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INDIAN OIL CORPORATION LTD

(REFINERIES DIVISION)
GUWAHATI REFINERY
GUWAHATI

ELECTRICAL OPERATION MANUAL

DOC NO: GR/MR/SMS/D/07

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FORWARD

This manual is prepared for the Electrical-operating manual of Guwahati refinery

based on few standards and vendor manuals, and also taking into consideration the
experience of the past.

It is a compilation of the prevailing practices, experiences of personnel in the

operation & maintenance field and guidelines from relevant codes and standards.
However, this, in no way, replaces or supercedes the codes/ standards or statutory
regulations wherever applicable.

(S.K.DHARGUPTA)
CHIEF POWER & UTILITIES MANAGER
GUWAHATI REFINERY
IOC GUWAHATI

CONTENTS

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1. ELECTRICAL SIDE OF POWER PLANT IN SIMPLE LANGUAGE.

2. BASIC OPERATING PARAMETERS OF TPS OPERATION.
3. DEFINITIONS OF EQUIPMENTS.
4. BLOCK DIAGRAM OF POWER GENERATION
5. UNITS OF ENERGY-RELATIONSHIP AMONG ENERGY
UNITS AND CALORIFIC VALUE OF FUELS
6. POWER FACTOR-DEFINITION, DISADV.OF LOW POWER FACTOR

7. POWER FACTOR IMPROVEMENT EQUIPMENTS.

8. ELECTRICAL EQUIPMENTS AND THEIR OPERATION
a. UNDERGROUND OB CABLES
b. SWITCHES
c. ISOLATORS
d. FUSES
e. CIRCUIT BREAKER
f. RELAYS
g. BATTERY BANK
h. BATTERY CHARGER
i. BATTERY HANDLING
j. UPS (UNINTERRUPTIBLE POWER SYSTEM)
k. POWER TRANSFORMER
l) AUTO TRANSFORMER

9. NORMAL OPERATION OF THE SUB STATIONS

10. PROCEDURE FOR INCOMER CHANGEOVER
11. AUTO / MANUAL CHANGEOVER SCHEME
12. GENERAL INFORMATIONS OF NEW UNIT SUB- STATION. .
13. PROCEDURE FOR TACKLING EMERGENCY.
14 LOAD SHEDDING SCHEME AT GUWAHATI REFINERY
15. ELECTRICAL EQUIPMENTS ISOLATION PROCEDURE
16. LIST OF APPROVED DISPLAY BOARDS / INSTRUCTIONS
17. SUDDENLY TRIPPED TGS (BLACK STAR)
18. TG START-UP ELECTRICAL
19. SYNCHRONISATION OF TG WITH ASEB
21. UPS OPERATION OF HT SUB-STATION OPERATOR.
22. ELECTRICAL SHUT DOWN OF TGS& DISCONNECTION OF ASEB FROM
TGS
22. TREATMENT FOR ELECTRIC SHOCK
23. INSTRUCTION TO ELECTRICAL CONTROL ROOM
OPERATORS & OFFICERS
1. ELECTRICAL SIDE OF POWER PLANT IN SIMPLE
LANGUAGE

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PARAMETERS GENERATED BY TUTBO GENERATORS

MAGNITUDE (QUALITY) OF VOLTAGE: - Magnitude of rated voltage

generated by generator is 6300 volt (AC), which is produced due to D.C
excitation current flowing in generator rotor and rotation of the rotor by
turbine at 3000 rpm. Both rotation and field excitation are necessary for
generation of A.C. voltage. Even if speed drops to slight extent A.C. voltage
will be maintained by AVR/DVR till it is beyond the control of it.

FREQUENCY OF GENERATED VILTAGE: - Frequency of generated voltage

is 50 c/s all over India including ours with 2 poles generator, if we rotate it
by turbine at 3000 rpm. We get frequency of generated voltage = 50 c/s.
(Formula of frequency is: -No of poles RPM/120)
R.P.M. = Revolution per minute.

These two parameters (i.e. voltage and frequency) most be perfectly steady
in rated value with in tolerable limit of variation for proper operation of any
power system.

Who keeps these parameters constant automatically: -

I) Frequency Speed governor of Turbine.

II) Voltage Automatic voltage regulator (AVR/DVR) of

Generator.

WHY BATTERY IS NEEDED IN POWER PLANT: - In case of a fault occur,

In the system. A.C.voltage may dip to such extent that charger trips and
in such case no breaker will trip / no relay will operate. Actually, that time
HT breaker must trip / Relay must work to normalize rest of the system. So
DC supply ensured 100% through battery is used for breaker control / Relay
protection.

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2. BASIC OPERATING PARAMETERS OF TPS OPERATION

THE TPS SHALL ENSURE SUPPLY OF POWER, STEAM, AIR & WATER AS FOLLOWS UNDER
NORMAL CONDITION.

POWER GENERATED AND CAPACITY IN OUR TURBO GENERATORS AS BELOW:-

EQUIPT STATUS CAPACITY VOLTAGE FREQUENCY
TG # 1 --------------DISMANTLED NIL NIL NIL
TG # 2 --------------DISMANTLED NIL NIL NIL
TG # 3 ------------- RUNNING 8 MW 6.3KV(+ / - 5%) 50 HZ (+/- 3%)
TG # 4 ------------ RUNNING 8 MW 6.3KV( +/ - 5%) 50 HZ (+/- 3%)
TG # 5 ------------ RUNNING 12.5 MW 6.3KV 50 HZ

*** ALSO WE IMPORT POWER FROM ASEB ***

STEAM GENETATED AND CAPACITY IN OUR BOILERS AS BELOW: -

EQUIPT STATUS CAPACITY PRESSURE (HP) PRESSURE(LP) TEMPC(HP) TEMPC(LP)
BL # 1 DISMANTLED
BL # 2 DISMANTLED
BL # 3 RUNNING 20 TN/HR 35 ATA (+/-1) 12 ATA (+/- 2) 440(+/-10) 270(+/-10)
BL # 4 RUNNING 20 TN/HR 35 ATA (+/-1) 12 ATA (+/- 2) 440(+/-10) 270(+/-10)
BL # 5 RUNNING 40 TN/HR 35 ATA (+/-1) 12 ATA (+/- 2) 440(+/-10) 270(+/-10)
BL # 6 RUNNING 50 TN/HR 35 ATA (+/-1) 12 ATA (+/- 2) 440(+/-10) 270(+/-10)
BL # 7 RUNNING 50 TN/HR 35 ATA (+/-1) 12 ATA (+ /-2) 440(+/-10) 270(+/-10)

1. WATER IS COMING FROM INTAKE PUMP HOUSE THROUGH INTAKE PUMPS IN OUR SYSTEM.
2. CIRCULATION WATER SHALL BE SUPPLIED TO PROCESS UNITS THROUGH COOLING WATER
PUMPS (18-PM-01A/B/C ) AS PER FOLLOWING PRESSURE & TEMPERATURE :-

