A study on Electrical equipment used in working

modules and power distribution at AVCTPL

An Industrial Project Report

Submitted In Partial Fulfillment of the requirements for the Award of the Degree of

BACHELOR OF TECHNOLOGY IN

ELECTRICAL ENGINEERING

Submitted by

DEEPAK KUMAR DASH

Under the Esteemed Guidance of

Mr.D.Kiran Kumar

(Associate Manager, H.R., AVCTPL)

Mr.Siddhant Chatterjee

(Head of Engineering Department, AVCTPL)

DEPARTMENT OF ELECTRICAL ENGINEERING

GANDHI INSTITUTE OF ENGINEERING & TECHNOLOGY GUNUPUR – 765 022, Dist.: Rayagada (Odisha), India

(Approved by AICTE, Govt. of Orissa and Affiliated to Biju Patnaik University of Technology)

2015-16

DECLARATION

I hereby declare that the Industrial project “A study of

electrical equipment used in working modules and power

distribution at AVCTPL” submitted for the B.Tech Degree is

done by me with the association of “Adani Vizag Coal

Terminal Port Pvt.ltd, Port Area, Visakhapatnam, Andhra

Pradesh 530035, India.”

Name & Signature of the Student:

Saswat Mohapatra

Place: AVCTPL, Vizag

Date: 15-06-2015

ACKNOWLEDGEMENT

We would like to express our profound sense of gratitude to all for having helped us

in completing this dissertation. We would like to express our deep felt gratitude and sincere

thanks to our guide “Mr.B.Pradeep Kumar, H.O.D., electrical” for his skillful guidance,

timely suggestions and encouragement in completing this project.

We are highly obliged to our project coordinator Mr.Siddhant Chatterjee, Head of

the Engineering department, for having extended his affable guidance, constant supervis ion

and encouragement throughout the progress of this project, which helped us to complete it

within the stipulated time.

We would like to express our sincere thanks to Mr.D.Kiran Kumar, Associate

Manager, H.R., AVCTPL, for providing the necessary facilities for the successful

completion of this work.

Last but not least, we wish to thank our Instructor & Other Staffs, our parents and

all our friends for their constant moral support, cooperation and encouragement during this

period.

CONTENTS

ABSTRACT i

LIST OF FIGURES & TABLES ii

INTRODUCTION 1-2

CHAPTER 1: WORKING MODULES OF AVCTPL 1.1 Introduction 3

1.2 Intermediate transfer tower(ITT) 3 1.2.1 Definition 3

1.2.2 Types 4

1.2.2.0 ITT1 4

1.2.2.1 ITT2

1.2.2.2 ITT3 4

1.2.2.3 ITT4 4

1.2.2.4 ITT5 4

1.2.3 Use of automation 4

1.3 Intermediate Belt Conveyor 5

1.3.1 Definition 5

1.3.2 Types 5

1.3.2.0 IBC1 5

1.3.2.1 IBC2 5

1.3.2.2 IBC3 6 1.3.2.3 IBC3A 6

1.3.2.4 IBC4 6

1.3.3 Use of automation 6

1.4 Stacker and Reclaimer 7

1.4.1 Definition 7

1.4.2 Modes of operation 7

1.4.3 E-house and its function 7

1.4.4 Use of automation 9

1.5 SILO 9

1.5.1 Definition 9

1.5.2 Functional part of SILO 9

1.5.3 Technology of choice and automation 11

1.5.4 Wagon loading 13

1.6 Pump house 13

1.6.1 Need of pump house 13 1.6.2 Main component of pump house 13

CHAPTER 2: CONTROL ROOM 2.1 Introduction 15

2.2 Layout view of AVCTPL 15

2.3 Layout view of DS System 16

CHAPTER 3: AVCTPL SUBSTATION GRID

3.1 Main objective of Distribution system 17

3.2 Functional parts of substation grid 17 3.3 A Brief lay out of distribution of AVCTPL 22

3.4 New glance of technology in distribution 23 3.5 Case study analysis on distribution system 24 3.6 UPS System 25

3.7 DG Supply 26 3.8 Reactive power compensation 26

3.9 some industrial measurements 27

CHAPTER 4: SAFETY 4.1 Definition 28 4.2 Need of Safety for AVCTPL 28

4.3 Safety equipment and procedure 29

REFERENCE 30

ABSTRACT

In today's world of power shortages, increasing demand and the energy efficiency

debate, how the electricity network is run right through from the power station to consumer

end is becoming ever more important. 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 other important functions. Between the generating station

and consumer, electric power may flow through several substations at different voltage levels.

A Distribution substation transfers power from the transmission system to the distribution

system of an area. It is uneconomical to directly connect electricity consumers to the main

transmission network, unless they use large amounts of power, so the distribution station

reduces voltage to a level suitable for local distribution.

The highest priority in a substation is to detect and isolate failures in the transmiss ion

system as hastily as possible. Upholding power quality is one of the main functions of a

substation, and it affects operating conditions of the whole transmission and distribution

networks. Power quality information is of strategic importance for electricity companies and

essential for ensuring competitive operation.

In this era, every industry frantically needs both the performance and efficiency

simultaneously so as to maintain the performances and efficiencies of different electrica l

machine is the new challenges for the engineers.

