1.

INTRODUCTION

IOCL Bongaigaon refinery is located at Dhaligaon in chirang district of assam, 200 km away
from guwahati. On 5th December , 1969, then the prime minister of india, Mrs. Indira Gandhi
announced in the lok sabha the government decision is to set up a new Refinery cum
petrochemical complex in assam. The honorable prime minister laid the foundation stone of the
complex in 1972 at Bongaigaon refinery and petrochemicals limited (BRPL) was incorporated as
government of india Undertaking under the administrative control of the ministry of petroleum
and natural gas on 20th February, 1974.

Bongaigaon Refinery is the eighth Refinery of Indian Oil Corporation Limited. Formed
upon the amalgamation of Bongaigaon refinery &petrochemical limited (BRPL) with Indian oil
on march 25, 2009. It has two crude distillation units (CDU), two delayed cocker units (DCU)
and a cock calcinations unit(CCU) with a processing capacity of 2.35 MMTPA of crude oil. The
First CDU with a capacity of 1MMTPA was commissioning in the year 1979. The capacity was
further increased to 1.35MMTPA in 1986. An LPG bottoling plant with a capacity of 44,000
MTPA was also commissioned in the year 2003.

Presently the refinery produces a wide range of petroleum products namely LPG,
Naphtha, MS, SKO, HSD, LDO, LSHS, LVFO, RPC, CPC, Needle coke and solvents (petrosol
and Bonmex-II) by Processing Assam crude and Ravva Crude (from the Ravva oil fields of
Krishna Godabori Basin).

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 2. CAPTIVE POWER PLANT
2.1. INTRODUCTION TO CPP
IOCL Bongaigaon requires electrical power and steam for its process requirements. It produces
its own power and steam required for process parameters. The captive power plant generates the
required power to meet the requirements of IOCl Captive Power Plant is required for the
following purpose:-

I. Good Quality of Power:- Power quality is simply the interaction of electrical power
with electrical equipment. If electrical equipment operates correctly and reliably
without being damaged or stressd, we would say that the electrical power is of good
quality. On the other hand , if the electrical equipment malfunctions, is unreliable, or
damaged during normal usages, we would suspect that the power quality is poor.
II. Reliability:- power from grid is highly unreliable due to sudden power outages not in
control of the refinery which may lead to huge economic and production losses.
Hence to maintain a reliable 24x7 power supply, captive Power Plant is required.
III. Efficiency:- Efficiency is high as steam generated in the refinery can directly be
used for generation of power resulting in less losses. Also as the source and
destination of power are close to transmission losses are also reduced leading to high
efficiency.

2.1.1 SOURCE OF ELECTRICAL POWER

The CPP has a Gas Turbine Generator (GTG) having capacity of 21.195 MW. There are three
Steam Turbine Generator (STG) having capacity of 16x3=48 MW. Generation takes place at
11KV from both STGs and GTG. Further, 132 KV supply is available through 132/11 KV step
down grid transformer from Assam Power Distribution Company Limited (APDCL) for VHP
steam is produced in the boilers to meet the process steam requirement and also to run the steam
turbine and generate power and meet the power requirement of the refinery units. The fuel used
for boilers are FO, FG, LDO, CPP also has a DM plant, FO pump house and a cooling tower.

2.1.2 SOURCE OF STEAM

There are five boilers to meet the steam requirement of the STGs and process. Each boiler is of
84MT/Hr capacity at it generates steam at 485̊ c, 66kg/cm. Normally two or three boilers are
kept on run depending on load demand. More than three boilers may also be run depending on
the load demand.

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2.1.3 SOURCE OF DM WATER

There are two DM water plants under CPP. One plant is older with the capacity of 4x49 MT/Hr.
The newer plant commissioned in 2012, came as a part of DHDT project with a capacity of 1.81
MT/Hr. Raw underground water is used and converted to DM water in DM Plant. It consists of a
pressure filter, anion exchanger (SBA), Cation exchanger (SAC) and a mixed bed. DM water
used in CPP boilers & HRSG for steam generation and other refinery units.

2.1.4 SOURCE OF AIR

There are four air compressors of 885 m³/hr capacity each. Normally these compressors remain
as standby as the air network is interconnected with refinery. In the event of low air pressure,
Alarm is actuated and the compressor is to be mutually started.