PRESSURE: - 2.0 KG/CM ----- 2.5 KG/CM TEMPERATURE:- 29DEG.C ------ 33DEG.C
AIR
INSTRUMENT AIR: - MOISTURE FREE DRY AIR AT 5.8KG/CM ---- 6.4KG/CM AND AT AMBIENT
TEMPC. SHALL BE SUPPLIED THROUGH OUR AIR COMPRESSORS (13KM-01A/B/C ).
SERVICE AIR: - SHALL BE SUPPLIED AT 6.0KG/CM ----7.0KG/CM UNDER NORMAL CONDITIONS.
HOWEVER AS PER PLANT REQUIREMENTS DUE COMPRESSOR MAINT, SERVICE AIR MAY NOT BE
AVAILABLE FOR SHORT DURATION.
3. DEFINITIONS OF EQUIPMENTS

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ALTERNATORS

Alternator is coupled to a steam turbine and converters mechanical energy of the

turbine into electrical energy.
The alternator at Guwahati refinery is air-cooled. Necessary excitation is provided by
means of:

* Static Excitation equipment Controlled by DVR (Generator#4)

* Pilot Exciter directly coupled with the Generator shaft.
Excitation controlled by DAVR of (Generator#3)

TRANSFORMERS

Transformers are the devices, which step up or step down the voltage as per the
requirement. Transformers are the static apparatus for transferring power from one circuit
to another without change of frequency. In Guwahati refinery all the power transformers
are utilized for step down the voltage. Only DG sets transformers are utilized for step up
the voltage. Based on the utilities, transformers are divided into following categories:
* STEP UP TRANSFORMER: Transformers used to step up the voltage. At
Guwahati refinery, DG power is generated at 415 Volts. 415V DG voltage is stepped up
to 6.3 KV to match our generation voltage to transfer power to our system.
* STEP DOWN TRANSFORMERS: Transformers used to step down the voltage. At
Guwahati Refinery, most of our utilities/motors are operating at 433 Volts; therefore
generated power is step down from 6.3KV to 433 Volts.
* AUTO TRANSFORMERS: Used for HT motors starting. Autotransformer reduces
the line currents of the HT motor.
* UNIT STEP TRANSFORMERS: Utilized at GR for Lighting purposes e.g. 433/433
Volts transformers.
* INSTRUMENT TRANSFORMERS: It is a step down transformers, normally used
to step down the voltage from 433/230V, 433/110V or 230/110V.
* POTENTIAL TRANSFORMERS: It is used for metering and protection of line/
phase voltages.
* CURRENT TRANSFORMERS: It is used for metering and protection of the line
currents.

SWITCHGEARS

It houses such equipment, which locates the fault on the system and isolate the faulty part
from the healthy section. It contains Circuit Breakers, relays, switches, fuses & others
control devices.

4. BLOCK DIAGRAM OF POWER GENERATION

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Generated Electrical power from a power station is a complex power. This complex
power is the components of Reactive & Active power:
Complex Power (KVA) = Active Power (KW) + Reactive Power (KVAr)
Active Power (KW) is also called as real power as it actually does the work. Active
power is developed by steam input to turbine. Reactive power is also called as imaginary
power. Reactive power is induced from Excitation of the Generator.

3-PH COMPLEX POWER

BOILERS

FEED WATER STEAM

HEADER HEADER

HP LP
G
E
SIDE SIDE X
B3 E C
I
V N
B4 M

H
GOVERNOR E
B5 A CW INLET
C
D O
E N
COOLING
B6 R D
E TOWER
N N
R
B7 V CW OUTLET

CONDENSATE
PUMPS
DM
TANK

TO UNITS DEARATOR
BOILER FEED PUMPS

5. UNITS OF ENERGY RELATIONSHIP AMONG ENERGY UNITS

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1) Mechanical Energy : The unit of the mechanical energy is Newton-

meter or joule on the MKS or SI system.
2) Electrical Energy : The unit of Electrical energy is Watt-sec or joule.

3) Heat : Calorie is the unit of heat..It is the amount of heat required to raise
the temperature of 1gm of water through 1C. Kilocalorie is commonly
been used.

1 Kilo Calorie = 1kg 1C = 1000 gm 1C = 1000 Calorie

RELATIONSHIP

1) Electrical & Mechanical 3) Electrical & Heat

1Kwh = 1kw 1hr 1Kwh = 1kw 1hr
= 100 3600seconds = 1000watts3600
seconds
= 36 10 Joules = 36 10 Joules
= 3610 4.18 ca
lories
2) Heat & Mechanical = 8601000 calories
1 Joules = 4.18 joules = 860 K calories

6. POWER FACTOR DEFINITION, DISADVANTAGES OF LOW POWER

FACTORS.

In AC circuit, there is a phase difference ' between voltage and current. The term
cos is called the power factor of the circuit

I
I Sin or
. Apparent Power Reactive power

V
I cos or
Active power
In others words power factor (Cos ) = Active power (kW) / Apparent power (kWA)
From the above power triangle, followings are conclusive:

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1. Smaller the Reactive power component, higher is the power factor of the
circuit.
2. Higher the Active power component, Higher the power factor.

DISADVANTAGES OF LOW POWER FACTOR

Power formula for 3- ph power is:

P = 3 V L I L Cos

I L = P / ( 3 VL Cos )

From the above it is clear that for fixed power & voltage Load current is inversely
Proportional to power factor. The disadvantages listed below due to low power factor

1)
LARGE KVA RATING OF EQUIPMENT. Low power factor results in higher
KVA rating (KVA = KW/ Cos ).
2) LARGER CONDUCTOR . Lower the power factor, more current the conductor
to carry. To transmit more current, larger x- sectional area conductors are required .
3) LARGER LINE (COPPER) LOSSES. Losses = I R. Higher current mote
losses.
4) POOR VOLTAGE REGULATION.

CAUSES OF LOW POWER FACTOR. Major contribution of the lower power factor
is
Due to induction motors operates at lower power factor.

7. POWER FACTOR IMPROVEMENT EQUIPMENT

* Static Capacitors
* Synchronous condenser
* Phase advancers.

8. ELECTRICAL EQUIPMENT & THEIR OPERATION

a) UNDERGROUND CABLES

Electric power can be transmitted or distributed either by overhead lines or by

underground cables. Underground cables have several advantages such as Less
liable to damage through storm or lighting, low maintenance cost, less chances of
fault, smaller voltage drop and better general appearance.

However, their major drawback is that it has greater installation cost and introduce
insulation problem at higher voltage compared to equivalent overhead lines.

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CONSTRUCTION OF CABLE (IN GENERAL)

* Cores or conductor
* Insulation
* Metallic sheath
* Bedding
* Armoring
* Serving

OPERATION : Observe the cable by touching, if cable is exposed, if found

warm/
Hot its termination or loading shall be reduced. Cable entry points shall be sealed.
Cable trenches to be kept dry.

b) SWITCHES

Switches are the devices, which is used to open or closed the Electrical circuit in a
convenient way. It can be used under full load or no load conditions but it can not
Interrupt the fault currents.