The main focus on this project is to scrutinizing the efficient performance of the

industry by maintaining the power factor at the acceptable limit and providing healthy

performance to the machine used in different modules. So it provides a good economic strength

to the industry. The other objective of this project is to analyzing the new technology involved

in each working module and the type of electrical equipment used in each module of AVCTPL

distribution substation. A careful case study of the project can give an ephemeral idea about

the distribution system and the new technology used over here with its future appliances.

i

LIST OF FIGURES

Figure

No.

Description page no.

Fig. 1 BLOCK DIAGRAM OF PLC CONTROL 12

Fig. 2

LAYOUT VIEW OF AVCTPL 15

Fig 3

LAYOUT VIEW OF DS SYSTEM 16

Fig: 4

AVCTPL PANEL 20

Fig. 5 LAYOUT OF DISTRIBUTION OF AVCTPL 22

Fig. 6 LAYOUT OF UPS SYSTEM 25

Fig. 7 DG AND MAIN SUPPLY CONNECTION 26

LIST OF TABLES

Table

No.

Description pageno.

Table 1.0

SPECIFICATION OF HT MOTOR 3

Table 1.1

SPECIFICATON OF DRY TANSFORMER[E-HOUSE] 8

Table 1.2

SPECIFICATION OF MOTOR 10

Table 1.3

SPECIFICATION OF MOTOR[PUMP HOUSE] 13

Table 1.4

PANEL POWER SUPPLY 21

Table 1.5

SPECIFICATION OF DRY TRANSFORMER[LIGHTING] 24

Table 1.6

SPECIFICATION OF APFC 27

ii

INTRODUCTION

The Adani Vizag Coal Terminal Private Ltd (AVCTPL), a subsidiary of APSEZ and

also a part of Adani group which is global integrated infrastructure player with interests in

resources, logistics, energy and agribusiness. It is an Indian multinational company founded by

the former chairman Mr.Goutam Adani. AVCTPL had entered into a concession agreement

with Visakhapatnam Port Trust to set up fully mechanized steam coal handling facility with a

capacity of 6.4 million tonnes a year in March 2011 with completion deadline of August 2014.

The facility is completed eight months ahead of schedule at a cost of Rs400 crore.AVCTPL,

being a part of Visakhapatnam Port is strategic for coal imports to feed the local industries and

power plants of the states of Andhra Pradesh, Odisha, Chhattisgarh and Maharashtra.

AVCTPL occupies a large area of back up yard about 25 Acres. AVCTPL is basically

import terminal type to handle the cargo (steam coal) and terminal capacity is 5.0 MMTPA. It

is having a Berth of size 280 meters and width of 6.1 meters. It contains maximum vessel size

of 80000 DWT. It has a Deck top level of 3.65 meter.

Constructional AVCTPL is divided into three different working sites in such a way

that failure of any one site can cause a huge amount of loss to the company. So AVCTPL has

its own control room from where it invigilates any site easily at any time. AVCTPL has its own

substation which is situated inside the operational building. The port site is present in the west

side to the operational building. Two Mobile Harbor Crane (MHC) are employed there,

which is operated by the operator master. These are mainly running for luffing purpose of cargo

which is present inside the vessel. It can be also visualized directly through the control room.

AVCTPL has its own storing site used for cargo (i.e. coal) storage purpose. These site mainly

contains other working modules namely 2 Stackers, a Pump House and ITT towers. The

intermediate transfer tower(ITT) mainly consists of HT Motors(High Tension Motor) and

Chutes and all the ITT towers are interconnected by the IBC(intermediate belt conveyor).The

Stackers are mainly running in two modes i.e. stacking mode and reclaiming mode depending

on the operation to be operated. Pump house at AVCTPL has a reservoir at which it store water

and by the help of pump, water is pumped up and supplied to the water sprinklers. Water

sprinklers are mainly used for dust separation purpose. In general it is used environment safety

1

by preventing the unnecessary air pollution due to blowing of coal dust. AVCTPL has a large

cargo storing tank called SILO which is used for storing the cargo in large amount and used

for wagon loading. There is an ITT Tower (i.e.ITT5) is present on the SILO. It also has so

many parts which can be discussed later.

AVCTPL has a substation which is equipped with all the advanced technology. The

substation of AVCTPL mainly consists of FEEDERS, UPS ROOM, LIGHTING

TRANSFORMER ROOM, INCOMERS, RELAY TRIPS and ALARMS. All the

transformers, machines, HT Motor and diesel generators (DG) controls are integrated at the

substation with all type of safety has been taking into account. RELAY TRIPS mainly gives

protection to the electrically operated modules and DGs are used to give supply instantly for

lighting purpose of the plant. DGs are running when there is a failure of main supply

encountered.

AVCTPL has a control room which is situated on the operational building. This

control room is designed in such a way that the total control of the plant can be further possible

from this Centre. Control room control equipment are fully based on automation and it is only

possible through the application SCADA and PLC. The control room has two big size monitors

which are connected with the close circuit cameras. So it may help to invigilate the problem

encountered with the working modules easily in short period time.

AVCTPL mainly focused on the safety of its labors as well as environments.so for

safety of its labor it provides safety helmets, safety jacket, gloves and safety boots to all the

labors those who are going to the working field and for environment safety it uses some

equipment like DSS (DRY DUST SEPARATION), WATER SPRINKLER etc.