TABLE 2.1

SOURCES OF POWER AND STEAM

Machine Capacity Maker Uses

STG-1 16 MW BHEL POWER GENERATION
STG-2 16 MW BHEL -DO-
STG-3 16 MW BHEL -DO-
GTG 21.1 MW BHEL -DO-
HRSG 80T/h BHEL STEAM GENERATION
BOILER-1 84T/h BHEL -DO-
BOILER-2 84T/h BHEL -DO-
BOILER-3 84T/h BHEL -DO-
BOILER-4 84T/h BHEL -DO-
BOILER-5 84T/h BHEL -DO-
GRID 132/11 KV CG POWER DISTRIBUTION
TRANSFORMER 16MVA

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2.2 STEAM TURBINE GENERATOR
The CPP has three steam turbine generator (STG) having capacity of 16x3=48 MW. Power
generation take place at 11 KV from STG. There are 5 boilers to meet the steam requirement of
the STGs and the process. Each boiler is of 84 MT/Hr capacity and it generates steam at 485̊ c,
66kg/cm. normally two or three boilers are kept on run depending on the load demand. More
than three boiler may also be run depending on the load demand.

2.2.1 RANKINE CYCLE

(I) The Rankine Cycle is thermodynamic cycle which converts heat into work.

(II) The heat is supply extremely to a close loop, which usually uses water as working fluid.

(III) This cycle generates about 80% of all electric power used throughout the world,

Including virtually all solar thermal, biomass, coal and nuclear power plants.It is named

After William John Macqorn Rankine, a Scottish polymath.

(IV) Rankine cycle idelized cycle for steam power plants. This cycle is shown as

Figure no: 2.1 Rankine cycle

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 Fig No:2.2 Steam Surbine Generator

Process 1-2: Water from the condenser at low pressure is pumped into the boiler at high pressure.
This process is reversible adiabatic.

Process 2-3: water is converted into steam at constant pressure by the addition of heat in the
boiler.

Process 3-4: Reversible adiabatic expansion of steam in the steam turbine.

Process 4-1: Constant pressure heat rejection in the condenser to convert condensate into water.

The steam leaving the boiler may be dry at saturated, wet or superheated.

2.2.2 START UP PROCEDURE OF STG (COLD START–UP)

2.2.2.1 START UP CHECKS;

1. Initially main oil tank (MOT) level will be equal to 42 cms (approx), which is just below
overflow limit of MOT.

2. Start AOP-3(B) to transfer oil from MOT to overhead tank (OHT). Open the discharge valve
of AOP-3(B) slowly, keeping an eye on the MOT level.

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3. The oil will flow to the OHT through a 1 inch line. Keep the by-pass i/v close.

4. Start transfer oil pump-3 to transfer oil from bootom oil tank (BOT) to (MOT). The transfer
oil pump will keep running until the level of BOT reaches to 10 cms.

5. Put the m/c on barrier gear after achieving adequate oil temperature.

6. Start circulating water pump to establish water flow through the condenser.

7. Check condenser hotwell level and maintain normal level (50-60%).

8. Start condensate pump on recirculation from local and establish water flow through air Ejected
and Gland steam condenser.

2.2.2.2 WARM UP

1. Open all drain and vent valves onMS line to turbine fully.

2. Open equalizer of MS line to TG from warm up.Monitor rise temperature at 100̊ c/hr and
achieve rated temperature in 3.5 to 4 hrs.

3. Charge gland steam to turbine glands. Start vacuum pulling and achieve rated vaccum.

2.2.2.3 ROLLING OF STG

1. Put the vacuum defeat switch service from ECS.

2. Ensure 9PL3306B (for trip pr. Low) & (9PSL3303) (For governor oil pr. Low) is in by-passed
condition (from DCS& PLC ladder logic respectively)

3. Also ensure 9LSL3102 (OHT level) and 9PSL34A (Low pressure ) are normal.

4. Engage trip leaver on turbine front by lifting it upward. Check trip oil pressure (min. 5
kg/cm²).

2.2.2.4 START UP GENERATOR:

1. Close neutral breaker & field breaker (From ECS) after putting them in service position.
2. Check that the 220 V AC, 220V DC, 415 V AC supply to DAVR are in service. Build up
the exciter voltage to the rated voltage of the generator by operating DAVR. Put the AVr
in Auto & Remote Position.
3. Synchronize the m/c in Auto Position when Synchro-check relay permits. Increase the
load up to 2 to 2.5 MW& 1 To 1.5 MVAR.
4. Put generator air cooler in service. Put LO cooler in Service. Switch ON the vapor
extraction fan. Close all MS drains.