When the contacts of a switch are opened, an arc is produced in air between the
contacts. This is particularly true for circuit of high voltage or large current
capacity. The switches may be ( I ) Air switches ( II ) Oil switches. The contacts of
air break switch are opened in air that of the latter are opened in oil.

c) ISOLATORS

It is essentially a knife type switch and is designed to open a circuit under NO

LOAD
Its main purpose is to isolate one portion of the circuit from the other. It shall not be
intended to be opened while current is flowing.

d) FUSES

Fuses are installed in series to the circuit to be protected. The fuse consists of a
short piece of wire or thin strip, which melts when excessive current flows through
it for sufficient time.

Always installed the proper size, type & capacity fuses in the circuit . For motor
circuit, select the fuse rating as per the chart.
Always use the HRC fuses. Never use wire in place HRC fuse. Here is the list of
fuse selection for different capacities of DOL motors.

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SL MOTOR RATING FULL LOAD FUSE RATING

KW HP CURRENT MIN MAX
1 0.75 1.0 1.8 6 15
2 0.92 1.25 2.1 10 25
3 1.1 1.5 2.6 10 25
4 1.3 1.75 3.0 10 25
5 1.5 2.0 3.5 10 25
6 1.8 2.5 4.8 10 25
7 2.25 3.0 5.0 10 25
8 3.0 4.0 6.2 10 25
9 3.75 5.0 7.5 15 35
10 4.5 6.0 9.0 15 35
11 5.5 7.5 11 15 35
12 7.5 10.0 14 25 35
13 9.3 12.5 18 25 63
14 11 15 21 35 63
15 13 17.5 24 35 63
16 15 20 28. 35 63
17 18.5 25 35 63 100
18 22 30 40 63 100
19 26 35 47 80 160
20 30 40 55 80 160
21 33.5 45 60 80 160
22 37 50 66 125 160
23 44 60 80 160 225
24 55 75 100 200 250
25 67.5 90 120 200 320
26 75 100 135 200 350
27 90 125 165 250 400
28 110 150 200 250 500
29 132 175 230 350 600
30 150 200 275 400 700

e) CIRCUIT BREAKER

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DEFINITION : Circuit breaker is a device which ( i ) Make or break a circuit either

manually or by remote control under normal condition and ( ii ) Break a circuit
automatically under fault condition.

TYPE OF CIRCUIT BREAKER AT GUWAHATI REFINERY

On the basis of classification, GR have the following types of breakers :

(I) Oil circuit breakers: Oil circuit breaker employs some insulating oil for ARC
extinction. Application :- (a) 6.3 KV generation buses Siemens section.
(b) Non essential Bus breakers
(c) 12-02 sub station breakers
(d) Intake sub station breakers

(II) Air blast circuit breakers: This type of breakers high-pressure air blast is used for
extinguishing the ARC.
Application: - All LT breakers are Air circuit breakers at Guwahati
Refinery

(III) Vacuum circuit breakers : Vacuum circuit breakers in which Vacuum is used for
ARC extinction.
Application: - (a) All HT breakers of New sub-station (Make Siemens)
(b) Some breakers at TPS HT section (Make Siemens)

OPERATING PRINCIPLE

A circuit breaker essentially consists of fixed and moving contacts, called poles. Under
normal conditions, breaker contacts remain unchanged. When tripping coil get the
energy, breaker is tripped to isolate the live part from the fault (meaning thereby open
the breaker contacts). Breaker can also be tripped manually.

Actions to be taken while Racking out the breakers

* Trip (open) the breaker.

* Discharge the spring
* Switch off the breaker control supply.
* Insert the Rack-in / Rack-out handle.
* New Rack out the breaker to isolated position & remove Rack in/out handle.

Checks to be carried out in isolated position

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* Check the Current carrying parts, clean if carbon deposition with strong and dry
fabric.
* Check the oil level in the oil chamber. Get it filled, if level is low.
* Check Mechanical tripping and closing of the breaker.
* Check and clean the breaker chamber.
* Check the panel space heater & and maintain the temperature ~ 35 Deg C.
* Check the Vacuum in bottles after detaching lower poles hinging from lower poles.
* Check the breaker auxiliary contracts. Elevate the depressed contact pin.

Actions to taken while Racking in the breakers.

* Trip (open) the breaker manually, if it is closed.

* Discharge the spring.
* Insert the Rack- in /Rack- out handle.
* Now Rack- in the breaker up to test position.
* Switch ON the control supply.
* Check the opening /closing of the breaker in test position.
* Further Rack-in the breaker up to service position.
* Remove the Rack-in/Rack-out handle from the breaker.

Actions to be taken while breakers in operation

* Control supply shall be ON.

* Indication lamps shall be glowing.
* Spring shall be charged.
* Breaker chamber shall not be hot.

f) RELAYS

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DEFINITION: A protective relay is a device that detects the fault and initiates the
operation of the circuit breaker to isolate the defective element from the rest of the
system.

BUS BAR

CIRCUIT TRIP
CONTROL
BREAKER COIL SUPPLY

RELAY
RELAY
C.T COIL
FAULT

FIG : TYPICAL RELAY CIRCUIT.

The above sketch is the general arrangement of relay circuit with protection to open the
circuit breaker. From the above figure, it can be seen that when a fault occurs at
mentioned F on the system, the current flowing in the line increases enormous value.
This causes heavy current flow in to the relay coil, causing the relay to operate by closing
its contacts.
When the relay contact is made through, control supply to breaker trip coil gets through.
Trip coil in such cases after getting the energy; operate the circuit breaker to open the
faulty portion of supply system.

Types of relays installed at Guwahati Refinery

Basic relays : Most of the relays installed in old system are basic relays. They work on
the principal of (i) Electromagnetic attraction & (ii) Electromagnetic induction.

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Numerical Relays : Basic relays have low speed, less sensitivity & reliability reduces
in due course of time. One of the other major drawbacks of basic relays is that they
have the plug setting multiplier in steps of 0.25. Whereas numerical relays have the
setting range in plug setting multiplier of 0.1. Minimum setting on the over current
Electromagnetic relays is 0.25 whereas Numerical relays can be set at 0.1. Followings
are the Numerical relays installed at Guwahati Refinery:

Siemens Make relays (Installed in new Units HT sub-station and 33 KV switchgear).

7SJ600 Over current relays.

7RW600 Over / Under Voltage relays.
7VK512 Check synchronization relays.
7UT512 Differential relays.

ABB Make relays (Installed in new units sub-station).

SP130UC Over / Under Voltage relays.

SPAD 346 C2 Differential relays.

Alstom Make relays (Installed at 6.3 KV Gen Bus Alstom Section).

Micom P-121
Micom P-147

g) BATTERY BANK

Capacity of battery is defined in Ampere-hours

For example capacity of each battery bank 220V. TPS main battery charger is 600A/H.
It means 100A current can be delivered by battery for 6 hours.
OR
Battery can supply 50 amps X 12 hours.