2

CHAPTER 1: WORKING MODULES OF AVCTPL

1.1: INTRODUCTION AVCTPL has number of working modules like ITT, IBC, STACKER & RECLAIMER,

SILO, PUMP HOUSE, SUBSTATION GRID etc. In this chapter we are predominantly

emphasizing on the ITT (Intermediate Transfer Tower) and describing its function which

designating the smooth operation of the plant.

1.2: INTERMEDIATE TRANSFER TOWER (ITT)

1.2.1: DEFINITION

Intermediate transfer tower is one of the foremost functional unit of AVCTPL. It can be

demarcated as the tower which has a conveyor system which is again connected by a HT Motor

for running the conveyor belt in a particular direction depending on the mode of operation.

Further ITT TOWER also contains some mechanical systems like Pulley, scooping system,

Drop down system, PCS (Pull cord system), Hooter etc. and some electrical systems like BSS

(Belt side system) and metal detector (MD) and a HT Motor (3-ph induction motor). These are

the main system which can be found in each and every ITT Towers of AVCTPL.

SPECFICATION OF HT MOTOR:

[TABLE-1.0]

TYPE KW RPM EFFICIENCY VOLTAGE CURRENT DUTY POWER

FACTOR

3-PH 720 1492 94.5 6.6kv 77.0Amp S1 0.87

IMS (Inline magnetic Separator) is electromagnetic type which is used for the separation of

the ferrous metal. Apart from these equipment AVCTPL uses some PLC and SCADA

integrated circuit for automation control at the ITT Towers. There is a CBS (Chute Block

Switch) named switch present at all ITT Towers for the detection of any problem encountered

in the chute where the cargo is stored.

3

1.2.2: TYPES

In AVCTPL the ITT TOWER is broadly divided into 5 different Towers based upon their

position and working principle. These are namely as ITT1, ITT2, ITT3, ITT4 and ITT5.The

last tower i.e. ITT5 is present on the SILO.

1.2.2.0: ITT1

ITT1 is situated at the port side which provides the connecting medium between IBC1 and

IBC2. Its main function is to collect the cargo from hopper through IBC1 and sends it to ITT2.

1.2.2.1: ITT2

ITT2 is having a trichute which has a distinctive of bidirectional flow of cargo with the help of

a diverting gate. It mainly decides the flow direction of cargo to ITT3 or IIT4.So ITT2 is present

between ITT3 and ITT4.There is an electromechanical actuator is present in this tower.

1.2.2.2: ITT3

ITT3 provides the connecting medium between IBC3 and IBC2.It is not having any diverting

gate. It is unidirectional to ITT4.There is no additional electrical equipment is used over here.

1.2.2.3: ITT4

ITT4 receives cargo from ITT2 and ITT3 by means of a gate. The reclaiming process the major

factor of ITT4 which cannot be ignored. The cargo is carried out by the reclaiming process is

directly connected to the ITT5 present on the SILO.

1.2.2.4: ITT5

ITT5 is the last Tower of the AVCTPL ITT TOWERs which is present on the SILO. So

Here the cargo are store in the SILO and finally used for Wagon loading.

1.2.3: USE OF AUTOMATION

The use of automation increases safety, efficiency and performance of ITT. The use of PLC

and SCADA gives a very good performance on automatic control of the motor as well as in the

semiauto mode of operation. The program of plc is done by means of all the control condition

of electrical motor before starting. So before writing the program an engineer should focus on

4

all the braking and short circuit condition etc. All these mechanisms done so as to provide error

free environment and this leads to good performance of ITT.

Here we are using SIEMENS PLC device which are integrated with SCADA enable device

present at the control room of AVCTPL which is again connected to the other modules where

the control is required

AVCTPL also provides its WORKERS and ENGINEERS a pulse maker walky-talky for

direct contacts of workers with their respective engineers at the control room if any problem

encounter at any time.

1.3: INTERMEDIATE BELT CONVEYOR (IBC)

1.3.1: DEFINATION

IBC is the important constituent from all the working modules of AVCTPL through which

cargo is transferred. So IBC is having the high tensile strength because it is carrying the cargo

for the long distance.

In AVCTPL working area 1.5km length conveyor belt is present. As the belt is carrying cargo

so many protecting switch is present like BSS (Belt Side Switch), ZSS (Zero Speed switch),

BRS (Belt Rip Switch) etc. The function of all these parts are described in the use of

Automation part. Beside these protecting switch some other systems are connected with IBC

such as MD(METAL DETECTOR) is used to separate the ferrous metal from cargo which is

toned on the conveyor belt and a DROP DOWN SYSTEM is also used to prevent the init ia l

displacement of the cargo loaded belt which is caused due to sudden power supply to IBC.

One end of IBC is always connected to the motor and the other end is connected with the pulley.

1.3.2: TYPES

1.3.2.0: IBC1

IBC1 is related with the belt in which cargo is transferred from MHC (Mobile Harbor Crain)

to ITT1.

1.3.2.1: IBC2

The function of IBC2 is to transfer the cargo from ITT1 to ITT2 and from ITT2 to ITT3.Here

MD is present and it is used for the detection of the nonferrous metal.

5

1.3.2.2: IBC3

IBC3 is related to transfer of cargo from ITT3 to ITT4 and here two mode of operation is

present i.e. stacking mode and reclaiming mode in the respective operation.

