator winding of the main exciter .This winding then induces a magnetic flux in the air gap of the exciter. The rotor winding as it is rotating at the speed of the generator cuts flux and thus there is an induced emf (ac) in the rotor. this rotor current is rectified by the diodes and the consequents direct current(dc) is then fed through cables which run inside the hallow shaft the generator to the main field winding of the generators since the diodes are mounted on the rotor of the exciter of the regular maintence of carbon brushes etc.
y y
The HRSG is designed based upon the specific features of the gas turbine or reciprocating engine that it will be coupled to. Since the exhaust gas temperature is relatively low, heat transmission is accomplished mainly through convection. The exhaust gas velocity is limited by the need to keep head losses down. Thus, the transmission coefficient is low, which calls for a large heating surface area. Since the temperature difference between the hot gases and the fluid to be heated (steam or water) is low, and with the heat transmission coefficient being low as well, the evaporator and economizer are designed with plate fin heat exchangers.
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Chapter-3
Power distribution system in HPCL:
The modern distribution system begins as the primary circuit leaves the sub-station and ends as the secondary service enters the utilities. A variety of methods, materials, and equipment are used among the various utility companies, but the end result is similar. First, the energy leaves the sub-station in a primary circuit, usually with all three phases. Most areas provide three phase industrial service. There is no substitute for three-phase service to run heavy industrial equipment. A ground is normally provided, connected to conductive cases and other safety equipment, to keep current away from equipment and people.
Substations:
A substation is a part of an electrical generation, transmission, and distribution system. Substations transform voltage from high to low, or the reverse, or perform any of several
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other important functions. Electric power may flow through several substations between generating plant and consumer, and its voltage may change in several steps.
Fig: Substation
A substation that has a step-up transformer increases the voltage while decreasing the current, while a step-down transformer decreases the voltage while increasing the current for domestic and commercial distribution. The word substation comes from the days before the distribution system became a grid. The first substations were connected to only one power station, where the generators were housed, and were subsidiaries of that power station.
Switch gear:
The term switchgear, used in association with the electric power system, or grid, refers to the combination of electrical disconnects, fusesand/or circuit breakers used to isolate electrical equipment. Switchgear is used both to de-energize equipment to allow work to be done and to clear faults downstream. This type of equipment is important because it is directly linked to the reliability of the electricity supply.
making open manually-operated switches too dangerous to use for anything other than isolation of a de-energized circuit. Oil-filled equipment allowed arc energy to be contained and safely controlled. By the early 20th century, a switchgear line-up would be a metal-enclosed structure with electrically-operated switching elements, using oil circuit breakers. Today, oil-filled equipment has largely been replaced by air-blast, vacuum, or SF6 equipment, allowing large currents and power levels to be safely controlled by automatic equipment incorporating digital controls, protection, metering and communications. The technology has been improved over time and can be used with voltages up to 1,100 kV.
Transformers:
HPCL uses a wide range of transformers which are very important in the power distribution system. A transformer is a device that transfers electrical energy from one circuit to another through coupled conductorsthe transformer's coils. A varying current in the first or primary winding creates a varying magnetic flux in the transformer's core and thus a varying magnetic field through the secondary winding. This varying magnetic field induces a varying electromotive force (EMF), or "voltage", in the secondary winding. This effect is called mutual induction. HPCL is having approximately 79 transformers in the entire refinery with the ratings like 10MVA/11KVA, 11/3.3KVA, 3.3/1.1KVA, 1.1KVA/415VA and etc.
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Substation-50:
Substation-50 is one of the most peculiar and important substation in the HPCLs power distribution system. In this substation there will be two incomers from the captive power plant (CPP) which bears 11KV. The panels in this substation are of two kinds, they are Power Control Centre (PCC) and Motor Control Centre (MCC). The 111KV is first stepped down into 5 divisions, in this process the outgoing lines are fed to two types of motors like High Tension motors (HT) and Low Tension motors (LT). then the remaining lines will fed the 6 Motor Control Centre (MCC) (for motors) and 1 Light Distribution Board (LDB) panels.
y y
Required facilities like DG Incomer with AMF Functions, Cut-off of nonessential feeders at the event of failure of mains power. Panel with provision to connect bus duct at main incomer side.
DOL starter 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 squirrelcage motor, the motor will draw a high starting current until it has run up to full speed. This starting current is commonly around six times the full load current, but may be as high as 6 to 7 times the full load current.
Variable-frequency drives are widely used. In ventilation systems for large buildings, variable-frequency motors on fans save energy by allowing the volume of air moved to match the system demand. They are also used on pumps, elevator, conveyor and machine tool drives.
VFD motor:
The motor used in a VFD system is usually a three-phase induction motor. Some types of single motors can be used, but three-phase motors are usually preferred. Various types of synchronous motors offer advantages in some situations, but induction motors are suitable for most purposes and are generally the most economical choice. Motors that are designed for fixed-speed operation are often used. Certain enhancements to the standard motor designs offer higher reliability and better VFD performance, such as MG-31 rated motors.
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VFD system
The inverter circuit is probably the most important section of the VFD, changing DC energy into three channels of AC energy that can be used by an AC motor. These units provide improved power factor, less harmonic distortion, and low sensitivity to the incoming phase sequencing than older phase controlled converter VFD's. Since incoming power is converted to DC, many units will accept single-phase as well as three-phase input power (acting as a phase converter as well as a speed controller); however the unit must be de-rated when using single phase input as only part of the rectifier bridge is carrying the connected load.
Dynamic breaking:
Using the motor as a generator to absorb energy from the system is called dynamic braking. Dynamic braking stops the system more quickly than coasting. Since dynamic braking requires relative motion of the motor's parts, it becomes less effective at low speed and cannot be used to hold a load at a stopped position. During normal braking of an electric motor the electrical energy produced by the motor is dissipated as heat
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inside of the rotor, which increases the likelihood of damage and eventual failure. Therefore, some systems transfer this energy to an outside bank of resistors. Cooling fans may be used to protect the resistors from damage. Modern systems have thermal monitoring, so if the temperature of the bank becomes excessive, it will be switched off.
Rectifier in VFD:
A rectifier is an electrical device that converts alternating current (AC), which periodically reverses direction, to direct current (DC), which is in only one direction, a process known as rectification. Rectifiers have many uses including as components of power supplies and as detectors of radio signals. Rectifiers may be made of solid state diodes, silicon-controlled rectifiers, vacuum tube diodes, mercury arc valves, and other components.
Bibliography
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HPCL official website Wikipedia.com Network protection and automation guide Google.books.com Google.images.com Power systems J.B.Gupta Electrical machines P.S.Bhimbhra
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