At Guwahati Refinery, we monitor the physical condition of batteries e.g. condition of:

* Cable connection at Battery bank terminals.

* Sulphonation on cell.
* Tightness of connectors.
* Physical condition of caps
* Cracks on cells.

h) BATTERY CHARGER

INTRODUCTION : Battery chargers are designed to supply a constant voltage for

any load within its rating. Beyond 100% of rated load, the output voltage will drop
rapidly, thereby protecting the charger and the system to which it is connected. With a

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battery connected to the out put, the charger will supply sufficient current to maintain
the battery at full charge regardless of variations in line or load within its rating.

LIST OF GR CHARGERS

SL LOCATION INPUT-SUPPLY OUTPUT-VOLT

1.0 TPS MAIN BATTERY CHARGER 415V, 3-PH, 50HZ 220V DC
FOR SWITCHGEAR CONTROLS
2.0 TPS NEW CHARGER 415V, 3-PH, 50HZ 220V DC
INSTALLED AT TG 5 ROOM
3.0 OLD HT SUB-STATION 415V, 3-PH, 50HZ 110V DC
CHARGER
4.0 NEW UNITS HT SUB-STATION 415V, 3-PH, 50HZ 110V DC
CHARGER

All the battery chargers are provided with two modes of operation viz. Boost & Float
battery charger. Charger in Float or Trickle mode is the normal operation of the charger.
Put charger in Boost mode of operation once in three months, if batteries are not
employed in Boost mode or charger is not put in Boost mode.

METERING

AC input voltage and input current.

DC output voltage and current.

INDICATIONS ALARMS

Input supply ON (R, Y, B phase) Output low

Boost ON Output high
Trickle / Float ON Charger Fail
Output ON Earth Fault

INDICATING LED

Input AC over Voltage

Input AC under Voltage
Input AC phase failure (single phasing)
AC phase sequence reverse
Failure of the any DC power supplies
OPERATION

Typical Block diagram of the charger is given below:

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LOAD
AC =
MAINS
RECTIFIER
CONVERTS
AC TO DC
BATTERY
BANK

AUTOMATIC CHARGE CONTROL

This feature enables the charger to detect the need of the battery for charge and
automatically Boost it to full capacity. Charger returns to the float mode after
completely charging the battery. This feature is optional. At GR this feature is not
available.

MANUAL CHARGE CONTROL

Normal operation of the charger is in float mode. Switch over of charger from Trickle
to Boost mode or vise-versa can be accomplished manually.

To change the charger into Boost mode, just press the push button marked Boost on
the chargers front panel.

Falling of the Boost current below the set value (or ~ to float current), bring the charger
back to Float by pressing push button marked Float on the charger front panel.

FORMULA FOR DC OUTPUT VOLTAGE

The 3-ph full wave bridge rectifier provide a variable DC voltages at in output

VDC = 0.675 US (1 + COS )

Where VDC = dc voltage output
US = rms ac voltage input of the bridge
= the delay angle of triggering of rhyristor

i) INSTRUCTION FOR BATTERY HANDLING

DO S

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1. Keep the battery dry and clean.

2. Check the leakage of electrolyte from battery.

3. Check specific gravity of each cell .it should be 1.200.

4. Check voltage of each cell. It should be 1.2 volt DC .
5. Check inter cell cell for proper tightness.
6. Check the electrolyte level, and ensure that it does not fall below the
minimum level that is indicated on the marking label.
7. Use DM/DI water to top up the cell for compensating of label.
8. Ensure that the battery cable lugs are electro plated.
9. Ensure that the transport seal (plastic strip vent cap) is removed before
charging.
10. Keep vent caps always closed during charging and discharging.
11. Use insulated tools while working on the battery to prevent accidental
short circuit & consequent damage.
12. Ensure proper functioning of charger and proper connections to the
battery.
13. Ensure that cell connections have been made as per the wiring
diagram provided. Red washer on cell indicates positive polarity and
blue washer indicates negative polarity.
14. use alkaline electrolyte only since this is an alkaline battery

DO NOT S

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1. Dont use apparatus like hydrometers, capillary tubes,

thermometers etc. used in lead acid batteries in order to
contamination of electrolyte.
2. Dont use petrol, kerosene or any strong chemicals, wire, hard
brush to clean the battery and interconnection terminals.
3. Dont use aluminum cables for making connection to the battery
terminals.
4. Dont keep open vent caps open and expose electrolyte to air.
5. Dont spill water or electrolyte on and around the battery.
6. Dont measure specific gravity immediately after adding DM/DI
water since this will indicate a lower specific gravity due to
inadequate mixing of the water with electrolyte in the cell.
7. Dont remove the vent caps for topping up since frequent removal
can damage the vent cap and the cell lid. Gently press catch to
open the spring-loaded vent lid the.
8. Dont use acid since the battery requires alkaline electrolyte.
Addition of acid will cause permanent battery damage.
9. Dont charge the battery without removing the transport seal from
the vent, or while the battery is covered.
10. Dont adjust terminal connection during charging to prevent
sparking which can ignite the oxygen and hydrogen gases which
are given off by the battery towards completion of charge, cause a
fire/explosion.
11.Dont smoke in the battery room since it is fire hazard.
12. Dont keep batteries in the same room where acid batteries are
kept.

J) UPS

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At Guwahati Refinery we have Tata Libert make UPS systems. The block diagram of
UPS system is :

INPUT MAINTENANCE
MCCB BY-PASS SW
SVR

ST SW
ISOLATOR

INPUT
MCCB
L
O
RECTIFIER INVERTER
A
D

INPUT OUTPUT
ON/OFF ON/OFF
SWITCH SWITCH

BATTERY
BANK

BLOCK DIAGRAM OF UPS

Operator Control panel

The operator control panel is divided into three functional areas :-

Mimic Indications
Control switches
&

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LCD display panel

MIMIC INDICATIONS

Six LEDs are mounted on a single line diagram to represent the various UPS power
paths
These leds, which are annotated in figure shows the current UPS operational status and
should to interpreted as below

LS3 LS5

LS1 LS2 LS4 LS6

MIMIC INDICATIONS DIAGRAM

LSI : INPUT SUPPLY OK / RECTIFIER OPERATIVE

This LED illuminates when the input isolator is closed, the input supply is within 20%
of nominal voltage, and the rectifier is operative.

LS2 : BATTERY VOLTAGE OK

This LED glows when the battery circuit breaker is closed and the voltage is with in
UPS operating range.

LS3 : BYPASS SUPPLY OK

This LED glows when the static bypass supply is within 10% of its nominal voltage
(and the static bypass isolator is closed)

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LS4 : INVERTER OUTPUT OK

This LED glows when the inverter is operating and its output is within a preset
acceptable voltage window.

LS5 : LOAD ON BYPASS

This LED glows when the output isolator is closed and the load is connected to the
Inverter via static switch.