1.3.2.3: IBC3A

IBC3A deals with the transfer of cargo from ITT2 to ITT4.Here also both stacking mode and

reclaiming mode is present.

1.3.2.4: IBC4

The main goal of IBC4 is to transfer the cargo from ITT4 to ITT5.MD is present over here.

1.3.3: USE OF AUTOMATION

The use of automation makes more efficient while IBC performing its operation. So in IBC,

many protecting switch is present like

BSS: It is an electrical device which internally connected with a sensor.It is used to prevent the

Cargo carrying belt to be one sided. So here a switch is present which is connected to

Belt support in order to sense the exact position of the belt. If belt is encountered any

problem with the position then the sensor activated and the related IBC panel is stop

working for the solution.

ZSS: The function of ZSS is to protect the belt, if the belt is cut in the middle or longitudina l ly.

As the motor is connected through IBC externally, during the cutting of belt in the

middle, motor will not stop but pulley will be stopped. A pulse formation mechanism is

connected to the pulley. If the pulley is stopped working then pulse formation will also

stopped. So we can easily determine by looking the pulse formation.

BRS: If the belt is cut vertically then neither motor nor pulley will stop.So in this condition we

are having a sensor i.e. transmitter and receiver and it is connected below the belt

Conveyor. Transmitter transmits the IR waves and receiver receives. If the belt is cut in

the middle then cargo will be wasted at the middle and disturbs the IR wave. After that

the sensor will activate and will stop the working of the HT Motor.

6

All the protecting switches are programed before the starting of motor accordingly. Apart from

these automation there is a manual switch present across the sides of the conveyor known as

PCS. This switch is connected through a rope so that any worker can pull the rope from any

position so as to stop the running conveyor and find the problem related to the belt then the

motor is disconnected from the gearbox.

1.4: STACKER AND RECLAIMER

1.4.1: DEFINATION

AVCTPL is having two Stacker and Reclaimer i.e. one is on the running mode and the other

one is on the standby mode (namely STACKER1 and STACKER2) .The function of the stacker

is to stack or creating the heap of cargo. The function of Reclaimer is to take the cargo from

the heap to the SILO. It is shortly designed as SCR (Stacker cum Reclaimer).SCR is having so

many functional units like E-house, conveyor and bucket etc.

1.4.2: MODES OF OPERATION

SCR is having two modes of operation like (i) STACKING

(ii) RECLAIMING

In stacking mode, cargo is collected from ITT2 and ITT3 and it is used for creating the heap of

12meter. There is two stack pile is present in AVCTPL campus where heap of cargo is made.

In reclaiming mode, the cargo is collected from the heap and allow for transferring the cargo

to the ITT4, then ITT5 and finally SILO respectively through the conveyor belt.

1.4.3: E-HOUSE AND ITS FUNCTION

The function of E-house is to provide the power supply to the working module present on the

SCR. As two SCRs are present so two E-house are available for SR1 and SR2.

SCR takes 6.6KV from the substation grid and step down to 0.433 KV/433V by means of DRY

TRANSFORMER.

7

SPECIFICATION OF DRY TRANSFORMER [E-HOUSE]:

The E-house acts as a small substation and used to provide the supply to different working

modules. It consists of PLC panel, AOP, MLDB (Main line Distribution Board).

[TABLE 1.1]

TYPE

3

FREQUENCY

50 HZ

AMB. Temperature

45 C

IMPEDANCE RISE

5.14%

CORE AND WINDING

3420

INSULATION CLASS

F

NO LOAD VOLTAGE

HV 6.6 KV LV O.433 KV

CURRENT

HV 109.35 AMP LV 1666.72 AMP

CONNECTION TYPE

-

8

1.4.4: USE OF AUTOMATION

The PLC used over here is basically SIEMENS. All the control logic deals with the sensors

and performed by means of RELAY which makes the system to be understand easily by every

Engineers.

1.5: SILO

1.5.1: DEFINATION

It is the most important constituent among all the working module of AVCTPL. The function

of SILO can be defined as to collect the cargo from ITT5 and stored at a large amount

approximately 3600 tonnes per hour and released it during wagon loading.

1.5.2: FUNCTIONAL PART OF SILO

The functional part of SILO is the tank where the cargo is stored and the control mechanism

related to the wagon loading.

SILO has so many working modules like POWER STACK, ACCUMULATOR and

CONTROL ROOM for wagon loading etc. In SILO, so many systems are present like,

HYDRAULIC SYSTEM, AIR BLASTING SYSTEM, DFDS(Dry Fog Separation

System).SILO is operated at operating pressure of 18000 psi(1psi=0.06895 Bar=0.06895*10^5

Pascal).

DFDS is the mixture of water and dust used to settled down the dry dust. This function is

similar to DSS.

In SILO, POWER STACK is present which consists of (i) MOTOR

(ii) PUMP

(iii) ACCUMULATOR

Motor and Pump are mechanically coupled. The motor having following specification which

is on the next page.

9

SPECIFICATION OF MOTOR:

[TABLE 1.2]

TYPE 3-PH IM

% EFFICIENCY 93.5%

AMB.TEMPERATURE 50 C

FRAME 250m

DUTY S1

IP 55

FREQUENCY 50hz

VOLT 415v

KW 55

AMP 97

RPM 1482

POWER FACTOR 0.86

Pump is having a big inlet diameter and a small outlet diameter and one end of the pump (outlet)

is connected by means of a FILTER to filter out any raw particle. The inlet of the pump is

hydraulic oil filter is having filtered unit of 10 microns. It is having 300hours maintenance

period.

