Professional Documents
Culture Documents
ACKNOWLEDGEMENT
I wish to place on record my deep sense of reverence & gratitude to Mr. JAIVINDER SINGH, HOD-CM(Electrical),for his keen interest, and help which have sustained my efforts at all stages of this undertaking. Also I would like to thank Mr. M.K.PRASAD(MGR), Mr.NIKHILKUMAR(MGR),Mr.VIKAS Mr.S.P.DWIVEDI(Sr.ENG), SRIVASTAVA(Sr.ENG), GOEL (Sr.ENG), Mr.DHEERAJ
Mr. KUMAR RAHUL(Sr.ENG) and Mr.RISHIKESH ROY(MGR) Mr.SOMEN MANDAL(CM) for their constant guidance and great support. It gives me great pleasure to acknowledge my humble & sincere indebtness to Mr. AJAY SHARMA (finance) for providing encouragement and all help needed despite of his multifarious responsibilities. This work bears the impact of many persons who made significant contribution in formal or informal way. I am thankful to all of them.
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PREFACE
Knowledge of something useful can become redundant. The difference between a successful and an unsuccessful professional lies not only in the amount of knowledge one has, but how much he can actually use in various situations. It is with this objective that every student of B.Tech has to undergo four to six weeks of summer training in the corporate world to get the first hand experience of working in an organization. I was fortunate enough in doing my summer training at GAIL, PATA which is a prestigious NAVARATNA STATUS company.
VEDANT
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Inplant Training,GAIL(PATA)
This is to certify that Vedant, student of GLA Institute of Techonology & Management,Mathura has undergone a Vocational Training in Electrical System at Gail(PATA)Unit from 17th june, 2011 to 16th July, 2011(4 weeks duration) . He has prepared the project report under my guidance. Date:
Mr. Jaivinder Singh HOD-CM (Electrical) GAIL, PATA
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INDEX Introduction GAIL at a glance History and importance Vision Plant description GAILs pipeline network GAIL UPPC(PATA) Complex Introduction to Electrical Section Page 5 Page 6 Page 8 Page 9 Page 10 Page 15 Page 16 Page 16 Page 18 Page 19 Page 20 Page 24 Page 30 Page 34 Page 38 Page 40 Page 42 Page 45
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Transformer Motors Steam Turbine Generator Emergency Power Supply Variable Speed Drives Cathodic Protection
Energy saving
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namely, HDPE plant and Swing LLDPE/HDPE Plant. Butene-1 used as co-monomer in the production of HDPE & LLDPE is produced in Butene-1 Plant licensed by M/s Axens, USA.
GAIL AT A GLANCE
GAIL is Indias flagship natural company, integrating all aspects of natural gas value chain(including Exploration & Production, Processing, transmission, distribution and Marketing)and its related services. It is outstanding public sector enterprises in the country. In rapidly changing scenario, it is spearheading the move to new era of clean fuel industrialization, creating a quadrilateral of green energy corridors that connect major consumption centers in India with major gas fields ,LNG terminals and other cross border gas sourcing points. GAIL is also expanding its business to become a player in the International market. GAIL is one of the NAVARATNA enterprises and ranks among the top ten companies in India. Today, GAILs Business Portfolio includes: 5,800 km of natural gas high pressure trunk pipeline with a capacity to carry 130 MMSCMD of natural gas across the country. 7 LPG gas processing units to produce 1.2 MMTPA of LPG and other liquid hydrocarbons. North Indias only gas based integrated Petrochemical complex at PATA with a capacity of producing 3, 10, 00 TPA of polymers. 1,922 km of LPG transmission pipeline network with a capacity to transport 3.8 MMTPA of LPG. 30 oil and gas Exploration blocks and 3 coal bed methane blocks.
