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The single line diagram includes these important components of the power plant.
3 outgoing lines to Pattoki, CP mill and Chunian
2 HV lines, bus bars, per phase (132 KV 50 Hz 1600 A)
4 transformers (65 MVA 132/15 KV no load 136KV)
11 generators with diesel engines, capacity 17 MW each
1 steam turbine capacity 14 MW
MV line rated at 15KV 50 Hz 3600 A
4 auxiliary transformers (2500 KVA 15000/400V no load 415V)
1 small transformer for admin building (400 KVA 15000/400V no load 415V)
LV line at 400V
1 backup generator
Also there are several isolators and circuit breakers shown along the cables.
We discuss all of these components, their ratings, working principle and protection in detail in the
subsequent sections.
Switch Yard
For an electrical engineer one of the most important parts of the power plant is the switch yard. The switch
yard deals with dangerous high voltages so the ground is covered with gravel and stones for insulation, and
the entire switch yard is barred. These stones provide a high surface area for heat dissipation and also such
ground has the advantage that it does not allow stagnant water to accumulate in case of rain.
transform
er
CVT
CT
SF6
breaker
isolator
bus bar
In the coming sub sections we look at the ratings and working principles of these components. Their
function in the switch yard would be discussed in detail. Protection of these components is a vast field and
it would be dealt with separately in section 5.
Fig 1.1
2.
Fig
1.2
Advantage: relatively simple relaying. Any bus bar can be isolated without interrupting the supply.
of
Fig
1.3
2.4 Isolator/Disconnector
An isolator is a device which can be used to switch from one terminal to the other while the line is off
power. Unlike the circuit breaker it cannot change its state while the line is carrying current. This is because
it has got no material to quench the arc which would be produced by disconnecting two conductors while
high current is flowing. The type of isolators used here are called two column rotary Disconnector and it is
manual operated. The ratings of these isolators are as given below
Rated voltage: 145 kV
Rated current: 1250 A
Rated short time current 1s: 40 kA
Rated peak withstand current: 100 kA
3.
High dielectric strength (despite a very high potential difference across it, it would insulate the two
ends of the contacts)
Excellent thermal stability (arc quenching can generate a lot of heat but due to thermal stability SF6
can tolerate high temperature without being decomposed or changing any of its properties too
significantly)
Good thermal conductivity (it can cool down and dissipate heat much quickly)
The operating mechanism of the breaker [6] can be best described by dividing the breaker into two parts,
the pole mechanism and the operating mechanism. The pole mechanism is contained inside the bushing. It
contains the contacts, both arcing contacts and the auxiliary contacts. It also contains the SF6 gas in two
separate chambers, compression section and the auto puffer section. The operating mechanism contains a
motor and two energizing coils. These coils get control signal and depending on those signals the closing
and opening operations take place. The operating mechanism is contained inside a metal box attached to the
bottom of the poles. The operating mechanism is connected to the pole mechanism by a pull rod system.
For breaking the circuit the motor would separate the auxiliary contacts and this would automatically cause
the gas from compression section to be released at the time when arcing contacts separate. However if the
fault current is very large like in a short circuit, the heat from the arcing would cause extra pressure to
develop in the auto puffer section and gas from that section too would be released and would quench the
arc. In this way the extra arcing is taken care of without putting in any extra effort. The heat produced from
the arcing itself functions to quench the arc. On closing the contact, the motor pushes the piston such that
both the SF6 chambers get filled with gas and are ready for next breaking operation.
The ratings of the circuit breaker used in the switch yard is
Rated Voltage: 145 kV
Rated current: 2000A
Rated Frequency: 50 Hz
Withstand voltage 1min at 50Hz: 275 kV
Rated breaking current: 40kA
Making current/peak: 100kA
Number of auxiliary contacts: 9NO + 9NC
ground. These capacitors act as potential divider for the AC voltage at the primary. A tapping is taken from
the CVD and send to the EMU where through electromagnetic induction a voltage is induced at the
secondary of the transformer. The CVD is inside a porcelain bushing and it terminates into a cylindrical
unit at the bottom of the bushing which contains the EMU.