In the power stack we are having the cooling system by means of recirculation pump and Heat

exchanger by means of fan. Cooling pressure can be measured by cooling system pressure,

stand by pressure and pump pressure. Here the circulation type is 1-phase.

Air Blasting System is present to blast the compressed the compressed nitrogen cylinder if the

cargo remains in the heavy solid form in case of gate removal. So by doing this we are breaking

the heavy solid cargo to small pieces. At the top of the tank 4 Gates and 8 Cylinders and at

the bottom of the tank 2 Gates and 4 cylinders are present. The blasting of the cylinders is

done by means of the solenoid coils and it is operated by 24vDC supply.

The operation of the Gate opening and closing is done by means of hydraulic system during

wagon loading.

10

Why Hydraulic system is preferable then the Electrical system during opening and

closing of gate during wagon loading?

We can’t use electrical system during the opening and closing of Gate during wagon loading

because electrical systems are used on those systems where are needing sudden changes in the

operation but here we need a smooth operation. Another reason is this operation is done by

means of pressure, as hydraulic system is responsible for creating the pressure but electrica l

system is not able to create any pressure.

.Apart from the step down transformer is also there for stepping down to low voltage and

rectifier arrangement is also there for conversion from ac to dc (24dc).

1.5.3: CHOICE OF NEW TECHNOLOGY AND USE OF AUTOMATION

SILO is having some new technology like use of sensor and automation in its working unit. In

the pump inlet we are having FILTER CLOG SENSOR to sense the filtered particle. We are

having proximity sensor like contact type and non-contact type. In contact type manually we

have to do and in non-contact type, below 5mm sensor will sense. Three types of proximity

sensor are available i.e. (i) fully close

(ii) Mid way

(iii) Fully open

If we consider a new technology, in power stack breather is present to remove the vapor from

the hydraulic oil.

3 modes of operation are dealing with the SILO i.e. auto, semiauto, manual mode. For

automatic mode of operation, we are having the PLC OF MARIT which is connected

through every sensor unit and performed operation by Relay

[P.T.O]

11

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BLOCK DIAGRAM OF PLC CONTROL :( MERIT)

[FIGURE- 1]

Here the term secondary is referred as the stand by, RB refers to the relay Board. MCB refers

as Miniature circuit Breaker. RS 232 is used for communication of data but here technica lly

it is called as command CPU is involved for execution of all the command.

So many command is given by control room of SILO i.e. Gate command open/close, Motor

command, solenoid command for blasting etc.

PRIMARY

CPU

CPU

SECONDARY

CPU

PRIMARY

I/O

SECONDARY

I/O

RB1 RB2 RB3 RB4

RB5

RB6

RB7

MCB1 MCB2 MCB3 MCB4 MCB5 MCB6 MCB7 MCB8

MCB16 MCB15 MCB14 MCB13 MCB12 MCB11 MCB10 MCB9

POWER

SOCKET MCB17 RS232

RS 232

LAN

CONVERTER 24 DC

12

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1.5.4: WAGON LOADING

It is the final touch of the entire processing system of AVCTPL. Here the wagon is present on

the track and the open/close command is given from the control room. According to the

command, cargo is put into the respective wagon and wagon loading takes place.

There are two sensors relates with the wagon loading i.e. BOXN and BOXNHS. BOXN sensor

is present at the height of 1 meter from the ground level. BOXNHS SENSOR is present at the

height of 1.2 meter from the ground level which gives the position of wagon.

1.6: PUMP HOUSE

1.6.1: NEED OF PUMP HOUSE

Pump house is the very important working module not only for AVCTPL but also for

environmental point of view. As AVCTPL is basically a coal port industry so there is

occurrence of dust during stacking, reclaiming and wagon loading etc. But the thing is that we

can’t compromise for the environmental safety. So any how we have to settle down the dust

by using DSS and water sprinkler etc.

VPT has made a conditional attachment with AVCTPL that heap should not exceed more then

12meter. The strong wind flow also makes the dust in heavy amount. So the need of pump

house becomes more essential for AVCTPL.

1.6.2: MAIN COMPONENT OF PUMP HOUSE

The main component of pump house is water sprinkler and pump. The pump used over here is

basically (i) CENTRIFUGAL PUMP and (ii) INLINE PUMP. Water is collected from the large

reservoir by means of pump and is supplied to sprinkler.

The motor in which pump is mechanically coupled is normally 3-ph Induction motor.

SPECIFICATION OF MOTOR [PUMP HOUSE]

[TABLE-1.3]

TYPE 3-Ph

FRAME 160 meter

VOLTAGE 415V

CURRENT 21.0 AMP

FEQUENCY 50 Hz

EFFICIENCY 88.4%

CONNECTION TYPE

RPM 1450

INSULATION TYPE F

13

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0

Pump is having capacity 360HP, pressure 0.5kg/m^2 and speed 1170rpm

Here also we are having auto, semiauto and manual mode operation. So we can control the

operation of the sprinkler directly from the control room or we can do manually that depends

on the choice of the operation. The details layout of the DS SYSTEM is explained in

CHAPTER 2.