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13,000 km of OFC network offering highly dependable bandwidth for telecom service providers. Joint venture companies in Delhi ,Mumbai, Hyderabad, Kanpur, Agra, Lucknow, Bhopal and Pune, for supplying piped natural gas (PNG) to households and commercial users, and compressed natural gas (CNG) to transport sector. Participating stake in the Dahej LNG terminal and the upcoming Kochi LNG Terminal in Kerala.. GAIL has been entrusted with the responsibility of reviving the LNG terminal at Dabhol as well as sourcing LNG. Established presence in the CNG and City Gas sectors in Egypt through equity participation in 3 Egyptian companies:Fayum Gas Company SAE, Shell CNG SAE and National Gas Company SAE. Stake in China Gas Holding to explore opportunities in the CNG sector in mainland China. A wholly-owned subsidiary company GAIL Global(Singapore) Pte Ltd in singapore.
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In 1999, GAIL set up northern Indias only Petrochemical plant at PATA. GAIL become the first Infrastructure Provider Category II license and signed the countrys first Service Level Agreement for leasing bandwidth in the Delhi-Vijaypur sector 2001, through its telecom business GAILTEL. In 2001, GAIL commissioned worlds longest and Indias first cross country LPG Transmission from Jamnagar to Loni. GAIL today has reached new milestones with its strategic diversification into Petrochemicals, Telecom and Liquid Hydrocarbons besides gas infrastructure. The company has also extended its presence in power, LNG regasification, City Gas Distribution and exploration and production through equity and joint ventures participations. Incorporating the new found energy into its corporate identity, GAIL (India) ltd on Nov 22,2002. Within the period of 15 years GAIL has emerged and maintained its position as the no.1 gas company in India. It has won the excellent performance awards for the past five years consecutively and also safety awards from the Oil Industry Safety Directorate (OISD) and British Safety Council. It has an ISO-9002 certification for its pipeline system. LPG plants and Gas Technology Institute and also ISO-14001 certification for its LPG plants at Vijaypur, Vaghodia and along the HVJ Pipeline making it the 1st Indian company in the petroleum sector to secure this certification. Recently the running LPG plant at UPPC PATA was dedicated to the nation on 20 th June01 by the Honorable Oil and Petroleum minister Mr.R.Naik. As a GAIL subsidiary, UPPC PATA is an integrated Petrochemical Complex with an investment of Rs.2500 Crore itself and LPG plant is installed with a capital investment of Rs.460 Crore. This complex recovers ethane, propane (C2/C3) from natural gas.
VISION
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Be the leading company in natural gas and beyond with global focus ,committed to customer care, value creation for all stake holders and environmental responsibility.
PLANT DESCRIPTION
Gas Sweetening Unit
The gas from the HVJ pipeline contains about 5 to 6 % CO2 by volume which interferes with C2-C3 recovery in GPU where deep cryogenic conditions are involved. In view of this it is necessary to remove CO2 from the feed gas down to 50 PPM level. The sour feed gas enters the bottom of the absorber where it contacts counter currently with the descending lean solution. The acid gas component in the gas is absorbed by the solvent and the sweet gas leaves from the top of the absorber. The rich solvent solution loaded with acid components is drawn from the absorber bottom and flashed in to the flash drum to recover dissolved heavy hydrocarbons. The flashed rich solution is then
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fed to the regenerator through a lean/rich exchanger. In the regenerator the acid components are stripped off by the reboiled vapor generated through the regenerator reboiler and the solvent is recovered as lean solvent which is recycled as absorber top.
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is separated in reflux drum and pumped back to the column. The vapor from the reflux drum is expanded in the de-methaniser overhead gas expander compressor to result in temperature reduction in the plant to -117 C. The cold gas is utilized in the process. A part of the exit gas from intermediate stage of the exit gas compressor is used for molecular sieve regeneration, recompressed and recycled back to HVJ pipeline.