Current measurement:
A current transformer is installed at the secondary end of the step-up transformer. It is always installed in
series with the line. It secondary terminals are shorted so that high voltages do not develop. The ratings of
the current transformer being used at NPL are
Max system voltage: 145kV
Rated voltage: 145kV
Rated frequency: 50Hz
Primary rated current: 600 x 1200A
Secondary rated current: 1A
Rated burden and accuracies:
-core1: cl. 0.5 Fs 5/ 15 VA
-core2: 5P20/ 20VA
-core3: 5P20/ 20VA
-core4: 5P20/ 20VA
It contains a coil wound around the transmission line. The coil does not touch the line, the link is purely
inductive. The current passing through the line induces a current to flow through the coil as well. The coil
is calibrated such that it scales the current through the line to a max of 1A through the coil.
Both the instrumentation transformers are oil filled for cooling and insulation purposes. Significance of oil
would become clear in the next section of power transformer.
voltage side, the winding is helical whereas for the lower current, higher voltage side the winding would be
disk type to withstand a short circuit fault current. Cellulose paper is used to insulate the windings from the
core. For electrical insulation oil is being used.
Mineral oil serves two very important purposes in the transformer tank. First it provides electrical
insulation. Oil has a very high dielectric strength compared to water or air. So even though there are very
high voltages at small distances from each other, the oil does not break down (ionize) and provide a path
for current to flow. Secondly oil is used as a cooling medium in the transformer tank [9]. Life expectancy is
halved for every 8 degree rise in temperature. There are several different cooling techniques which are
conventionally written as ONAN, ONAF, OF etc. ONAN stands for oil natural, air natural cooling. Natural
oil cooling occurs through convention flow of oil inside the tank without any external aid. For forced oil
cooling a motor and pump are installed inside the tank which keep the oil in motion. However in the
transformer that NPL uses only ONAN and ONAF methods are available. The surface area for radiation is
increased by installing radiators on all sides of the transformers. Oil flows through these radiators and
passes the heat to the air outside the tank. Forced cooling is achieved through use of DC fans installed
underneath the radiators. When the temperature of the oil goes above a certain threshold e.g. 73 the fans
are switched on automatically and the cooling method is switched to ONAF. There are a total of 15 fans for
forcing the hot air away from the radiators.
The transformer has an oil storage tank called the conservator tank, attached to the main tank. The
conservator has the function to make sure that the transformer tank is always completely filled with oil. The
pipe connecting conservator to the main tank passes through a Buchholz relay whose function we can see in
the transformer protection section. The transformer breathes as it intakes air from the surroundings. The air
passes through a breather into the conservator tank. Breather contains silica gel which absorbs water from
the air before letting it in. water can be damaging for insulation inside the transformer. Silica gel changes
its color as it absorbs moisture. The silica gel particles used at NPL change from golden to white when they
have absorbed their capacity of moisture and this indicates that they need to be replaced.
At the secondary end of the transformer there are 17 taps available from the windings and any one of them
can be connected to the outgoing lines. A motor unit is present to switch from one tap to the other
depending on the voltage at the grid lines. As load on the grids increase, the voltage drops, the tap of the
winding has to be changed accordingly. This system is called on load tap changing (OLTC). The OLTC has
its own oil chamber in the conservator and its own breather. The OLTC at the transformer used at NPL
allows the voltage to be changed from 122.4kV up to 149.6kV at the same input voltage of 15kV.
The transformer has 15 CT inside it for function as protection transformers, instrument transformers and for
thermal imaging.
Engine Hall
NPL has two engine halls. Each of them has 6 Generators. One has 5 diesel engines and a steam turbine
while the other has 6 engines. Many auxiliary units also function in the engine hall. In this section we
would look at the various important components of the engine hall, their ratings, functions and working
principle.
3.1Generators
Some important specifications from the technical datasheet of these generators are:
Manufacturer: Converteam Ltd.