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 2.2.2.5 STG SHUT DOWN:

1. Take out extraction from service.

2. Reduce the load of the generator to around 1.5 to 2 MW by transferring the load to other
running generator.
3. Open generator breaker. Reduce excitation taking AVR on manual and open field breaker
voltage.
4. Trip the turbine from control room or local.
5. In case of any emergency press emergency stop push bottom from control panel to stop
the M/C immedietly.
6. Start AOP immediately after tripping. If AOP , start EOP.
7. Cut- off the Vacuum and gland steam supply.
8. At speed zero when rotor gets stand still put the TG on turning gear immediately without
any delay. Before putting on turning gear the jacking oil pump must be started & should
be stopped after the M/C is put on turning gear.
9. Isolate M/S line and open drains and by-pass valve of steam trap.
10. Ensure MINIMUM position of MANUAL & AUTO pot of AVR panel.
11. Close speder gear & starting Device At Local Governor Desk.
12. Put Generator & Neutral Breakers in TEST Position.

2.2.3 TURBINE DETAILS

Single cylinder, extraction, condensing, axial flow, steam turbine coupled with generatorthrough
speed reduction gear box, stages= 1+6+12

Type EK-1400-2

Power output 16 MW

Speed of turbine 5500 rpm

Trip speed 6500 rpm

Steam inlet pressure:

Normal/maximum 62/62.5 kg/cm²

Steam temperature:

Normal/maximum 480/485̊̊ C

Steam outlet pr./temp. 0.10kg/cm², 49̊ C

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2.2.4 TURBINE PROTECTION
1. Low vacuum trip.
2. Lube oil pressure low trip.
3. Axial shift very high.
4. Extraction pressure low
5. Extraction pressure high.
6. Emergency trip.
7. Trip oil pressure low trip.
8. Over speed trip 6050 rpm.

2.2.5 BOILER

Bi-drum, water tube, oil/gas fired vertical boiler.

Quantity: 4+1=5

Designation: F13/20 VU 60 54/2-32

Fuel oil or Refinery gas:

FC 85% Vol Mat 9.4%

Moist 1% Ash 0.1%

2.2.6 TURBO GENERATOR DETAILS:

Type: TGP 221240/2

Rating: 20000 KVA, 16000 KW

Voltage: 1.1 Kv±5%

Power factor: 0.8 Lag

Frequency/RPM: 50 Hz/3000 rpm

Rated capacity with one cooler out: 15000KVA

Full load Amps: 1050 amps

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Brushes per slip rings: 6

Volume of cooling air: 13.5 NCUM/sec

Critical speed of the rotor: 1600 rpm

Minimum diameter of slip rings: 380 mm

Minimum diameter of commutator 238mm

Rotor voltage (Rated): 194 V

Rotor current (Rated): 514 amps

2.2.7 GENERATOR PROTECTION:

The core of an electrical power is the generator. A modern generating station unit is a complex
system comprising the generator stator, Winding and associated transformer and unit transformer
and boiler complete with auxiliary fans and pumps, faults of varied kinds may occur within the
system for which different protective means are required. The amount of protection will be
governed by economic considering, machine and its importance to the power system as a whole.

The following hazards requires consideration:

1. Stator insulation faults.

2. Over voltage.
3. Unbalanced loading.
4. Rotor faults.
5. Loss of excitation
6. Loss of synchronism.
7. Failure of prime mover.
8. Low vacuum.
9. Lubrication oil failure.
10. Loss of boiler firing.
11. Over speeding.
12. Rotor distortion.
13. Difference in expansion in stationery and rotating parts.
14. Excessive vibration.

Hence the following protection are required:

1. Gen. Diff. Relay (87G)

2. Gen. 2nd Rotor E/F

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3. Gen Over voltage (59G>120%)
4. Buss- diff. Lock-out Relay (96)
5. Gen. Reverse Power Relay(67W)
6. Gen. E/F Relay (64)
7. Gen. U/F Relay (47.4 c/s)
8. Gen Field Failure Relay (40)
9. Gen. Negative phase sequence Relay (46)
10. Gen. Back-up O/C Relay (51)
11. Gen. Back-up E/F Relay (51N)

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2.3 GAS TURBINE GENERATOR
The GTG of IOCL, BGR has a rated capacity of 21.195 MW. It supplies most part of the
electrical load of the refinery. A gas turbine generator consist of 3 important parts. Air
compressor, Combustion chamber and Turbine section.The gas turbine operates on the principle
of the Brayton cycle, where compressed air is mixed with fuel and burned under constant
pressure conditions. The resulting hot air is allowed expand through a turbine to perform work.
The turbine then drives the generator coupled to the same shaft to produce power.

The resulting exhaust gases Turbine has a high temperature of around 544 which is then
used to generate steam at 64kg /cm2 in the HRSG( Heat Recovery Steam Generator) and meet
some part of the steam demand of the refinery.