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the top and the heavier at the bottom. The ethane-ethylene mix from deethaniser top is processed for removal of acetylene and is thereafter sent to ethylene column for further separation. In the etheylene column, the ethane-ethylene mixture is separated into ethylene product at the top and ethane at the bottom which is again recycled back to furance for cracking. The heavier bottoms from de-ethaniser is fed to de-propaniser which separates the propane-propylene mixture at the top and all the heavier fractions at the bottom. The propane propylene mixtures are separated in the propylene column where by-product propylene goes as the top product and propane is obtained at the bottom. This propane is again recycled back to furnace for production of ethylene and propylene. The heavy fraction from de-propaniser bottom is fed to the debutanisser, which separates the feed into C4 mix byproduct at the top and gasoline by product at the bottom.
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an extruder to get pellets of required size, which are subsequently bagged for shipment. The recovered hexane from centrifuge and dryer is sent to hexane recovery section, where the hexane is stripped to yield byproduct low polymer. The stripped hexane is next dehydrated for removal of moisture and recycled back for reuse.
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stream from LB column is then fed to high boiler (HB) column from where recycle solvent is available as top product and high boilers (low molecular weight polymers) as the bottom product. The ethylene stream from LB column is sent to the ethylene column from where ethylene vapor obtained from the top is recycled back to cracker for recovery. The bottom product from ethylene column is sent to the co-monomer column from where pure comonomer is obtained as top product and solvent is recovered as bottom product. The bottom product from the HB column is sent to the RB column from where low molecular weight polymer is taken out as grease.
Butene - 1 plant
The process in Butene-1 plant involves dimerisation of ethylene into butene1. It is used as co-monomer in LLDPE/HDPE swing plant. Feed ethylene along-with recycled ethylene is fed to the reactor where reaction is takes place in presence of catalyst and butene-1 is produced. The reactor outputs are vaporized in steam exchangers and sent to flash drum. Liquid from flash drum is taken to catalyst waste removal section for waste catalyst recovery. The vapor from flash drum is sent through cooler to surge drum and liquid separated in surge drum is taken to recycle column. Vapor ethylene from recycle column is recycled back to reactor, while liquid from the bottom of recycle column is fed to butene-1 column. The product butene-1 is available from the top of the
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butene-1 column while heavier hydrocarbons are available as by-product from the bottom of the same column.
Utilities
The utilities requirement for the GAIL, PATA include power, raw water, steam, cooling water, DM water, fire water, plant air, instrument air, and nitrogen. The solid/semisolid wastes are also generated from various utility units viz. DM water plant (spent Cation/Anion samples), Nitrogen plant (spent alumina balls and spent molecular sieve).
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Two Incomers are coming from NTPC AuGPS which are at 220 KV.
220 KV SF6 type CGL(five in number) make out door circuit breakers are used.
Vacuum Circuit Breakers are used at 33 KV side of transformer. This power is fed to SS#1, and there are 4 section of 33 KV bus. All the bus bars are connected in parallel so that in case one incomer fails other
can
Power at 6.6 KV level is fed to various substation all over the plant through cables.
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SS#18
This power is fed to HT motors and Transformer for plant operation. For LT load 6.6 KV is step down to 415 v. SS#1 act as a main distribution substation where all the downstream plant are fed from. SS#11 caters to the upstream plants namely GCU and GPU. SS#12 caters to the downstream plants namely LLDPE/HDPE.
For fire protection purpose fire water pipeline is laid all over the plant .They have the following main equipments
4 no. of HT motor (310 KW) driven water pumps 5 no. of diesel engine driven pumps . 3 no. of jockey pump (45 KW) for maintaining fire water pressure at around 10 Kg/cm sq.
Circuit breaker used at various voltage level panel are 220 KV SF6 circuit breaker made by CGL. 33 KV Vacuum circuit breaker made by Siemens. 6.6 KV SF6 circuit breaker made by Voltas.
In switchyard we use wave trap for communication purpose. This is known as PLCC. The full form of PLCC is Power Line Conductor Communication.
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In switchyard we have 2 bus bars. Bus bar 1 is energised by incomer 1 and bus bar 2 is energised by Incomer 2 . We have done this for the reliability of the system.
In Switchyard we can experience Corona Effect .There we can hear hissing sound due corona. We use hollow conductor to reduce Skin Effect.