Voltage and frequency: 15000V 50Hz
3.2 AVR
Automated voltage regulator is placed next to the generator in a panel along with other controllers of the
generator. The functions and modes of operation for AVR are discussed in the control section of the report.
Listing a few functions
1) Provide excitation current by rectification.
2) Synchronize generator with the MV bus.
3) Control the reactive power and hence the power factor of the generator.
Figure 4 coupling
of engine and
generator
Each cylinder head has one air inlet and one exhaust outlet, 2 valves for inlet and 2 valves for exhaust, and
one Injector pump. There are safety valves as well in the cylinder heads which open when the temperature
reaches dangerously high level. The diesel engine uses 4 stroke mechanisms in the internal combustion
engine to rotate the crankshaft. The 4 steps involved in each cycle of piston movement are listed below
Steps
1) As the piston goes down, it pulls in air from the inlet and the inlet valves open (inlet stage)
2) Once the cylinder head is filled with air, and the piston has reached bottom dead center, the piston goes up
and compresses air. Inlet valves and exhaust valves are both closed. (compression stage)
3) Injector throws in fuel at very high pressure when the piston has reached top dead center. The signal to
inject fuel is mechanically triggered by the piston. Combustion occurs and piston is pushed down due to
force of expansion. (expansion stage)
4) Piston again moves up and this time exhaust valves are open. Products of combustion go out through
exhaust (exhaust stage)
5) Repeat step 1
Top dead center -> piston level when maximum compression occurs
Bottom dead center -> piston level when maximum intake of air occurs
In the mechanism described above we are only getting a linear vertical motion of the piston. Through gears
attached at the bottom end of the piston this linear motion is converted into the rotary motion of the
crankshaft. This crankshaft is coupled to the rotor of the generator through another gear system. A small
motor is attached at the point of coupling which may sometime be used to rotate the stator for cleaning and
debugging purposes.
There is a certain firing order which is followed for the fuel injection in the cylinder heads. It depends on
the gearing at the time of manufacture. Pistons in every cylinder head are not moving at the same phase.
They reach top dead center at different times and firing order is decided keeping that in mind.
Engine cooling is done through water as there is no danger of electric short circuits in the engine. LTHT
pumps (low temperature high temperature pumps) are used to pump cooling water throughout the engine
cylinder heads. Air filters are used before the air inlet in the cylinder heads. These are used to cool and
purify the incoming air. Cool air has higher efficiency compared to hot air because it is denser and in the
same volume provides more expansion force, or in other words, uses less fuel to provide the same
expansion.
To maintain a certain level of viscosity and to purify the lube oil, separators are used inside the engine hall.
They make sure that only the lube oil with the required viscosity should enter the engine. The speed of the
motors involved in those separators is controlled by VFD whose working principle would be discussed
later.
Another important auxiliary system in the engine hall is the starting air tanks. They hold the starting air at
high pressure which is required to provide some initial rotation to the crankshaft when the engines are not
operating. 6 compressors are used for starting air and they keep the air under a pressure of around 30 bars.
Other auxiliary systems include heaters to maintain the temperature of the furnace around 100c and
temperature of lube oil around 65c.
Super heater
600
625
18.5/15
Evaporator
2250
3000
18.5/15
Economizer
750
327
18.5/15
Deaerator
1600
1000
18.5/9
382/327
211/201
211/165
211/180
20
20
20
20
LP evaporator
Economizer
HP evaporator
Super heater
Steam drum
Deaerator
Fig 5 boiler
system
Some of the parts of the boiler listed above can be seen in figure 5. The four chambers of the boiler can be
seen in the figure as well. LP evaporator stands for low pressure evaporator. It contains steam with very
high water content and low temperature. This steam is passed to the feed water tank where it is heated and
sent to the chemical dosing unit where mineral contents and PH of the water are readjusted for boiler
protection. Then the feed water tank sends the steam to a pumping unit which transfers it to the economizer
section of the boiler. The economizer section stores some of the steam in the steam drum where it is kept at
high pressure and temperature. From the steam drum steam is moved to the HP evaporator for further
heating and eventually in the super heater section the steam is perfectly dry with minimum water contents
and the required temperature and pressure. From the super heater, the steam is carried to the turbine passing
through further actuators along the way. The motors shown as circles on the right of the boilers are used to
pump steam from one chamber to the other.