2.3.1 OPERATION
When the turbine starting system is actuated and the clutch is engaged, ambient air is drawn
through the air inlet plenum assembly, filtered and compressed in the axial-flow compressor. For
the protection during strat-up, the 10th stage extraction valves are open and variable inlet guide
vanes are in the low flow start up position. When the starting system has accelerated the the
rotor to ignition speed, the spark plugs are energised and the fuel is turned on. In case of liquid
fuel, equal amounts are distributed to each combustor by an external flow divider. The resulting
fuel/ air mixture is ignited in the chambers containing spark plugs and the flame propagates
through the crossfire tubes to the rest of the combustor. When the chambers are lit, as indicated
by the flame detectors, the start up stage sequence continues. When the high speed relay
accurate at 95% Speed, the 10th stage extraction bleed valve closes automatically and the variable
inlet guide vane actuator energized to open the inlet guide vanes to the normal turbine operating
position. Air from the compressor flows into the annular spaces between the outer combustion
liners.

The hot gases from the combustion chambers flow through the ten separate transition pieces.
The gases then enter the two stage turbine section of the machine. Both stages consist of a row,
the kinetic energy og the jet is increased, with an associated pressure drop.

After passing through the 2nd stage buckets, the gases are directly into the exhaust hood
and the diffuser which contain a seriesof turning vans to turn the gases from an axial direction a
radial direction, to minimize the exhaust hood losses. The gases then pass intotile exhaust
plenum and are introduced to atmosphere through exhaust stack.

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 Resultant shaft rotation is used either to turn a generator rotor for electrical power
production , or to drive a centrifugal compressor in industrial process application.

2.3.2 BASIC DIAGRAM OF GTG

Fig No: 2.1

2.3.3CYCLE
Gas or combustion operates on Brayton cycle. Gases expand through turbine producing
sufficient power to drive the compressor and load devices. Gases are exhausted till the
temperature at high temperature.

In closed cycle the fluid usually air or helium circulates continously through compressor,
turbine and heat exchanger. In BGR, the fluid used a mixture of Air , Naptha and high speed
diesel. Heat is supplied outside the cycle by a nuclear rack, coal burner or other source .

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 Regenerators are used to increased the efficiency. The mass effective utilization of fuel
input is available through cogeneration or combined heat and power. A typical cycle has the gas
turbine generating power and producing steam which is sent to an industrial process.

2.3.4BRUSHLESS EXTITATION IN GTG

The Gas Turbine Generator of IOCL, BGR employs the use of brushless excitation to eliminate
the losses due to brush contacts. As shown in the figure below, the rotor shaft houses the rotors
of Synchronous Generator. The exciter, the permanent Magnet gen and a rotating rectifier.

The starting sequence is as follows:-

1. Initially a Diesel Generator is used to rotate the shaft.

2. The rotation of the rotor of the permanent magnet generator induces 3 phase ac current
which is converted to dc current.
3. This dc current is then fed to the stator of the exciter, inducing ac current in the rotor.
4. The ac current is converted to dc current which is fed to the rotor of the synchronous
generator of field excitation.

2.3.5EFFICIENCY

1. STG => 37%

2. Boiler =>97%
3. GTG ( single cycle) => 27 %
4. GTG ( co – gen cycle) =>70 %
5. Combined cycle power plant => 85%

2.3.5MOTOR STARTIN SCHEME

The motor starting scheme employs use the following circuits:-

1. Control Circuit
2. Power circuit

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 As shown in the figure, the power circuit is used to supply power to the motor while the
control circuit supplies power to the components for the start and stop motor; and for the
signals to indicate the operation mode of the motor,

2.3.6PROCEDURE
1. The contacts 1,2; 3,4; 5,6; are normally open(NO) and the contacts 7,8; 9,10 are
normally closed(NC) previously. Contact 9,10 is spare and used as digital input in
SCADA/ HMI.
2. When SW1 is switched on i.e. it gets energized with 415 volt, AC suplly, the NOs
become NC s and vice versa
3. Now when the stop push button is switched on, the hold circuits( 1,2) closes and CI
gets connected , simultaneously contact 3,4 and 5,6 get closed and hence motor is
connected and the LED glows indicating ON.
4. Now let the full load ampere rating of the motor is 16A and let the overload relay is
set at 95% of FLA of motor.
5. When this valve is exceeded, the relay senses this o/v and the contact above stop push
button heats up and bends to move to next contact hence energizing trip circuit and the
amber LED glows indicating “ TRIP”.
6. When we need to switch off the motor the contact 7,8 has to be closed indicating the
green LED.