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CHAPTER 2: CONTROL ROOM

2.1: INTRODUCTION

AVCTPL is having a control room in which all the command for every operation, certain

instruction and automatic mode of operation is possible. The thing is that here we are having a

complete visualization of each and every working site. Here every time engineer scrutinizing

the operation of entire working module and giving the required instruction and command.

The presence of control room giving very efficient operation of AVCTPL. More over here we

can see the wagon loading activity.

2.2: LAYOUT VIEW OF AVCTPL

In control room we can see the entire layout of the AVCTPL. So each and every site of working

module can be seen with respect to its function in the control room.

[FIGURE-2]

As we have discussed the entire working modules which are present on the layout in the

previous chapter. Here we only focus on the short notation of the variables like,

1. Z- ZSS 2. B- BSS 3.P- PCS 4. MD- METAL DETECTOR

15

2.3: LAYOUT VIEW OF DS SYSTEM

As we have discussed the presence of DS system is very much essential for the environmenta l

safety point of view. Here we careful focus on the layout.

[ FIGURE-3]

In this layout we are having total 55 water sprinkler which are operated by means of side wise

like, in STOCK PILE 1 first sprinkler no.1 and sprinkler no.2 will turn on then 2 and 22

respectively. All the sprinklers are operated on the same sequence.

16

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CHAPTER 3: AVCTPL SUBSTATION GRID

3.1: MAIN OBJECTIVE OF THE DISTRIBUTION SYSTEM

The main planning approach for electrical distribution system to optimize the number of

feeders and their roots. It is very much essential for the electrical substation is to maximize the

network reliability and minimize the total installation and operational cost.

So from generation of electricity to utilization distribution system plays an intermed iary

operation. So without distribution system the consumers can’t get the electricity from the

generation station.

Here also AVCTPL is having own substation grid and with a distribution system to each

working modules which readily depends on the electricity.

3.2: FUNCTIONAL PART OF SUBSTATION GRID

The main functional unit of SUBSTATION GRID are (i) Transformer

(ii) CT & PT

(iii) ACB & VCB

(iv) Feeder and distribution panel

(v) Reactive power compensation

(vi) UPS

(vii) DG Supply

1. TRANSFORMER

We can say that transformer is the main constituent of the entire sub-station because

step up and step down of the voltage can be done by means of transformer. AVCTPL substation

Grid receives the 33KV supply from the APEPDCL. This high voltage is stepping down to 6.6

KV and this 6.6 KV is again stepping down to 433 KV. We are using both 6.6 KV for the

working of all HT MOTOR and 433KV for the DISTRIBUTION and LIGHTING purpose.

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There are total 4 step down transformer and 1 one to one transformer is there. Out of 4

transformer two transformers are used for 33KV/ 6.6KV and two transformer are used for

6.6KV/433V. The thing is that one is always running and other one is always on the stand by

position.

Apart from that a single one to one transformer is there used for the lightening purpose, so

sudden change in the fluctuation of the voltage can be filtered out. This transformer is dry type

transformer.

There are two methods are used for transformer tap changing i.e. 1. On load tap changer

2. Off load tap changer

During the on load tap changer method the transformer is connected through the load and

charged condition and during the off load tap changer method, we have to off the transformer

first and change the tap. The changing of tap is required because we can’t get the constant input

voltage for the transformer so there is a problem of getting the desired output.

33KV/6.6KV transformer is called as on load tap changer and 6.6KV/0.433KV transformer

is called as off load tap changer.

2. CT & PT

CT- current Transformer

PT- Potential Transformer

CT is used for current measurement and PT is used for potential measurement.

There are two types of PT used namely LINE PT and BUS PT.

3. ACB & VCB

ACB- Air Circuit Breaker

VCB- Vaccum Circuit Breaker

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3. FEEDER AND DISTRIBUTION PANEL

We are having two FEEDERS like FEEER1 and FEEDER2 and its main function is to feed the

power from VCB (Vaccum Circuit Breaker) to TRANSFORMER for step down of

high.voltage. There are two INCOMER are present like INCOMER1 and INCOMER2 which

are used for giving the power to all HT MOTOR. Two INCOMERS are connected by means

of BUSCOUPLER. BUS PT is used over here to give the information about the INCOMER

that which one is running and finally 6.6KV is coming from the INCOMER is stepping down

to 0.433KV and used for the distribution

[P.T.O]

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AVCTPL is having a panel like

[FIGURE-4]

PANEL TYPE 1 (MAIN)

PANEL TYPE 2(DISTRIBUTION)

MV APFC1 SPARE PH CSS1 SPARE SR1 SPARE MHC1 SPARE

IBC1 IBC2 IBC3 SPARE DIST TRAFO1 SPARE BUS APT INCOMER1

BUS COUPLER BUS PT WITH INCOMER2 DISTTRAFO2 SPARE IBC3A IBC4-M1 IBC4-M-2

BUS RISER

SPARE MHC2 SPARE SR2 SPARE SILO CSS2 MV APFC SPARE2

PANEL TYPE 3

MLDB- MAIN LINE DISTRIBUTION BOARD PH- PUMP HOUSE

PCC- POWER CONTROL CIRCUIT MCC- MOTOR CONTROL CIRCUIT

1 2 3 4 5 6 7 8

16 15 14 13 12 11 10 9

24 23 22 21 20 19 18 17

28 27 26 25 29 30 31 32

BETTERY

CHARGER1

INCOMER3

10KW

IN

MLDB DG INCOMER BUS

COUPLER2

MCC2 PCC

INCOMER

2

BUS

COUPLER1 PCC

INCOMER2

1

FEEDER1

2

INCOMER

3

FEEDER2

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AMFC- AUTO MAIN FAILURE CONTROLLER:

[AMFC provide consistent power supply to the load in the absence of main supply.]