LS6 : LOAD ON INVERTER

This LED glows when the output isolator is closed and the load is connected to the
Inverter via static switch.

CONTROL SWITCHES

Seven tactical switches are located on the operation panel, together with an emergency
stop push button, which is fitted with a safety cover to prevent inadvertent operation.

SWITCH S1 (Vo) output volts

When this switch is pressed, the lower line of the LCD display shows the output line to
line voltages on all three phases. For single phase, it shows phase to neutral voltage.

SWITCH S2 (Fo) output frequency

When this switch is pressed, the lower line of the LCD display shows the output
frequency

SWITCH S3 (Io) output current

When this switch is pressed, the lower line of the LCD display shows the output line
(And neutral) currents for 3 phases. For single phase it shows phase current only.

SWITCH S4 (B) -- Battery

When this switch is pressed, the lower line of the LCD display shows the battery
voltage
And current. Note that a discharging current is symbolized by a preceding minus (-).

SWITCH S5 ((-)) Alarm reset

Pressing this switch cancels the audible alarm. The alarm led and messages will remain
active if a detected fault condition is still present.

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SWITCH S6 Inverter OFF

Pressing this switch turns OFF the inverter and causes the load to be transferred to the
static bypass supply.

SWITCH S7 Inverter ON

Pressing this switch activates the inverter and caused the load to be transferred to the
inverter side of the static switch after the inverter voltage had time to stabilized.

SWITCH S8 Emergency stop

When the emergency stop is pressed it disables the static switch block entirely (so
removing load power). It also disables the rectifier and inverter, and trips the battery
circuit breaker. Under normal circumstances it does not remove UPS input power
since this is applied through a manually controlled isolator, however, if the UPS input
power is connected via a circuit breaker having an electrical trip facility the
emergency stop signal can be used to drive the external circuit breakers trip circuit.

There are two LEDs contained within the switch panel area:

LS7 - Alarm

This led accompanies the audible alarm warning when any alarm condition is initiated.
The audible warning can be cancelled by reset switch (S5) but LS7 will only extinguish
after the alarmed condition has reverted to normal.

LS8 Inverter status

This green led situated near the inverter ON switch illuminates when the inverter is
selected
ON.

k) POWER TRANSFORMER

BATTERY AREA TRANSFORMERS CAPACITIES OF GUWAHATI REFINERY

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SL DESCRIPTION VOLT RATIO CAPACITY

1.0 ASEB GRID TR-1 & TR-2 33KV / 6.3KV 5000KVA
2.0 HOME SERVICE TR (WORKING&S/B) 6.3KV/0.433KV 750KVA
3.0 TPS AUXILIARIES TR-1 &TR-2 6.3KV/0.433KV 630KVA
4.0 12/02 SUB-STATION TR-1 & TR-2 6.3KV/0.433KV 1000KVA
5.0 12/01(CDU) SUB-STN TR-1 & TR-2 6.3KV/0.433KV 1600KVA
6.0 UNIT CT SUB-STN TR-1 & TR-2 6.3KV/0.433KV 1600KVA
7.0 DCU SUB-STN TR-1 & TR-2 6.3KV/0.433KV 2000KVA

8.0 ETP SUB-STN TR-1 & TR-2 6.3KV/0.433KV 1000KVA

9.0 12/06 SUB-STN TR-1 & TR-2 6.3KV/0.433KV 560KVA
10.0 12/6 ONE NEW TR INTRODUCED 6.3KV/0.433KV KVA
11.0 NU SUB-STN TR-21 & TR-22 6.3KV/0.433KV 2500KVA
12.0 NU SUB-STN TR-23 & TR-24 6.3KV/0.433KV 2500KVA
13.0 NU SUB-STN TR-25 & TR-26 6.3KV/0.433KV 2000KVA

l) AUTO TRANSFORMER

BATTERY AREA AUTO TRANSFORMERS CAPACITIES OF GUWAHATI REFINERY

SL DESCRIPTION VOLT RATIO CAPACITY

1.0 13-KM-01A(AIR COMPRESSOR) 6.3KV/6.3KV 5969KVA
2.0 13-KM-01B(AIR COMPRESSOR) 6.3KV/6.3KV 5969KVA
3.0 13-KM-01C(AIR COMPRESSOR) 6.3KV/6.3KV 5969KVA
4.0 49-KM-01A (RE-CYCLE COMP) 6.3KV/6.3KV 5969KVA
5.0 49-KM-01B (RE-CYCLE COMP) 6.3KV/6.3KV 5969KVA
6.0 49-KM-03A (MAKE UP GAS) 6.3KV/6.3KV 5969KVA
7.0 49-KM-03B (MAKE UP GAS) 6.3KV/6.3KV 5969KVA
8.0 53-KM-02 (MAIN AIR BLOWER) 6.3KV/6.3KV 8461KVA

AUXILIARIES 0F TRANSFORMER

* BUCHOLZ RELAY : The relay serves as main protection for any minor or major
faults that may develop inside the transformer. Such fault always result in generation of
gases which causes the operation of mercury switches giving signal for audible alarm or
isolate the transformer from the network or both.

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 24

* WINDING & OIL TEMPERATURE INDICATORS (WTI & OTI) : These

indicators are precision instruments, specially designed for protection of transformers.
In general Guwahati Refinery operate power transformers on ~ 40 % loading. At this
loading WTI shall not exceed > 60 deg C. WTI & OTI also perform the following
functions :-

Indicate maximum oil temperature and maximum hottest spot temperature of

winding.

Operate an alarm or a trip circuit at a predetermined temperature.

Switch on the cooling equipment when winding attains a preset high temperature
and
Switch it off when the temperature drops by an established differential
(transformers with forced cooling are not existing in Guwahati Refinery).

* PRESSURE RELIEF VALVES (PRV) : A major fault inside the transformer

causes instantaneous vaporization of the oil, leading to extremely rapid build up of
gaseous pressure. If this pressure is not relieved with in a few milliseconds, the
transformer tank can get ruptured, spilling oil over a wide area. The consequent damage
and fire hazard possibilities are obvious. A pressure relief device provides instantaneous
relieving of dangerous pressure.

* OIL LEVEL INDICATOR : Normally all transformers (except Home service

transformers) are provided with an expansion vessel called conservator to take care of
oil volume due to rise in temperature. Oil level in conservator goes up when load on the
transformer increases or ambient temperature increases. Similarly oil level comes down
when load or ambient temperature reduces. All the large transformers are fitted with a
magnetic oil level gauge with a mercury switch. The contact of mercury switch is
normally being added to initiate an alarm when conservator is almost empty.
GR operate its power transformers almost at steady load, therefore variation in
conservator oil level due to load is less. Conservator oil level at GR is maintained 40 to 60
%

* BUSHING AND CABLE SEALING BOX : Low and High voltage leads are
taken out of the transformer tank to enable to make cable connections through
Bushings. The bushing is a structure carrying a conductor through a partition in the tank
and insulating the conductor from partition.