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 3.UNINTERRUPTED POWER SUPPLY (UPS)

The UPS system is connected between a critical load such as digital driver and automation
distributed digital process control system. UPS is designed to furnish a well regulated output
voltage with high frequency stability. The system is unaffected by variations in the main
supply and during periods of power failure, will continue to supply power for a period
sufficient to allow an orderly shutdown of load equipment or start-up of standby generator.

3.1DESIGN CONCEPT OF UPS

To allow the UPS equipment to continue to supply power after the mains supply has failed, a
standby power source is needed. This consists of a large battery of lead acid or nickel
cadmium cells. These cells have high discharge capability, rapid recharge rates and require
little maintenance.

As battery supply only DC voltage, the circuit of the UPS must convert this to a three
AC sine wave voltage. The three phase sine wave input to the UPS must also be connected via
UPS circuitry to the battery. The way in which this is achieved is shown in the simple block
diagram.

Block diagram of UPS

Fig No: 3.1

The three phase mains supply is connected to the input of the UPS module. It is rectified
by the rectifier section of the UPS module to 247.5V dc. The battery is connected in parallel with
the rectifier output and is charged at 247.5V dc float charge voltage. The 247.5V dc bus is also

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applied to the inverter section which consists of three pairs of inverter phases converting the dc
voltage into square waves at the correct frequency, and at 120 degree apart to from three phases.
The UPS output voltage is controlled by adjusting the firing angle between the two inverters
within a phase. The output from each phase is then connected to filter section. The filter section
consists of a series inductor and 5th, 3rd and 7th harmonic traps which convert the output from the
inverters into suitable for connection to the computer load.

When the main supply fails, current is drawn from the battery to supply the inverter
section which will continue to operate until the battery is discharged. The period for which the
battery will sustain power to the load is known as the autonomy time and will of course the
dependent upon the battery size and load. To protect the load against extended mains outages it
is unusual to back up the mains supply with a standby generator which, when the mains fails,
will automatically come online. This reduces the require autonomy time which in turn, allows the
use of smaller and therefore cheaper batteries. Where large loads are involved, or improved
reliability is desirable, several (up to 6) un-power UPS module may be paralleled using a system
output assembly. In the system configuration, it is usual to design the system such that it includes
a redundant module i.e. use more modules then necessary to power the load systems designed in
this manner will fault and trips off-line. The number of modules connected to the system output
assembly is electronically counted and if the number of modules off-line exceeds the system
redundancy, then the loads will automatically be transferred to the bypass supply by the SOA
control circuitry. To further transferred to the bypass supply.

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 4.AUTOMATION VOLTAGE REGULATOR (AVR)

4.1INTRODUCTION
The AVR is designed for use with dc excited ac generators of medium capacity and mainly
comprises of error detection, an amplifier, a firing circuit and a single phase full wave half
controlled thyristor diode unit.

The functions of the regulator are to adjust the generator excitation automatically to
response to deviation in bus bar voltage detected by error detection circuit.

4.2DUTIES OF AVR

 Control of system voltage between prescribed limits.

 Increase of excitation under the system fault condition so that maximum synchronizing
power exists when the fault is cleared to prevent loss of synchronization.
 Preventive dangerous over voltages on the occurrence of sudden loss of load on the
system.

The AVR is designed for use with DC excited AC generator of medium capacity and main
comprises of error detection, an amplifier, a fixing circuit and a single phase full and half
controlled thyristor diode unit. The function of the regulator is to adjust the generator
excitation automatically in response the PCC

Power control centre is considered to be the heart of an electrical system in any industry.
Therefore it shall offer users long term reliability, safety, low maintenance & testing time.

4.3 SPECIAL FEATURES OF AVR

Some special features of AVR are as follows:

1) Quick response in half a second or even less, if suitable field forcing is provided on the
exciter.

2) Proper selection of semiconductor devices assume reliable operation of the regulator in half
ambient temperature.

3) Safe operation in view of margin allowed on the ratings of all semiconductor devices.

4) A compounding of quadrature injection type is to stabilize the reactive KVA loading of the
generator when operating in parallel with other generating sets.

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5) Manual control of the generator for starting and for emergency purposes is means by
conventional hand control.

4.4GOVERNING BODY
Governing system is an important control system in the power plant as it regulates the turbine
speed, power and participates in the grid frequency regulation.

Need for governing system:

 The load on a turbo generating unit does not remain constant and can vary as per
consumer’s requirement.
 The mismatched between load and generation results in the speed.
 When the loads varied, the generation also has to vary to match it to keep the speed
constant.
 This job is done by the governing system. Speed which is an indicator of the
generation-load mismatched is used to increase or decrease the generation.