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SWITCHYARD
1) It is a medium for exchange of power from source to load or from one source to another. 2) It consists of switching equipment, measurement, protection and control equipment required for power generation and utilization. 3) The main components are:
Isolator, Earth Switch, Current Transformers (CT), Capacitive Voltage Transformers (CVT), Lightening Arrester (LA),
Wave Trap,
Potential Transformers (PT), Line matching unit (LMU), Lightening Mast (LA).
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Negative phase sequence :
Three phase balanced load produces a reaction field which is constant and rotates synchronously with the rotor field system. Any unbalanced condition could be resolved into positive, negative and zero sequence components. The +ve sequence is similar to the balanced load. The zero sequence component does not produce armature reaction. The -ve sequence component is similar to that of the +ve sequence but the resulting reaction field rotates in the opposite direction. Hence the flux produced by the negative phase sequence current cuts the rotor at double the rotational speed thereby inducing double frequency currents. As a result, eddy currents produced are very large and cause severe heating of the rotor windings particularly damper windings. The losses in the rotor are proportional to the square of the degree of the unbalance.
Pole slipping :
Pole slipping may occur in the generator due to instability. It causes severe shock to both machine and grid due to violent oscillations in both active and reactive power. The angular displacement of the rotor exceeds the stability limit the rotor will slip a pole pitch usually known as pole slipping.
Overvoltage or overfluxing :
The generator can develop dangerously high voltage in the event of maloperation of AVR or load throws off while generator excitation is under manual control. Since voltage generated is directly proportional to flux, quantity of flux increases at
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overvoltage. Due to increase of flux, losses in the stator increases due to which core will get heated up and thus reducing the life of the generator.
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3. Fire protection:
Sprinkler system is utilized to protect the transformers from fire hazards.
4. High oil temperature protection. 5. High winding temperature protection. 6. Pressure relief valve (PRV). 7. Overfluxing protection:
The condition of overfluxing could arise in case the voltage at the machine terminal rises or its frequency drops or both occurring simultaneously.
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TRANSFORMER
A transformer is a device that transfers electrical energy from one circuit to another through inductively coupled conductors the transformer's coils. Except for air-core transformers, the conductors are commonly wound around a single iron-rich core, or around separate but magnetically-coupled cores. A varying current in the first or "primary" winding creates a varying magnetic field in the core (or cores) of the transformer. This varying magnetic field induces a varying electromotive force (EMF) or "voltage" in the "secondary" winding. This effect is called mutual induction. If a load is connected to the secondary, an electric current will flow in the secondary winding and electrical energy will flow from the primary circuit through the transformer to the load. In an ideal transformer, the induced voltage in the secondary winding (VS) is in proportion to the primary voltage (VP), and is given by the ratio of the number of turns in the secondary to the number of turns in the By appropriate selection of the ratio of turns, a transformer thus allows an alternating current (AC) voltage to be "stepped up" by making NS greater than NP, or "stepped down" by making NS less than NP.
PRINCIPLE OF OPERATION
The transformer is based on two principles: firstly, that an electric current can produce a magnetic field (electromagnetism) and secondly that a changing magnetic field within a coil of wire induces a voltage across the ends of the coil (electromagnetic induction). Changing the current in the primary coil changes the magnetic flux that is developed. The changing magnetic flux induces a voltage in the secondary coil. The voltage induced across the secondary coil may be calculated from Faraday's law of induction, which states that:
where VS is the instantaneous voltage, NS is the number of turns in the secondary coil and equals the magnetic flux through one turn of the coil. If the turns of the coil are oriented perpendicular to the magnetic field lines, the flux is the product of the magnetic field strength B and the area A through which it cuts. The area is constant, being equal to the cross-sectional area of the transformer core, whereas the magnetic field varies with time according to the excitation of the primary. Since the same magnetic flux passes through both the primary and secondary coils in an ideal transformer,[12] the instantaneous voltage across the primary winding equals
Taking the ratio of the two equations for VS and VP gives the basic equation for stepping up or stepping down the voltage
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CONSTRUCTION
The construction of the transformer basically includes the following:
CORE RADIATORS CONSERVATOR BREATHER OIL LEVEL INDICATOR EXPLOSION VENT WINDING COOLANT TAP CHANGER HV/LV BUSHINGS BUCKHOLZ RELAY
CORE:
Transformers for use at power or audio frequencies typically have cores made of high permeability silicon steel. The steel has a permeability many times that of free space , and the core thus serves to greatly reduce the magnetizing current, and confine the flux to a path which closely couples the windings The effect of laminations is to confine eddy currents to highly elliptical paths that enclose little flux, and so reduce their magnitude. Thinner laminations reduce losses, but are more laborious and expensive to construct. Thin laminations are generally used on high frequency transformers, with some types of very thin steel laminations able to operate up to 10 kHz.