The function of AMFC is to maintain the constant power supply to the load in the absence of

the main supply. It is having DG set of protection.

This panel supplies the power that can be shown below:

[TABLE-1.4]

PANEL NO. NAME OF THE PANEL POWER

3 PH CSS1 500 KVA

5 SR1 1250 KVA

7 MHC1 1350 KW

9 IBC-1 220 KW

10 IBC-2 450 KW

11 IBC-3 720 KW

12 DIST TRAFO 1.5 MVA

22 IBC 3A 720 KW

23 IBC-4-M-A 450 KW

28 SR2 1250 MVA

31 MV APFC2 1400 KVAR

The function of APFC (Automatic power factor control) is to control the power factor that can

be discussed in the reactive power compensation part.

MCC panel supplies the power to all HT MOTOR present at the ITT. This panel is having

THRUSTER BRAKE for all the IBC and all the induction related to the ITT can be seen like,

oil circulation trip, radiator pump trip, radiator pump on, radiator pump off, actuator

on and actuator off etc.

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3.3: A BRIEF LAY OUT OF DISTRIBUTION OF AVCTPL

[FIGURE-5]

LA- lightening arrest NGR- Natural Ground Register

ACB- Air Circuit Breaker VCB-Vaccum Circuit Breaker

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3.4: THE NEW GLANCE OF TECHNOLOGY

AVCTPL substation grid is having various new technology like TRAFO FAULT RELAY,

MASTER TRIP RELAY, ANNOUCIATOR, MULTIFUNCTIONAL METER, O/C &

E/F RELAY and PROTECTIVE RELAY etc.

TRAFO FAULT RELAY:

The use of TRAFO FAULT RELAY is to protect the transformer from overcurrent. It is of

IDMT (Inverse Definite Time Relay Type).

MASTER TRIP RELAY:

MASTER TRIP RELAY is the main trip relay to which all the protection relays like distance

relays, overcurrent relays, earth fault relays and differential relays are connected in parallel.

That means master trip relays are providing the type of fault caused in the electrical drives to

the user in the display board continuously unless until it is respond by someone.

ANNOUCIATOR:

An ANNOUCIATOR panel is a centralized warning panel where a group of light used to

display the message related to the central industrial purpose. It is very costly to install and it is

dedicated to the wiring to the alarm initiating device to the process plant.

O/C & E/F RELAY:

This relay is used in the transformer winding in terms of CT and PT. Suppose three phase is

there having rated current 100A in each phase. If the current flow in one phase is above the

100A then this will go to OVER CURRENT RELAY (O/C) but if the current flow in any one

phase is below the rated current i.e. 10-20 AMP then this will go for EARTH FAULT RELAY

(E/F).

Apart from these there is a presence of MULTIFUNCTIONAL METER in which we can

able to see all the current rating like voltage, current, frequency, power factor, kw, KVAR,

KVA and %THD(TOTAL HARMONIC DISTRIBUTION) etc.

LA (lightening Arrester) is present to protect the cable from high flash over voltage. The

rated lightening impulse withstand voltage of each feeder is 170 KV.

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SPECIFICATION OF DRY TRANSFORMER (LIGHTING)

In the entire substation the automatic modes of operation is also available by means of PLC

and SCADA. We are having the PLC of SIEMENS in all the panel. But practically semi auto

mode is used over here.

3.5: CASE STUDY ON THE DISTRIBUTION SYSTEM:

We have studied all the working unit of substation and we have seen each and every working

performance of each unit. But my point view if there is a presence of SF-6 Circuit Breaker

[TABLE-1.5]

TYPE

3

FREQUENCY

50 HZ

AMB. Temperature

45 C

VECTOR GROUP

Dy11

CORE AND WINDING

3420

INSULATION CLASS

F

NO LOAD VOLTAGE

PRIMARY 0.415KV SECONDARY 0.415KV

CURRENT

PRIM 486.92 AMP SEC 486.92 AMP

POWER

350 KVA

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instead of ACB and VCB then then the performance may be improved. Otherwise each

working module present over here is having very good eye-catching performance.

3.6: UPS SYSTEM

The meaning of UPS is uninterrupted power supply. The meaning itself defines its

functionalities that the power supply should be continuous. UPS system consists of

RECTIFIER, INVERTER, SMPS (Switch Mode Power Supply) and BATTERY. Here ac

supply is converted to dc by means of rectifier and stored in battery and in the absence of main

supply that stored dc is again converted to ac by means of inverter.

LAYOUT OF UPS SYSTEM:

[FIGURE-6]:

MANUAL BYPASS

BYPASS ISOLATOR

AC SUPPLY

O/P

SWITCH MODE INVERTER POWER

POWER SUPPLY(SMPS) STSW

BATTERY ISOLATOR

BATTERY CHARGER

BATTERY CHARGER is used to store the DC supply which is converted from AC in terms

of RECTIFIER.