4.5THE EXTITATION SYSTEM

The excitation system consists of a separated excited dc generator, whose shaft is rigidly coupled
to the main shaft of turbo generator; the field of the exciter is controlled by an automatic voltages
regulator (AVR). The variation in the terminal voltage is transmitted to the AVR equipment,
which in turn control the field of the exciter. The exciter then restores the terminal voltage of
turbo generator to the rated value.

4.6EXCITER’S TECHNICAL DATA

Type: EXI173166/4

Rating: 130KW, 220KV, 591A, 3000RP

Exciter Ceiling Voltages: 132V for 15V

Main Pole Air Gap: 8mm

Inter Pole Air Gap: 12mm

Nominal Exciter Relay: 1.3

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4.7BRUSHES

Number: 24(4 sets, each of 6 brushes)

Size: 32:16 mm sq.

Grade: EG14

Main Diameter Of The Commutator: 250 mm

4.8AVR IN GTG
AVR is used in GTG to supply and regulate the excitation field current in the rotor winding. As
shown in the figure (next page), the URTs (T31, T32) and the CTs (T21.1-21.3) helps the AVR
to monitor the output power of the GTG.

If the output power generated is less than the required value, the AVR will increase the
thyristor gate firing pulse, which will increase the DC output to the exciter and in turn will
increase the excitation current in the GTG rotor. Vice-versa if the output power generation is
higher than the required value.

4.9PCC
Power control centre is considered to be the heart of an electrical system in any industry.
Therefore it shall offer users long term reliability, safety, low maintenance & testing time.

4.9.1ADVANTAGES OF PCC

 Type tested assemblies offering highest reliability.

 Test and disconnected position with door closed for safety.
 For every rated current range, optimum connection conditions for cables and bus bars.
 Separate function compartments consisting of a switching device, auxiliary equipment
and a cable connection compartment for safety.
 Free choice of the supply direction without any sacrifices in terms of technical
specifications.
 High short-time current carrying capacity for time graded short-circuits protection (up to
500 ms) assures reliable operation the switchboard without being affected by short-
circuits.
 Indication and operation in the door closed condition.

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4.10MCC
A motor controller is a device or group of devices that serves to govern in some predetermined
manner the performance of an electric motor. A motor controller might include a manual or
automatic means for starting and stopping the motor, selecting forward or reverse rotation,
selecting and regulating the speed, regulating or limiting the torque and protecting against
overloads and faults.

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 5.ELECTRICAL WORKSHOP
5.1INSULATION RESISTANCE
Insulation Resistance (IR) is a measure of the insulating property of dielectric materials and is
typically expressed in mega-ohms. The insulation resistance includes both volume surface
resistance and can be expressed as the parallel combination of the two.

IR= (Rv *Rs ) /(Rv + Rs )

Volume resistivity: Rv ( ohms cm ) also called bulk resistance represents the resistance
per unit volume associated with a dielectric material.

Surface resistivity: Rs ( ohms/sq.) also called sheet resistance represents the resistance per
unit area and accounts the leakage path on the outside surfaces of the capacitor. This is a material
property; however, surface contamination and porosity also influence this parameter.

5.2POLARIZATION INDEX (PI)

PI is a variation of the 1R test. It is the ratio of IR measured after voltage has been applied for 10
minutes (RIO) to the IR measured after one minute (RI),

I.e. PI = R 10/ R1

A low value of PI indicates the windings may have been contaminated with oil, dirt etc.
or absorbed moistures. In the test, a relatively high DC voltage is applied between the copper
conductor and the stator or rotor core usually between the winding and ground as the machine
core and body are grounded. By applying ohm’s law, IR at time t is then,

RI=V/IT

V is the DC voltage applied and IT is the current flowing in the circuit.

5.2.1PI TEST

A Polarization Index (PI) test generally performed at the same voltage as the insulation
Resistance (IR) test.

A general guide to interpreting the PI test result are as follows:

Table no: 5.1

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 PI INSULATION CONDITION

<1 Dangerous

<2 Questionable

<4 Good

>4 Excellent

5.3DIELECTRIC ABSORPTION RATIO

In this test the testing device is applied and 1R measurements are taken after 30 seconds and 60
seconds. The dielectric absorption ratio (DAR) is calculated as:

DAR=R60/R30

Where R60 and R30 are the IR test measurements at 60 and

30 seconds respectively.

A General guides to interpreting the DAR test result are as follows:

Table no: 5.2

DAR INSULATION CONDITION

<1.25 QUESTIONABLE

< 1.6 ADEQUATE

>1.6 GOOD

5.4HOW DO YOU PERFORM AN ISOLATION?