RADIATORS:
The radiators are the fins that are attached to the main body of the transformer ,hence increasing the contact surface area by providing a circulatory path to the oil. Now it circulates in a convection cycle and cooling becomes more efficient. Since the heat can be dissipated more easily and efficiently now, the rating of the transformer can be increased.
CONSERVATOR:
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The oil is filled through the opening in conservator at the top. The conservator is never filled fully since the oil volume varies according to the temperature. The oil either expands or contracts according to the heating Hence conservator acts as a supplementary space for the oil in case of expansion.
EXPLOSION VENT:
In case of some fault, there can be a sudden passage of huge amount of charge through the transformer. This produces immense heat resulting in the vaporization of oil and production of gas. In order to avoid any possible explosion in the body of the transformer a pressure release vent or explosion vent is provided. The end of it capped by a brittle material that is destroyed and the gas is released.
BREATHER:
The breather is used to suck in the air whenever the oil contracts so as to maintain the inside pressure equal to the outside pressure .In order to avoid the sucking of moisture along with air, SILICA GEL is provided along with oil to absorb the moisture. The absence of moisture is so much important because even a small amount of its presence reduces the dielectric constant of the oil considerably.
WINDING:
The conducting material used for the windings depends upon the application, but in all cases the individual turns must be electrically insulated from each other to ensure that the current travels throughout every turn. Larger power transformers operating at high voltages may be wound with copper rectangular strip conductors insulated by oil-impregnated paper.Both the primary and secondary windings on power transformers may have external connections, called taps, to intermediate points on the winding to allow selection of the voltage ratio. The taps may be connected to an automatic ON LOAD TAP CHANGER(OLTC) for voltage regulation of distribution circuits. Certain transformers have the windings protected by epoxy resin. The OLTC is always connected on the HT side since sparking is less, reason being the current which is also less on the HT side.
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HV/LV BUSHINGS:
The bushings are provided to isolate the live wire from the main body and hence the energisation of the transformer casing. The conductor passes through the bodyof the bushing.
BUCKHOLZ RELAY:
In the field of electric power distribution and transmission, a Buchholz relay, also called a gas relay or a sudden pressure relay, is a safety device mounted on some oil-filled power transformers The Buchholz Relay is used as a protective device sensitive to the effects of dielectric failure inside the equipment. The relay has two different detection modes. On a slow accumulation of gas, due perhaps to slight overload, gas produced by decomposition of insulating oil accumulates in the top of the relay and forces the oil level down. A float operated switch in the relay is used to initiate an alarm signal. If an arc forms, gas accumulation is rapid, and oil flows rapidly into the conservator. This flow of oil operates a switch attached to a vane located in the path of the moving oil. This switch normally will operate a circuit breaker to isolate the apparatus before the fault causes additional damage.
In GAIL (PATA) there are various type of transformer used. Now total no. of transformer in Gail (PATA) are
In switchyard there are two 40 MVA Transformer are used. They step-down 220 KV to
33 KV.
In SS#1 there are 4 ,25/31.5 MVA Transformer which are use to step-down 33 KV to 6.6KV.