The deaerator is not mentioned in the figure. It serves the function of removing air from the system,
particularly oxygen. It consists of chemicals that can absorb oxygen from the steam.
4.3 Actuators
In case we dont want the exhaust to enter the boiler we have actuators that close the passage of exhaust
going into the boiler and open an alternate path which take the exhaust straight to the chimney. In this way
the boiler is bypassed. In this section we discuss the control and working mechanism of these actuators.
There are many kinds of actuators but those which allow the maximum control are electric actuators. They
are usually connected to a valve controlling flow of a fluid, in this case the exhaust gases. The important
components of the actuators are:
1) Motor: any motor can be used for opening or closing the valve. In case of boiler exhaust, servo motor
is employed due to its high locking ability.
2) Limit and torque sensors: They are sensors used to sense when the limit of opening and closing has
been reached. These sensors transmit position of the valve as a voltage signal.
3) Gearing: locks the motor in its position and also controls the speed
4) Valve attachment: Connect actuator strongly to the valve.
5) Hand wheel: for manually changing the valve position.
6) Control circuitry: contains feedback loops for maintaining the position of the valves. There are
switches that increase or decrease the angle of the servo accordingly.
Actuators are also used at many other locations all over the plant. They adjust the amount of steam entering
the turbine, the amount of water leaving the RO plant, the amount of HFO flowing in the fuel treatment
house etc.
5 Protection Schemes
The protection used must have certain attributes which would make it more efficient. First of all whatever
protection is used it must be very reliable. It must only trigger an action when the device is actually under
some threat, not during some abnormal operating conditions. For reliability it is a good idea to have back
up protection as well. Another important quality is that the protection must be very selective. It should be
able to identify exactly where the fault has occurred and then trigger the required action to isolate the faulty
part without disrupting rest of the system. Another important attribute of good protection is that it finds the
right balance between accuracy and speed. Both bear an inverse relation. In order to be accurate the device
needs more information that can only come with time but with more time the device is more likely to be
damaged. Lastly the protection must exhibit the correct amount of sensitivity. It must not trip at every little
diversion but still be good enough to respond to the tiniest of faults.
Keeping these attributes in mind many protection schemes have been designed and each of them makes use
of a component called relay. NPL is one of the modern IPPs in Pakistan and all the protection here is done
by numerical relays instead of electromechanical relays. Numerical relays are microprocessor based and it
is just one device that performs all the required protection for several different faults. Almost all of these
schemes use protection transformers, both current and voltage as well. Like the instrumentation
transformers described earlier, these transformers step down voltages and current so that they can be
handled by electronic devices. However there is a very purpose based difference in the working of these
two types of transformers. The instrumentation transformers are not designed to measure fault currents, so
their secondary output saturate very near the rated voltage or current at the primary end. Whereas the
protection transformers saturate at 5 or 6 times the rated current or voltage so that information about even
the high currents or voltages is received accurately.
A very brief description of some different protection schemes is provided here.
Over current protection:
Simple over current protection can be provided by feeding the secondary output of a current transformer to
a relay. The current transformer would provide a representation of the current flowing through the line to be
protected. (See figure 6). The plug settings of the relay can be used to set a threshold for the current above
which the relay would trigger some action. The option of time settings brings two further varieties in the
over current protection. These are called definite time over current relay and inverse time over current
relay. The time setting allows user to program a time after detection, that a relay should wait before sending
the trip signal.
Fig 6 over
current
relay
In the definite time over current relay, the relay waits for a fixed time set
by the user irrespective of the magnitude of the fault current. The inverse
time over current relay is based on the concern that very large current
should be quickly handled but with smaller fault current the relay can
afford to wait for some time. So in this type of relay the time setting is
done such that the waiting time is inversely dependent on the magnitude
of fault current. The exact relation can have some variety which makes
the relay either inverse definite minimum time (IDMT), very inverse or extremely inverse type relay.