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Generally, two leads (positive and negative) are connected across an insulation barrier.
(Obviously, its a good idea to have a basic familiarity with the item to be tested. Basically, it
should be known what is supposed to be insulated from what. The equipment to be tested will
determine how to hook up the meghometer).

After the connection are made, the test voltage is applied for 1 min.(This is a standard
industry parameter that allows one to make relatively accurate comparisons of reading from past
tests done by technicians.) During this interval, resistance reading should be drop or remain
relatively steady.

Larger insulation system will show a steady decrease; smaller systems will remain steady
because the capacitive and absorption currents drop to zero faster than on larger systems.

After 1min the resistance value should be read and recorded. When performing insulation
resistance testing, consistency must be maintained. Why ? Because electrical insulation will
exhibit dynamic behaviour during the course of the test; whether the dielectric is “good” or
“bad”. To evaluate a number of test results on the same piece of equipment, the test have to be
conducted the same way and under the relatively same environmental parameters. The resistance
measurement reading will also change with time. This is because electrical insulation materials
exhibit capacitance and will charge during the course of the test.

5.5WHAT MAKE INSULATION GO BAD ?

When the plant electrical system and equipment are new, the electrical insulation should be in
top notch shape. Furthermore, manufacturers of wire, cable, motors and so on have continually
improve their insulation service in industries, nevertheless, even today , insulation is subject to
many effects which can cause it to fail-mechanical damage, vibration, excessive heat or cold,
dirt, oil, corrosive vapours, moisture from process, or just humidity on a muggy day.

In various degrees, these enemies of insulation are at work as time goes on combined
with electrical stresses that exist. As pin holes or cracks develop moisture and foreign matter
penetrates the surfaces of insulation, providing a low resistance path for leakage current.

Once started the different enemies tend to aid each other, permitting excessive current
through the insulation. Sometimes the drop in insulation resistance is sudden as when equipment
is flooded. Usually, however, its drop gradually, giving plenty of warnings, if checked
periodically. Such check permit planned reconditioning before service failure. If there are n o
checks, a motor with poor insulation, for example may not only be dangerous to touch when
voltage is applied, but also be subject to burn out. What was a good insulation becomes a
conductor.

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5.6 BREAKDOWN VOLTAGE

The breakdown voltage of an insulator is the minimum voltage that causes a portion of an
insulator to become electrically conductive.

5.6.1BREAKDOWN VOLTAGE TESTING OF TRANSFORMER OIL

The insulation oil of voltage and current transformer fulfils the purpose of insulating as well as
cooling. Thus the dielectric quantity of transformer oil is a matter of secure operation of a
transformer. As transformer oil deteriorates through aging and moisture ingress, transformer oil
should, depending on economics, transformer duty and other factors, be tested periodically.

5.6.2TESTING PROCEDURE

To assess the insulating property of dielectric transformer oil, a sample of the transformer oil is
taken and it’s breakdown voltage is measured.

a. The transformer oil is filled in the vessel of testing device. Two standard compliant test
electrodes with a typical clearance of 2.5 mm are surrounded by the dielectric oil.

b.A test voltage is applied to the electrodes and is continuously increased up to the breakdown
voltage with a constant, standard compliant slew rate of e.g. 2kV/s.

c. At certain voltage level breakdown occurs in an dielectric arc, leading to a collapse of the test
voltage.

d.An instant after ignition of the arc, the test voltage is switched off automatically by the testing
device. Ultra-fast switch off is highly desirable, as the carbonization due to the electric arc must
be limited to keep the additional pollution as low as possible.

e.The transformer oil testing device measures and reports the root mean square value of the
breakdown voltage.

f. After the transformer oil test is completed, the insulation oil is stirred automatically and the
test sequence is performed repeatedly.

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g. As a result the breakdown voltage is calculated as mean value of the individual measurements.

5.7 SPECIFICATION OF INSTRUMENT USED

BAUR make oil BDV test set

Electrodes: mushroom type

Spacing: 2.5 mm

Stirrer: continuous

Test frequency: 60 Hz

5.8 INSTRUCTION

1. Switch ON the main switch.

2. Keep MOTOR switch in DECREASE position and also press OPERATE push button
and watch anti clockwise movement of CONTRON KNOB. When CONTROL
KNOB reaches zero pre-requisite condition HV system energizes with illumination of
HT lamp situated in the KV meter.
3. Toggle the MOTOR switch to INCREASE position. The CONTROL KNOB will
start moving in the clockwise direction. The Kv meter will start indicating the
generated HIGH VOLTAGE.
4. Switch OFF the motor by MOTOR switch at desired voltage for DECREASE voltage
keep motor switch on DECREASE and voltage can be adjusted to desired voltage in
case of failure the circuit will trip automatically with memory indication on Kv meter
and extinguishing the HT lamp.
5. The HT will not energize if the TOP GLASS is open or the CONTROL KNOB is not
at zero position.