There is one 20 MVA and one 30 MVA Transformer which are connected to STG
Low rating Transformer are used for distribution purpose. The distribution transformers
are generally connected in delta-star configuration, providing a neutral on the secondary side. The delta on the other hand makes sure that the harmonics, basically
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the third harmonic current which are zero sequence currents get captured in the delta and do not cause losses in the system(Since DO NOT CIRCULATE IN THE SYSTEM ANYMORE). Also it is deemed necessary to provide a path to the third harmonic without its suppression so as to get a sinusoidal voltage on the secondary side.
Lightning Transformer in SS#1 are used to protect system from lightning fault.
The lighting transformer or the isolation transformer are used to increase the impedance
of the system so that any fault on the secondary side(lighting side) is not manifested severely on the primary side i.e. the PANELS causing any major outage.
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Tripping relay type VAJ Trip current supervision relay Type VAX MK-2 Auxiliary relay type: Buckholz alarm Oil temperature Alarm Oil level low alarm Auxiliary relay type VAA : PRV valve WDG Temp Alarm PRV Trip
Auxiliary Relay type VAA : Buch relay Oil trip WDG trip
Overcurrent Relay (Inverse) type CDG Instantaneous earth fault Relay type CAG Over current Relay (Inverse) type CDG
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MOTORS
An electric motor is a device using electrical energy to produce mechanical energy, nearly always by the interaction of magnetic fields and current-carrying conductors. The reverse process, that of using mechanical energy to produce electrical energy, is accomplished by a generator or dynamo. Traction motors used on vehicles often perform both tasks. Electric motors are found in myriad uses such as industrial fans, blowers and pumps, machine tools, household appliances, power tools, and computer disk drives, among many other applications. Electric motors may be operated by direct current from a battery in a portable device or motor vehicle, or from alternating current from a central electrical distribution grid. The smallest motors may be found in electric wristwatches. Medium-size motors of highly standardized dimensions and characteristics provide convenient mechanical power for industrial uses. The very largest electric motors are used for propulsion of large ships, and for such purposes as pipeline compressors, with ratings in the thousands of kilowatts. Electric motors may be classified by the source of electric power, by their internal construction, and by application. Here the main load in the plant ins mainly of motors . The two biggest motor in the plant are in Downstream-2350 KW main LLDPE extruder and 710 KW for gear pump in HDPE plant. The most of the motors in plant are Induction motor.
INDUCTION MOTOR
An induction motor (IM) is a type of asynchronous AC motor where power is supplied to the rotating device by means of electromagnetic induction. Commonly used motor in industry is squirrel cage motor (the rotor bars with short circuit rings resemble a squirrel cage (hamster wheel)).
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CONSTRUCTION
The stator consists of wound 'poles' that carry the supply current to induce a magnetic field that penetrates the rotor. In a very simple motor, there would be a single projecting piece of the stator (a salient pole) for each pole, with windings around it; in fact, to optimize the distribution of the magnetic field, the windings are distributed in many slots located around the stator. There are three types of rotor: Squirrel-cage rotor: The most common rotor is a squirrel-cage rotor. It is made up of bars of either solid copper (most common) or aluminum that span the length of the rotor, and are connected through a ring at each end. The rotor bars in squirrel-cage induction motors are not straight, but have some skew to reduce noise, harmonics and magnetic locking as well. Most of the motors in the plant are squirrel cage type.
Slip ring rotor: A slip ring rotor replaces the bars of the squirrel-cage rotor with windings
that are connected to slip rings. When these slip rings are shorted, the rotor behaves similarly to a squirrel-cage rotor; they can also be connected to resistors to produce a high-resistance rotor circuit, which can be beneficial in starting
Solid core rotor: A rotor can be made from a solid mild steel. The induced EDDY
Current causes the rotation.
In plant starting of induction is done by direct on line starting(DOL Starter).We do not use any other method for the starting of the Induction motor such as the Star-Delta starter method or Resistance starting.