Sometimes it is required that over current is detected in only one direction, and in the other direction the
relay restrains from tripping. This type of relay makes use of the phase difference between the voltage and
current to decide the direction of current and it requires both CT and PT for complete information. One of
those signals usually the current signal is skewed using variable capacitors and resistors to add a little phase
offset. Now when the phase difference between the voltage and current becomes equal to that phase offset,
we know that in reality the voltages and current are in sync and the current is about to change direction.
The electromechanical system in relay is such that maximum torque is produced at that instant and hence
the phase offset is also called the maximum torque angle and it defines the boundary between trips and
restrain region.
Distance protection:
It deals with monitoring the impedance of the system under protection, while taking the data from one
point. The impedance of a system would be a function of distance from that point. The protection is
programmed such that it would create a trip signal whenever the impedance of the zone falls below a
certain threshold. For doing so it requires input from CT and PT at that point. We only need to provide
those input to a numerical relay and the micro processor would calculate the impedance, but in case of
electromechanical relays, the voltage signal would provide the restraining torque while current signal
would provide the operating or tripping torque. In case of low impedance the operating torque would
exceed the restraining torque and trip signal would be generated.
Differential protection:
Another protection scheme with very precise zone is the differential protection. Differential protection is
very well illustrated in figure 7.
Fig 7
differential
protection
Whenever a fault occurs in the system, the current leaving and entering it are not the same. In case of
transformers, the ratio of input current to output is fixed for normal operation but random when a fault
occurs. So this information about the current entering and leaving the system is utilized in this sort of
protection scheme. The ratio of current transformers is selected such that the current at their secondary ends
are equal during normal operation. The difference of these currents called the spill current is used to operate
the relay.
A further improvement to this scheme is the percentage differential protection. There is always some error
spill current which is high for larger currents. The secondary current of the current transformers are used
for a restraining torque, which means that for larger currents, the excess spill error current would be
compensated by the excess restraining torque.
The common electrical faults that might occur in the transformer are due to loss of insulation. They include
phase faults like phase to phase or phase to earth fault. For protection from such faults, the following two
schemes are used by the numerical relay attached to the transformer.
1) Percentage Differential protection (primary protection)
2) Over current protection
3) Distance protection
Over fluxing can be detected by the relay through calculating the voltage to frequency ratio. That ratio must
always remain in a certain tolerable range when fluxing in the transformer is operating normally.
When the transformer first starts, it pulls in a large amount of current called inrush current due to saturation
of its magnetic core. It is quite likely that the inrush current would be greater than the threshold or trip level
of the over current relay. For preventing this from happening the numerical relay then calculates the
magnitude of currents 2nd harmonic and if it is large, the relay restrains from tripping.
There is one more electrical fault in the transformer which cannot be detected by the numerical relay. This
is the inter turn fault and it causes heavy currents to flow within the windings. This can be detected using
the Buchholz relay.
Buchholz relay has two mechanisms to detect faults. It has a float whose level changes with level of oil in
the relay. Second mechanism is a flap which detects the flow of oil from conservator to the main tank.
There are 4 types of fault that this kind of Buchholz relay would be able to detect.
1) Small inter turn faults will burn oil and small bubbles will be made that will flow and be trapped in the
relay. This would push down the oil level in the relay and the float would trigger an alarm
2) Heavy inter turn faults would burn the oil so quickly that it generates a fast flow of oil from
conservator to the tank through the relay. The flap would then trigger a signal to trip the transformer.
3) Oil leakage would have the same effect as the above fault. Again the flow of oil would be too fast.
4) Penetration of air inside the tank would result in that air being trapped in the relay and again the float
would trigger the alarm.
Finally overload protection is provided in the transformer through thermal imaging of the temperature of its
core windings. The overload condition of the transformer can be judged through the temperature of its
windings. However temperature of the winding cannot be directly measured as bringing any electrical
equipment near the winding would cause interference. Thus the idea of thermal imaging is used. In this
method a current transformer heats an element at its secondary end such that the temperature of that
element is a replica or an image of the actual temperature of the winding. The temperature of that element
is then recorded and sent to a numerical relay which decides whether the transformer is in overload
condition or not.
it would start to act like a motor resulting in catastrophic damage to the engine which is coupled to it. This
protection also monitors the excitation current. Unbalanced load is checked by over current protection of
neutral wire.