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 6.RELAY
A relay is a device that detects the fault and initiates the operation of the circuit breaker to isolate
the defective elements from the rest of the system. Many different types of relays are employed
for different protection schemes at different parts of the power system used in IOCL BGR.

The equipment to be protected are:

1. Generator
2. Switchgear
3. Transformer
4. Motor
5. Cables/overhead lines

6.1TYPES OF PROTECTION

6.1.1GENERATOR

Generators are costliest equipments in any power generation and distribution system. Hence it’s
protection is very critical. Following general protections are given below:

a.Reverse power

b.Field failure or loss of excitation

c. Under voltage

d. Under frequency

e. Short circuit

f. Differential

Example: Steam Turbine Generator(STG) protection at IOCL BGR

The REM543CG relay has the following protection elements configured presently to protect the
steam turbo-generators.

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6.1.2SWITCHGEAR

a.Over current protection (IDMT, Instantaneous)

b.Earth fault protection (IDMT, Instantaneous)

c. Bus bar differential protection

6.1.3TRANSFORMER

a. Above 5MM:

b. Over current protection (IDMT, Instantaneous)

c. Earth fault protection (IDMT, Instantaneous)

Transformer trouble alarm/trips:

1. Buchholz A/T
2. Oil level low A/T
3. Oil temperature A/T

6.1.4MOTORS

a. Below 37Kw:Bi-metal Overload relays

b. Above 37 KW and below 55 KW:BI-metal Overload +Earth fault(using CBCT)

c. 55KW and above: Motor protection relays

i.Short circuit protection

ii.Earth fault protection
iii. Thermal overload protection
iv.Unbalance protection
v. Locked protection

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 7.CIRCUIT BREAKER
A circuit breaker is an automatically operated electrical switch designed to protect an electrical
circuit damage caused by overload or short circuit. Its basic function is to detect a fault condition
and interrupt current flow. Unlike a fuse, which operate once and then must be replaced, a circuit
breaker can be reset ( either manually or automatically) to resume normal operation.

7.1OPERATING PRINCIPLE

A circuit breaker essentially consist of fixed and moving contacts called electrodes under normal
operating conditions; these contact remain closed and will not open automatic ally until and
unless the system becomes faulty. When a fault occurs on any part of the system, the trip coils of
the breaker gets energized and the moving contacts are pulled apart by some mechanism thus
operating this circuit. When separated under fault conditions, an arc is struck between them. The
current is thus able to continue until the discharge cease.

The production of arc not only delays the current interruption process but it also
generates more heat which may cause damage to the system. Therefore, a main problem in it is
to extinguish the arc within the shortest time so that heat generated by it may not reach a
dangerous value.

7.2DIFFERENT TYPES OF CIRCUIT BREAKER USED ARE

a. Air Circuit Breaker

b. Minimum Oil Circuit Breaker

c. SF6 Circuit Breaker

d. Vacuum Circuit Breaker

Fig No: 7.1

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 8.ELECTRICAL SYSTEM OF IOCL BGR
8.1 ELECTRICAL SUBSTATION
CPP STG substation covering 11KV generation and distribution bus and cable up to 5MW DG
set 11KV bus, 6.6 KV bus section, PCC and MCC along with five number of transformer. 5MW
DG set including 5MW DG set 11 KV generation/ distribution bus, PCC, MCC and transformer
in DG set area.

8.2 FUNCTIONS
1. The Main Substation receives power from CPP ( 3 STGs) and ASEB and GTG at 11kv from
where it is distributed to all process units

2. We are using 6.6 KV systems for running HT motors of 2oo KW and above upto 1775 KW.

3. For stepping down 1 KV power to 6.6 KV, we have 3 nos. of Transformers of rating 10/12.5
MVA located at MSS. 6.6 KV main bus is located in MSS from where source is provided to
both Refinery and Petrochemicals.

4. Over and above, we have outgoing feeders for all utility services from 6.6 KV bus at MSS.
We have altogether 42 nos. of panels (6.6 KV) at MSS.

Hence, we can conclude that the system has:

1. 3 nos. of Plant Transformer PTR # 01, 02, 03

2. 15 NOS. OF Motor Feeders (GR type feeders)
3. 2 nos. of Incomes
4. 1 nos. of Bus Couplers PTR 01, 02 were commissioned in 1978, then expanded during
1981-82 to cater to the requirements for utilities.

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