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Mechanical overload. Supply voltage changes - The most important consequence of a line voltage
change is its effect on the torque speed curve of motor. If stator voltage decreases then torque also decreases. If line voltage will be too high, flux per pole will be too high and iron losses and magnetizing current increases due to which temperature increases and power factor decreases. If voltage and frequency both vary, sum of two in % must not exceed 10%. 3. Unbalanced loading - A slight unbalance of three phase voltages produce a serious unbalance of the three line currents. 4. Single phasing - If one line is accidentally opened, current drawn from the remaining two lines will almost double leading to overheating of motor. 5. Frequency variation - Frequency change leads to changing in speed of the motor.
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2. 3.
Overload protection. Stalling protection - The motor would also have a speed switch to
detect stalling if the current relay remains picked up and speed switch continues to indicate stalling.
4. 5.
RATING OF STG
STG -2
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Stator Frame
The stator frame is fabricated structure made out of mild steel plates. It houses and support core together with the winding. Dovetail shaped steel guide bar are welded to the inside surface of the frame on to which core is assembled .The stator is fixed to the foundation frame at the footing.
Stator Core
The stator core is made of segments of insulated punching of non-grain oriented high quality silicon steel to give minimum electrical losses .These punching are assembled in a interleaved manner on the machine guide bars and are separated into packet of appprox- 50 mm .Ventilation ducts are provided between them .The core is then sprayed with insulation varnish in the slots and subjected to magnetization test.
Rotor Balancing
Rotor is balanced with the help of balancing weights are fitted in dovetail grooves providing in hubs and fan . The rotor is dynamically balanced and subjected to an over speed of 20% for two minute.
Bearing
The turbo generator rotor is supported in two journal bearing .The pedestals are gray iron casting and the bearing shell is manganese steel casting in two halves There is resistance thermometer provide in lower part of shell for measurement of temperature of bearing shell .The bearing lubrication is done by circulation oil under pressure .The oil pressure is to be maintained at 1.0 bar .The maximum permissible temperature for the bearing oil is 64 degree Celsius.
Ventilation Arrangement
The turbo generator is cooled by air circulation by mean of two axial fans. The air after circulation is cooled by air cooler .The air is drawn through suction ducts by axial fans mounted on either side of rotor. The warm air flows out through exhaust at the bottom of the stator frame.
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power supply to the A.V.R is taken from the permanent magnet generator directly coupled to the main exciter. The A.C exciter, P.M.G and rotating rectifier wheels are cooled by air. The Diode use rotating rectifiers are mounted on heat sinks made of cast aluminium. Cooling of diode is achieve by integral fins on the heat sink. Snubber circuit with capacitors and resistors are housed in the carrier ring and are connected in parallel to damp the over voltage spikes arising out of Commutation and hole stage effect. Permanent magnet Generator power supply of 220 V. AVR is a thyristorised, solid state, fast response, dual channel type. The output of AVR is fed to the field of main exciter which is of revolving armature, stationary field type.
POWER PLANT
A power station (also referred to as a generating station, power plant, or powerhouse) is an industrial facility for the generation of electric power. Some prefer to use the term energy center because it more accurately describes what the plants do, which is the conversion of other forms of energy, like chemical energy, gravitational potential energy or heat energy into electrical energy. At the center of nearly all power stations is a generator, a rotating machine that converts mechanical energy into electrical energy by creating relative motion between a magnetic field and a conductor .In Gail (PATA) there is Thermal power plant .There steam is used to rotate the turbine. There are three boiler in Power plant .The steam is then fed to the steam turbine. The steam is the process requirement and not basically produced for the plant requirement.
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NO. of DG set 2 1 4 1
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BATTERY CHARGER
The system consists of dual float cum battery charger 125v ,50 A built in single panel .Both charger are rated to supply the load as well as carry out the OFF-LINE boost charging of the battery. On A.C. side two chargers are supplied through the different incoming feeder. Each charger is provided with input ON switch,fuses, contractor, thermal over current relay,input surge suppressors. Different mode of operation of charger Float Mode When cells are charged only small amount of current flows to keep it fully charged as with time it get discharge. In Boost Mode When cells are being charged output DC voltage ranges from approximately float voltage to maximum output voltage. Initial charging mode Output DC voltage range is approximately Float voltage to maximum Output voltage.