RECTIFIER INVERTER

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3.7: DG SUPPLY

The function of DG supply is for back up purpose. The DG means DIESEL GENERATOR

which is connected by the BUS COUPLER in between two incomer. The performance of

AMFC is related to the DG SUPPLY. If the main supply is not present then the DG supply is

provided only for the lighting purpose.

The DG is connected to the main supply as shown below.

LOAD

DG SUPPLY KG KM T/F

AMF UNIT

[FIGURE-7]

3.8: REACTIVE POWER COMPENSATION

As all the load used over here is normally inductive load so the lagging power is more .So we

have compensate those lagging power. As Substation draws the heavy amount of power from

the APEPDCL grid so any how substation is to maintain the constant power factor otherwise

current consumption increases. In order to balance both the operation substation is provided

with CAPACITOR BANK in which reactive power is compensated and a constant power

factor is maintained. In substation we are having the CAPACITOR BANK of rating 1800.55

KVAR.

Actually the entire performance of the capacitor bank is known as APFC (Automatic Power

factor Control).

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The technical function of APFC is to maintain the constant power factor at a suitable limit.

The capacitor bank is connected across the 3-Ph bus line by means of relay.

SPECIFICATION OF APFC (AUTOMATIC POWER FACTOR CONTROL):

NET O/P KVAR 1800.55 KVAR.7.72 KV

RATED KVAR 1400 KVAR,6.6 KV

STEP CONFIGURATION 2*250KVAR + 2*450 KVAR

RATED CURRENT 122.47AMP

NO OF PHASE 3-Ph

RATED FREQUENCY 50 Hz

TEMP RISE 15 C

CONNECTION EXTERNAL

[TABLE-1.6]

3.9: SOME INDUSTRIAL MEASUREMENT

In AVCTPL we are having so many industrial measurement like MULTIMETRE,

MEGGER, CT & PT and TONG TESTER (CLAMP METER) etc.

In MULTIMETER we can measure the voltage, current, resistance etc. But now a days we

are using the TONG TESTER (CLAMP METER) in which we can measure the voltage

(ac/dc), resistance.

MEGGER is used for testing the HT motor before running means whether the motor is free

from short circuit or not and by using this we can measure the high resistance. If the MEGGER

reading is ‘0’ then the motor is unhealthy and if the motor reading is ‘infinite’ then motor

is healthy.

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CHAPTER 4: SAFETY

4.1: DEFINITION

SAFETY is the state of being “SAFE”, the condition of being protected against physical,

social, financial, consequences of failure, damage, error, accidents, harm or any other events

which could be considered undesirable. Safety can also be defined to be the control of

recognized hazards to achieve an acceptable level of risk. This can take the form of being

protected from the event or being protected from the event or from exposure to something that

causes health or economical losses. It can include protection of people or of possessions.

SAFETY is the foremost thing which is engrossed formerly by any hazardous industries like

coal industry.

4.2: NEED OF SAFETY FOR AVCTPL

In view of the above discussion AVCTPL is therefore need of the hour. There are some direct

costs/effects of an accident but there are certain indirect costs involved in it also e.g. machine

down time, damage of machine, ideal time of nearby equipment and horror created among

workers, loss of time etc. in aid cost compensation, legal implications and allied costs etc. So

safety measures would not only eliminates/avoid above cost but would mean performing their

moral responsibility towards workmen/ operators also.

More over AVCTPL is a coal industry so more focus on safety is required towards the health

of the workers and towards the environment for the smooth running of the industry. An unsafe

condition may be present in various forms i.e. in the faulty or defective electrical fittings, use

of defective tools, blowing of coal dust on the air etc. so to prevent the occurrence of oath of

accidents, unsafe acts have to be avoided or checked properly for the safety purpose at

AVCTPL.

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4.3: SAFETY EQUIPMENTS AND PROCEDURE

SAFETY INSTRUCTION

AVCTPL provides so many safety instruction like:

1. Use Helmet, Safety reflection jacket and Gloves while entering to the any working site.

2. Don’t touch any machineries without having the proper knowledge and don’t go alone to

any working site.

3. Read the instruction of any machine carefully while enter and touch the machine and can

take the reading.

4. See the Guard ring and don’t cross the guard ring during running condition. (If the guard

ring is not visible by you then tell your instructor to make you confirm about guard ring)

5. Don’t move under the conveyor belt during running.

6. Leave the working site if you hear any alarm sound.

7. Don’t go to heap site during the strong wind flow.

8. Carefully read the instruction guide given below the working module in order to run that

working module.

SAFETY equipment provided by the AVCTPL are HELMET, SAFETY REFLECTION

JACKET and GLOVES.

For the Environmental Safety concern AVCTPL provides water sprinkler, DSS and DFDS

in the dust producing site. Horticulture is also done in its campus to produce a pollution free

environment.

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REFERENCE

1. ELECTRIC MOTOR HAND BOOK, by James L. Kirtley, Jr., H.Wayane Beaty,

Nirmal K Ghai, Steven B Leeb, Richard H.Lyon.

2. INDUSTRIAL POWER ENGINEERING AND APPLICATION, by K C Agarwaal.

3. ELECTRICAL GENERATION AND DISTRIBUTION SYSTEMS AND POWER

QUALITY, by Rey G.R.

4. POWER SYSTEM-ANALYSIS AND DESIGN, by B.R. Gupta.

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