2) Differential protection (primary protection)
Differential protection is provided to the stator windings and it basically provides protection from shunt
faults and ground faults.
3) Voltage protection
Checks for over voltage at the stator windings and also checks for residual voltage when the generator shuts
down.
4) Frequency Protection
It provides under frequency, over frequency and unstable frequency detection.
5) Rotor speeding protection
It provides protection to the rotor in case of over speeding or under speeding.
6 Sensor Applications
Before moving to control it is important to understand how many of the important parameters in the plant
are measured. Most of these sensors send analog signals to the PLC (programmable logic control) cards
which then convert it to digital and process it.
1) Rotameters: Contains a vertical oriented glass or plastic tube with a freely moving float inside it. As a
fluid moves through the tube, the float rises and eventually reaches a steady state height where
equilibrium is reached between upward and downward forces. Upward forces are differential pressure
and buoyancy factors, while downwards is gravity. The height of the float is a function of mass flow
and can be calibrated accordingly. Rotameters are being used in RO plant of the NPL to measure the
flow of water that is being treated per unit time.
2)
Calorimetric flow meter: This scheme uses two heat sensors isolated from each other. One of the
sensors is heated. The flow of the fluid has a cooling effect on the sensor which is being heated. The
temperature difference between the two sensors then depends on how much the heated sensor has been
cooled. Hence the temperature difference is a function of flow rate and can be calculated by a control
unit. Such meters are being used in the engine hall to measure flow of furnace.
3)
Electromagnetic flow meter (hygrometer): it has high power consumption and can be used only for
conducting liquids like water. Energized coils on the pipe produce magnetic fields and EMF is induced
in the fluid and that EMF is related to the flow rate. EMF is measured by electrodes mounted in the
pipe. This method of measuring flow of water is being used in NPL at many of the pipes carrying
water to the boiler.
4) Positive Displacement flow meter: this is one of the modern methods and a very accurate one. This
method measures flow rate by rotation of a rotor caused by the fluid. The rpm is calibrated and linked
to the volume of the fluid. The number of rotation is counted by an electronic pulse transmitter and
converted to volume and flow rate.
5) Coriolis flow meter: The biggest advantage is that it measures the mass flow directly and not through
some indirect method like temperature measurement or pressure measurement. The fluid runs through
a pipe which is in state of forced vibrations. Due to Coriolis Effect on fluid, the tubes will deform and
an additional component would be added to the vibrations. This would cause phase difference in the
oscillations along the length of the tube and this can be measured using sensors. From these additional
oscillations the mass flow can be measured. Such flow meters are used in the engine halls to measure
flow rate of furnace. A remote logic unit makes the necessary calculations and the flow rate is
displayed on a meter.
to it and due to Hall Effect a voltage is generated. Voltage goes back to zero as the teeth moves away. In
this way a square shaped signal is received whose frequency is proportional to the speed of rotor.
Pressure switches and measurement devices make use of small piezoelectric disk shaped sensors, placed
under a diaphragm. The fluid is made to hit the diaphragm and based on its deformation we get a voltage
signal which is a representation of pressure. The conventional manometers can also be used to measure
pressure where their use is convenient.