* SILICA GEL BREATHER : It is connected with the conservator tank. It is

employed to prevent moisture ingress. It allows the changes in oil volume due to
change in transformer load. Due to above, air drawn is allowed through a cartridge

24
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packed with silica gel dissident, which dries the air effectively. A freshly regenerated
gel dries the air unto (-) 35 Deg C.

* BASIC FORMULA

Transformer KVA = 3 VL (in KV) x IL (in A)

Example: Calculate the primary and secondary side rated current of 6.3 / 0.433KV,
2.5 MVA power transformer.

I) To calculate primary Current on 6.3 KV side (apply the above formula)

2500 KVA = 3 6.3 IL (primary side Line current in A)

I L = 229.11A
II) To calculate secondary current on 0.433KV side (apply the above formula)
2500KVA = 3 0.433 IL (primary side Line current in A)

I L = 3333.53 A

IMPORTANT NOTES:

Avoid Switch ON and Switch OFF of transformer on loaded condition.

Switching ON or Switching OFF of transformer under loaded condition may lead
to transformer terminal flashover.

When transformer is switched ON, phenomena at the initial charging which last
within few microseconds take place. During the switching ON power transformer
draws as high as 8 to 10 times to rated current called transformer inrush current. For
example, when 2.5 MVA power transformers is switch ON, it may draw line current
from mains at 6.3 KV from 1832.88 A to 2291 A. (Reference Alstom Relay Manual).

9. NORMAL OPERATION OF THE SUB STATIONS

In all the sub station, Electrical power buses are provided with two incomers and one
bus coupler (expect 12/06 HT bus wherein two incomers without bus coupler is

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 26

installed and is in operation). Both incomers ON with Bus coupler OFF in Auto
are normal operation of the sub-station. Followings checks will be done to maintain
the sub-station healthy:

Both incomers ON , bus coupler OFF in auto mode in all the sub-stations.
No relay is operated. If any relay is found operated / or flag is dropped, intimate to
the Electrical Engineer and subsequently in consultation with SELE (M)/ ELE (T),
reset the relay / flag.
Observe the body temperature of the switchgear of individual panel by touching, it
should not be hot. If found hot intimate to Electrical Engineer and subsequently in
consultation with SELE (M)/ ELE (T), change the feeder and get it attended by
Elect Maint.
Control supply of the sub-station is available.
Maximum allowable transformer winding temperature, is 55 deg C above ambient.
Normal operating winding temperature is ~ 50 deg C as our power transformers are
operating at ~35% to 60% load. Any increase in temperature above 50 deg C
indicates some abnormality, under the circumstances transformer should be
attended.
Maintain the transformer oil level between 45% to 60% in conservator.
Check date of testing, validity date & inspection due date mentioned on a tag and
attached on fire extinguishers provided in sub-stations. The fire extinguishers will
be checked before expire.
In HT-201 Bus, keep Auto / Manual switch in Manual position if single TG is
in operation and in Auto position when Two TGs are in operation. Whereas in all
cases PCC-301, PCC-302 & PCC-303 should be kept in Auto
Keep the cables entries sealed & cable entry to be observed and arrenge to seal, if
found damaged.
Keep the cable trenches covered with RCC slabs outside the sub-station and with
checkered MS plates inside the sub-station building.
Sub-station pressurization system always to kept in operation.
Get the chemical & paste control measures being used in the sub-
station/switchgears room for lizard and rat control.
Keep the sub-station lighting up to date. Replace all the fused tube light fixtures.
Check the DC lighting as per schedule & replace the faulty circuit (if found) or
fused lamps.
Keep the transformer yards clean and free from vegetation. Revise the grabbles
inside the transformer yards with 1.5 inch sizes.
Keep the silica gel breather fresh.
Always lock the transformer yards with master key

10. PROCEDURE FOR INCOMER CHANGEOVER

Following procedure shall be followed for proper incomer changeover. Changeover of

incomer with Auto/Manul. The scope of this section is to what precautions and action to

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 27

be taken for proper changeover. Do the followings while changing over or taking back
both the incomers:

While changing over incomer i.e. Isolating one incomer and closing the bus coupler (in
general)

To isolate the incomer.

Communicate to ECR for closing the bus coupler.

Note down the current load on Incomer-I & Incomer-II.
Close the bus coupler with Bus coupler TNC switch.
Again note down the current on Incomer-I & Incomer-II. Both the incomers should
share current equally. Equal sharing will ensure the bus coupler proper closing.
Now Trip the desired incomer TNC switch.
Check that the load is shifted to other running incomer.
Now follow the isolating procedure, if isolation is needed.
Report the same to ECR that isolating is completed.

To take back both Incomers (e.g Incomer-I)

Note down the current load incomer II, the running incomer.
Close the up stream breaker of dead incomer I with up strem breaker TNC
switch.
Insert the down stream breaker in to service position of incomer I
See that the voltage meter of Incomer-I (Line PT) is showing the voltage.
Check all the three phase voltages of Incomer-I, after selecting voltmeter selector
switch to ensure that all the three poles are close properly.
Now close the downstream breaker of Incomer-I by TNC switch.
Note down the current on each Incomer i.e. Incomer-I & II and also check that load
must be shared equally by both Incomers.
Now switch off (open) the bus coupler breaker by bus coupler TNC switch.
Report the same to ECR stating that the changeover is completed.

11. AUTO/ MANUAL CHANGEOVER SCHEME

Two types of auto/manual changeover with following facilities exist:
I. Auto/manual: This scheme is operation in 12/06 LT siemens PMCC, CDU & DCU
LT s/stn only. In manual any breaker can switch ON/OFF. When any incomer failed or
under voltage has occurred, Bus coupler will close automatically.

II. Auto/manual/independent: This facility in existing in old HT sub station HT bus,

New Unit HT substation both HT & LT.

AUTO CHANGEOVER OF BUS COUPLER: Irrespective of types of changeover

implemented (SL I or II). Bus coupler will close automatically, when A/M switch is

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 28

selected in auto position, when upstrem breaker is tripped and line voltage is not
available. In normal condition, keep both the incomers ON and Bus coupler OFF in
AUTO, in this condition, if the incomer is tripped from upstream, bus coupler will close
automatically.

MANUAL CHANGEOVER MODE: Normal possition of the bus > Incomer-I is ON

Incomer II is ON; Bus coupler is OFF, in auto mode.

The objective is to close the bus coupler and open Incomer I. Do the followings:

Select the Auto/ Manual switch in Manual possition.

Note down the current on each incomer.
Close bus coupler with bus coupler TNC switch.
Check and ensure that load is shared bu both the incomers equally.
Now trip the Incomer-I with TNC switch.
Check and ensure that load is shared to Incomer-II

Now the object is to close the Incomer-I & open the bus coupler. Do the following:

Check and ensure that Auto/Manual switch is Manual position.