Total number of chargers in different area of plant : Area Upstream Downstream No. of chargers 6 4
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IOPS HDPE2 15 1
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Improve process control Reduce mechanical stress through soft starting Improve electrical system power factor
The plant has VSD drive in the range of 0.25 KW to 2350 KW. The maximum VSD drive rating is for 2350KW main LLDPE extruder supplied by ABB Finland. In the HDPE plant maximum VSD drive rating is 710KW for gear pump motor supplied by ANSALDO, Italy .Both are closed loop flux vector control drive. Most of the VSD drive are single unit and need lot of care for continuous polymer production. The microprocessor based drives are sophisticated one and to be handled carefully. Pulse Width Modulation inverter are available from 1 to 1000 HP.
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Inplant Training,GAIL(PATA)
CATHODIC PROTECTION
Corrosion is the electrochemical process through which loss of metal due to interaction with environment. Cathodic protection (CP) is a technique to control the corrosion of a metal surface by making it work as a cathode of an electrochemical cell. This is achieved by placing in contact with the metal to be protected another more easily corroded metal to act as the anode of the electrochemical cell. Cathodic protection systems are most commonly used to protect steel, water or fuel pipelines and storage tanks, steel pier piles, ships, offshore oil platforms and onshore oil well Casings. The pipeline will act as cathode and no corrosion will take place on its surface but occurs on metal being used for protection .Current flow from cathode to anode. Interim pipeline storage facility for LPG is being protected by permanent impressed current C.P. system using anode flex conductive polymer anode (24 no. of pipes of 36 diameters having 301.1 meters length). Mounded storage bullets (7 no.) for LPG and (2 no.) for propane being commissioned by permanent impressed current C.P. system using anode flex conductive polymer anode (93m. length and 63 m. diameter). In length from wastewater treatment are being protected by permanent impressed current C.P. system using high silicon chromium anode.
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Inplant Training,GAIL(PATA)
S No 1 2 3 4 5 6
ACTIVITY Monitoring of Transformer rectifier Unit Monitoring of pipe to soil potential(ON) Monitoring of Pipe to soil potential(ON-OFF) Monitoring of ALJB & anode ground bed Current measurement of pipeline Monitoring of Cased crossing
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Inplant Training,GAIL(PATA)
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Inplant Training,GAIL(PATA)
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Inplant Training,GAIL(PATA)
Avoid repeated rewinding of motors .Rewound motors show efficiency loss of up to 5% . Use of variable frequency drives ,slip power recovery systems and fluid coupling for variable speed applications like fans , pumps help to minimize the consumption.
Replacing aluminium or fabricated steel fans by moulded FRP fan with aerofoil design result in electrical saving upto 15 to 40 % .
Improper selection of pumps can lead to wastage of energy . A pump with 85% efficiency at rat flow may only have 65 % efficiency at half flow rate.
Loose belts between pumps and motors can save between 15-20% energy.
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Inplant Training,GAIL(PATA)
CONCLUSION
Industrial experience is deemed necessary for an engineering student. It is through an industrial training that one learns how to see the theoretical fundamentals in practical and how to apply the principles learned. We not only learn the engineering basics required but also get introduced to the latest trends in the industry. The industrial training at GAIL(PATA) lasted for four weeks, but in this four weeks itself I was able to earn a lot of practical knowledge. Also I got a chance to clear many concepts as well. It was through interaction with the highly proficient and experienced professionals that I understood the industrial culture and how they work, running such a huge Plant successfully. This interaction has not only brought knowledge to me but also introduced me to the industrial environment and the work culture. All in all the training session was quite interesting, all credit goes to the GAIL management and officials. I have hugely benefitted and believe that this will help me in becoming a better professional. .
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