Figure 8 LVDT
working
7 Control operations
Control room uses programmable logic cards to interpret meaning out of the voltage signals received from
the sensors and communicate it to the outside world. One of the basic functions of control room is to
acquire data and display information. The important information which is displayed on the panels:
1) Generator control panel
Information available
Name of information measurement
Range available
Phase current L1
Phase current L2
Phase current L3
Power factor
Frequency
Voltage
Engine speed
Turbo speed
Active power
Reactive power
0 to 2000 A
0 to 2000 A
0 to 2000 A
0.5 lagging to 0.5 leading
45 to 55 Hz
0 to 20 KV
0 to 650 rpm
0 to 30000 rpm
0 to 20 MW
4 Mvar used to 15 Mvar supplied
Q 7934 Kvar
F 49.77 Hz
0.90
IL2 697 A
IL3 711 A
IO2 0.015 A
Generator differential
current relay (displays)
IL1 738 A
IL2 704 A
IL3 716 A
Information
Label
Control oil pressure
Lube oil pressure
Turbine speed
5)
7)
9)
11)
Range
0 to 30 bars
0 to 4 bars
0 to 10000rpm
20)
22)
24)
26)
28)
30)
32)
34)
36)
Range
0.5 lagging to 0.5 leading
0 to 20 Mvar
0 to 20 MW
0 to 200 V
45 to 55 Hz
0 to 15 A
0 to 800 A
0 to 20 KV
12)
13)
14)
15)
16)
17)
Displays
Information
Power factor
Reactive power
Active power
Excitation field voltage
Generation frequency
Exciter field current
Generator ammeter
Generator voltage
37)
38)
Displays
1) Reactive Mvarh
2) Active MWh
39)
Label
Engine
Breaker
Engine Shutdown
Breaker trip
Lamp test
43)
46)
49)
52)
55)
58)
Option 1
Start
Closed
Reset
Reset
44) Option 2
47) Stop
50) Open
53)
56)
59)
61)
Knobs
62) Label
66)
70) Engine
control
74) Generat
or
control
78) Fuel
82) Excitati
on
86) Synchro
nizing
90) Selectio
n of
speed
measure
ment
63) Option 1
67) Generating
Auto
71) Speed
droop
75) Voltage
droop
64) Option 2
68) Set control
manual
72) KW isoch
65) Option 3
69)
76) Pf Vdc
77)
79) Decrease
83) Decrease
80) Increase
84) Increase
81)
85)
87) 0
88) Select/start
89)
91) Engine
92) Turbo A
93) Turbo B
73)
94)
2) Turbine instrument control panel
95)
96)
Push buttons
Knobs
98) La
bel
102)
Turbin
e
sp
ee
d
co
ntr
ol
106)
Over
sp
ee
d
110)Co
ntr
ol
mo
99) Option 1
100)
Option 2
101)
Option 3
103)
Lower
104)
105)
Raise
107)
Off
108)
Test
109)
111)Local
112)Remote
113)
de
114)
3) Generator control panel (steam turbine)
115)
116)
Knobs
117)Label
118)Opt
ion
1
119)Opt
ion
2
120)
Optio
n
3
125)
Raise
121)
Op
tion4
122)
Gene
rator
voltage
127)
Excit
ation
control
132)
Amm
eter
selection
137)
Turbi
ne speed
control
142)
Volt
meter
selection
123)
Lower
124)
N
128)
Off
129)
On
130)
131)
133)
Off
134)
L1
135)
V
136)
138)
Lower
139)
N
140)
Raise
141)
143)
Off
144)
U-V
145)
V-W
146)
U
126)
147)
148)
Push buttons
1) Lamp test
2) Auto sync initiate
3) Fail to sync reset
149)
1)
2)
3)
4)
5)
6)
Generator set
Electrical
Power
Lube oil
Emissions
Air system
7)
8)
9)
10)
11)
12)
Fuel oil
Heat recovery
Oily water
Water supply
Fire fight
Start air
13)
14)
15)
16)
17)
18)
Automation
Temp/press
Ambient
Deaeration
Cooling
Exhaust gases
W-
19)
Fig 9 transformer
22)
T1 and T2 are auxiliary transformers. LV bus tie is normally
open and all the other breakers are normally closed. Suppose the
transformer T1 is to be isolated for maintenance the procedure would
be to:
1) Synchronize the LV bus tie and close it. This would transfer the
load of T1 to T2.
2) Open LV CB1. Now the transformer is at no load condition.
3) Open MV CB1.
4) Close earth switch of transformer so that it is safe to handle.
23)
24) In this way T1 is isolated.