Note down the current on incomer- Incomer-II
Close Incomer I with incomer TNC switch.
Check and ensure both the incomer shares that load equally.
Now trip the bus coupler with bus coupler TNC switch.

INDEPENDENT MODE OF OPERATION: In inpendent moder of A/ M/ I switch

of bus coupler, both the incomers can either be colesed or opened independently. This
mode can only be operated under the following status only:

* Incomer I : ON
* Incomer II : ON
* Bus Coupler : ON

To understand better, following are the deliberations.

* Put the Auto / Manual Independent selection switch on Independent mode.

* Now you can trip or close anuy of the incomer with TNC switch.

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CHANGEOVER OF INCOMER-I & INCOMER-II WITH BUS COUPLER

NEW UNIT ( HT 201 )

TO PUT I / C 1 OFF & B / C ON

1. Put A/M switch in manual.

2. Check B/C synchronies in OFF possition.
3. Put trip selector switch in I / C I.
4. Put B/C synchronizing switch in ON position.
5. B/C will get ON automatically and after set time delay I/C I will get OFF.
Automatically.

TO PUT I / C I BACK IN SERVICE i.e I/C I ON & B/C OFF

1. Put A/M switch in manual.

2. Check B/C synchronies in OFF position.
3. Put trip selector switch on B/C.
4. Put B/C synchronizing switch in ON position.
5. I/C -I will get ON and after set time delay B/C will get OFF .

TO PUT I / C II OFF & B / C ON

1. Put A/M switch in manual.

2. Check B/C synchronies in OFF possition.
3. Put trip selector switch in I / C II.
4. Put B/C synchronizing switch in ON position.
5. B/C will get ON automatically and after set time delay I/C II will get OFF.
Automatically

TO PUT I / C II BACK IN SERVICE i.e I/C II ON & B/C OFF

1. Put A/M switch in manual.

2. Check B/C synchronies in OFF position.
3. Put trip selector switch on B/C.
4. Put B/C synchronizing switch in ON position.
5. I/C -II will get ON and after set time delay B/C will get OFF .

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12. GENERAL INFORMATIONS OF NEW UNIT SUB STATION

HT SWITCHGEAR

CONTACTOR PURPOSE

K - 10 BREAKER SERVICE CONTACTOR, WHICH WILL PICK UP WHEN

BREAKER IS IN SERVICE POSSITION
K - 19 BREAKER CLOSE IN SERVICE CONTACTOR, WHICH WILL PICK UP
WHEN BREAKER IS IN CLOSED IN SERVICE POSITION
K - 18 PICK UP WHEN EMERGENCY TRIP PUSH BUTTON IS RELEASED &
PRCESS CONDIRIONS ARE HEALTHY.

TRIPPING AND THEIR MEANINGS

1. MOTOR FEEDERS GOT OFF WHILE RUNNING INDICATES THE FOLLOWING: -

i. MOTOR TRIPPED ON UNDER VOLTAGE. IF UNDER VOLTAGE HAS OCCURRED.

THEN IT WOULD TRIP THE OTHER MOTOR FEEDERS AND ALSO SO AS TO
INCOMER.
ii. MOTOR TRIPPED ON PROCESS INTERLOCK. WHEN PROCESS INTERLOCK IS
OPERATED, K- 86P WILL ALSO OPETATE WHICH IS INSTALLED FORFLAGGING
ONLY.

2. ALL THE ELECTRICAL TRIPPINGS ARE PROVIDED THROUGH MASTER TRIP

RELAY. UNDER FAULT CONDITION IT WILL BE COME.

3. ALL THE HT MOTORS, IN GENERAL ARE DESIGNATED FOR 2 HOT AND 3 COLD
STARTS.

4. HORN 4 RELAYS OPERATION INDICATES THE INCOMER CABLE FAULT.

5. BUS DIFFERENENTIAL OPERATION INDICATES FAULT IN 6.3 KV BUS FAULT.

6. KEEP HT-201 BUS COUPLER IN AUTO POSITION WHEN BOTH TGS ARE IN
OPERATION.
KEEP BUS COUPLER SWITCH IN INDEPENDENT MODE WHEN SINGLE
TG IN OPERATION

7. KEEP ALL THE PANELS SPACE HEATERS ALWAYS ON

8. KEEP THE ENTIRE PCC & MCC BUS COUPLER IN AUTO UNDER NORMAL
OPERATION.

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13. PROCEDURE FOR TACKLING EMERGENCY

1. CHANGEOVER OF RUNNING TG AVR FROM AUTO TO MANUAL MODE:

In the case of change over of running TG, AVR from Auto to Manual mode then
immediately inform to electrical testing, SRSM and shift in charge of all units to be
informed not to start the HT motor and change over of any equipment should be done
with the clearance of TPS operation.

Close watch to be kept on the system voltage.

2. SYSTEM EARTH FAULT:

In case of system earth fault alarm all the outgoing feeders to be checked and faulty feeder to be
identified and to be isolated immediately.

3. SUDDEN LOAD THROWN OFF:

In case of sudden load thrown off due to tripping of running Unit/HT section frequency and voltage of
system will rise. In that case it is to be controlled manually immediately.

4. D.G. TRIPPING:

In case of DG set tripping, check the system load, if running TGs cannot take the load,

1. Load shed the non-essential load (Colony, ETP, OM&S and INTAKE Pumps),
Watch the frequency, if frequency has downward trend, ask the PNE of HDT to reduce the
load. Watch the system frequency it is O.K. than no further load shedding is required. If
frequency still has a falling trend, CDU may be load shaded.

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14. LOAD SHEDDING SCHEMES AT GUWAHATI REFINERY.

Presently we are having two load shedding schemes at Guwahati Refinery.

Microprocessor based Power and Steam Load shedding Scheme.

Back up Under Frequency based load-shedding Scheme.
Micro processor based load shedding Scheme
The Microprocessor based load-shedding scheme, has been revised and is
programmed in DCS to operate in the following conditions.
AUTO/ MANUAL LOAD SHEDDING FACILITY WITH STATUS DISPLAY ON
MONITOR.
MANUALLY FOUR GROUPS WITH COMMON PUSH BUTTON IN SERIES WITH
DEDICATED PUSH BUTTON.
FIRST GROUP (1.95 MW)
SECOND GROUP (5.45 MW)
THIRD GROUP (8.95 MW)
FOURTH GROUP (12.95 MW)

The status of the Microprocessor based scheme is seen in the Monitor at ECR.

32
 TG TRIPPING Boiler 3,4,6,7 Boiler 5,6,7 run
OPERATING CONDITION
TG 3/4 & 5 run
TG 3& run (or) Boiler 33 (or) Boiler
Boiler 3,4,6&7 are Boiler 3,4,5&6/7
running are running
4 run 5,6,7 run 3,4,5,6/7 run

BO IL E R 3/4 T RIP w h en
BO IL E R 3/4 T RIP w h en
T G 5 T RIP CO NDIT IO N
I II III IV V

b o iler 3,4,5&6/7 are

b o iler 3,4,6&7 are
BO IL E R 6/7 T RIP

BO IL E R 5 T RIP
L O AD IN T P H
L O AD IN M W

T G 3/4 T RIP
T G 3/4 T RIP
CO NDIT IO N

CO NDIT IO N

ru n n in g

ru n n in g
S .No .