25)
26) Now suppose the maintenance is complete and we wish to restore the transformer T1, the procedure
would be as follows:
1) Open the earth switch
2) Close MV CB1
3) Synchronize LV CB1 and close it. Now the transformer is supplying to load.
4) Open bus tie LV so that the transformer has its entire load.
27)
28)
Sensors: CT and PT
Actuator: Generator
Control variable: Terminal voltage
Controller: AVR PID control
Fig 10.1
2) Manual control
36)
In this mode it regulates the field current of the exciter. See figure 10.2
37)
38)
39)
40)
41)
Sensors: CT
Fig 10.2
Actuator: Generator
Control variable: Field current
Controller: AVR PI control
3) PF or Var regulator
42)
In this mode the AVR must maintain a certain PF by adjusting the value of reactive power. See
figure 10.3
43)
44)
45)
46)
47)
Sensors: CT and PT
Fig 10.3
Actuator: Generator
Control variable: Power factor and reactive power
Controller: AVR PID control
4) Open loop
48)
In this mode the AVR just once provides a fixed field current and then does not regulate it. See
figure 10.4.
Fig 10.4
49)
50)
51)
52)
53)
54)
Sensors: None
Actuator: Generator
Control variable: Field current
Controller: none
7.3 Synchronization
55)
When the generator is isolated, its frequency is controlled through the rpm of its rotor, which in
fact is controlled by the fuel intake. Fuel intake is adjusted by governor set points. The voltage at the
terminal is controlled by the excitation current. These two parameters can be controlled independent of one
another. For synchronization the terminals of generator and the MV bus bar should have the same voltage,
similar frequency, same phase sequence, and 0 phase difference at the time of connection. Synchronization
of generator with MV bus bar is one of the functions of AVR. The setup is illustrated in figure 11. [18]
56)
For Synchronization AVR acquires the
following inputs
Figure 11
Fig
All the AVR are connected to each other through12
RS 485 bus and they communicate with each
63)
other the reactive power being supplied. Each AVR or unit reads those values and so every AVR knows the
power factor at which all generators are running.
Fig
13
64)
When the generator is to be started from 0
voltages at its terminal, the AVR takes its terminal
voltage up to the bus voltage in the manner shown in fig
This is known as soft start. The reason for providing
some hold time is to minimize the in rush current by
allowing time for it to induce a back EMF in the system
a low voltage.
13.
at
Workshop Machines
68)
Workshop is the place of electrical and mechanical repair and maintenance of components from
the plant equipment. Workshop has a small instrument air compressor of its own for generating instrument
air at 7 bars used for drying parts that have been washed and for cleaning parts by blowing dust off them.
Some other machine available in workshop and their function is as follows:
69)
Sand blasting machine: for cleaning large machine parts without using water.
70)
Lathe Machine: for small operation like turning, facing, drilling etc
71)
Bench drill machine: Common drill machine for drilling holes in metal objects.
72)
73)
Valve grinding machine: for tuning the shape of the valve and smoothing its edges.
Fuel treatments
74)
The fuel is first unloaded from the containers at the decanting area. Fuel is pulled in by pumps and
carried to the pipes. There are heaters available in case the furnace is too cold to move. Sludge from the
container is first separated here and is carried in a separate pipeline. The pipe carries the furnace to a large
storage tank. NPL has three of those. From storage tank, fuel is transferred to buffer tank through pumps
installed in a transfer unit at the FT house. From the buffer tank, furnace goes to a separator unit in the FT
house where it is purified to remove water, sludge and any solid particles. The technique used to purify is
centrifugation which separates fluids based on their specific gravities or viscosities. Water and sludge being
denser than furnace settle at the bottom of the centrifuge tank. The furnace at day tank is then ready to be
used by the engine. It is transferred to the engine hall using pumps at the feeder unit of the FT house. The
motors in feeder unit are controlled by VFDs which adjust the speed of pumping based on furnace tank oil
level and the engine fuel requirement. Inside the engine hall is the booster unit which pumps furnace to the
fuel injectors and heaters that maintain the temperature of oil near to a 100c.
75)
76)
77)