MW TPH MW TPH MW TPH MW TPH

1 Colony 0.5 2 0.5 0.5 0.5 0.5 2 0.5 2 0.5 2

2 OM&S 0.6 6.4 0.6 0.6 0.6 0.6 6.4 0.6 6.4 4 0.6 6.4

3 CISF 0.15 0.6 0.15 0.15 0.15 0.15 0.6 0.15 0.6 0.15 0.6
Coke
4 0.7 2.8 0.7 0.7 0.7 0.7 2.8 0.7 2.8 0.7 2.8
Cutting
5 Intake 0.5 2 0.5 0.5 0.5 0.5 2 0.5 2

No power load s hedding

6 LRU 0.5 2 0.5 0.5 0.5 0.5 2 0.5 2

7 WGC 0.6 2.8 0.6 0.6 0.6 0.6 2.8 0.6 2.8
8 12-02 s/s 0.6 2.8 0.6 0.6 0.6 0.6 2.8 0.6 2.8
9 ISOSIV 0.5 2 0.5 0.5 0.5 0.5 2 0.5 2
10 CDU 0.8 10 0.8 0.8 0.8 0.8 10 0.8 10
11 ETP 1 6 1 1 1 6
12 HDT 2.5 10 2.5 2.5 2.5 10

13 INDMAX 2.2 8.8

14 DCU 1.2 4.8

15 CT 0.6 2.4
12.95 65.4 5.45 8.95 8.95 8.95 49.4 5.45 33.4 4 1.95 11.8
PLUS OM&S ONLY
PLUS OM&S PLUS OM&S
AND ETP OM&S
STEAM STEAM
STEAM STEAM

Boiler 3,4,5,6/7 run (or) Boiler 3,4,6&7 run (or) Boiler 5,6,7 run
OPERATING CONDITION
w hichever is applicable
B O IL E R 3 / 4 & 5

B O IL E R 5 & 6 /7
CASCADE TRIPPING FOR BOILERS

B O IL E R 6 & 7
B O IL E R 3 & 4
L O A D IN T P H
L O A D IN M W
S .N o .

MW TPH MW TPH MW TPH MW TPH

1 Colony 0.5 2 0.5 2 0.5 2 0.5 2 0.5 2
2 OM&S 0.6 6.4 0.6 6.4 0.6 6.4 0.6 6.4 0.6 6.4
3 CISF 0.15 0.6 0.15 0.6 0.15 0.6 0.15 0.6 0.15 0.6
Coke
4 0.7 2.8 0.7 2.8 0.7 2.8 0.7 2.8 0.7 2.8
Cutting
5 Intake 0.5 2 0.5 2 0.5 2 0.5 2 0.5 2
6 LRU 0.5 2 0.5 2 0.5 2 0.5 2 0.5 2

7 WGC 0.6 2.8 0.6 2.8 0.6 2.8 0.6 2.8 0.6 2.8
8 12-02 s/s 0.6 2.8 0.6 2.8 0.6 2.8 0.6 2.8 0.6 2.8
9 ISOSIV 0.5 2 0.5 2 0.5 2 0.5 2 0.5 2
10 CDU 0.8 10 0.8 10 0.8 10 0.8 10 0.8 10
11 ETP 1 6 1 6 1 6 1 6
12 HDT 2.5 10 2.5 10 2.5 10 2.5 10

13 INDMAX 2.2 8.8 2.2 8.8 2.2 8.8

14 DCU 1.2 4.8 1.2 4.8 1.2 4.8

15 CT 0.6 2.4 0.6 2.4 0.6 2.4
12.95 65.4 5.45 33.4 8.95 49.4 12.95 65.4 12.95 65.4
PLUS OM&S PLUS OM&S
PLUS OM&S
PLUS OM&S AND ETP AND ETP
AND ETP
STEAM STEAM STEAM
STEAM
ONE TG 3/4 33
ONE TG 3/4
 34

The details of Back up under frequency scheme is as follows.

UNDER FREQUENCY SETTINGS WITH LOADS
Sl no Loads Group MW

1 Colony 0.50
2 CISF 0.15
3 OM&S Feeder-2 0.30
4 LRU Compressor Group-1 2.70 MW 49.00hz:0.5s 0.50
5 Coke cutting 0.70
NE Panel
6 0.55
(Intake-1 + OM&S-1)
7 Intake-2 0.25
8 WGC Group-2 4.85 MW (2.15+2.70) 0.60
9 ISOSIV 48.75hz:0.75s 0.50
10 CDU 0.80
11 ETP Group-3 8.35 MW (3.5+2.15+2.70)MW 1.00
12 HDT 48.50hz:1.0s 2.50
Group-4 10.55 MW
13 INDMAX 2.20
(2.2+3.5+2.15+2.70)MW 48.25hz:1.25s
14 DCU Group-5 12.35 MW 1.20
15 Cooling Tower (1.8+2.2+3.5+2.15+2.7) MW 48.00hz:1.5s 0.60
Total Load Shedding 12.35 MW

TIME GRADING IN UNDER FREQUENCY SCHEME

FREQUENCY IN HZ

TOTAL L OA D S HE D
50. 00

49. 00 LS OF GROUP - I = 2. 70MW 2.70 MW

48. 75 LS OF GROUP - II = 2. 15 M W 4.85 MW
48. 50 LS OF G ROUP III = 3. 5 MW 8.35 MW
48. 25
LS O F GR. IV = 2. 2 MW 10.55 MW
48. 00
LS OF G R. V = 1. 8MW 12.35 MW

12.35 MW

0.5 1.0 1.5 2.0

TIM E IN SECO NDS

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15. ELECTRICAL EQUIPMENTS ISOLATION PROCEDURE

A) ISOLATION PROCEDURE FOR LT EQUIPMENTS

1. CHECKS & CONFIRMS THAT THE ISOLATION OF THE EQUIPMENT IS ASKED BY THE
OWNER LINE CLEARANCE FROM (OWNER: PRODUCTION IN CASE OF UNIT &
OPERATION IN CASE OF TPS).

2. INDENTIFY THE ISOLATION SOURCE CHECK THAT THE EQUIPMENT IS NOT IN

OPERATION (IN CASE PUMP & HEATERS ETC).

3. PREPARE THE ISOLATION PERMIT AND NOTE DOWN IN DETAIL ALL PTECAUTIONS
TAKEN IN THE LOG BOOK AS WELL AS IN THE ISOLATION BOOK (REGISTER)
INCLUDING SL NO & DATE. & ISOLATE EQUIPMENT FROM THE SORCE SIDE

4. PUT THE MEN AT WORK TAG ON THE PANEL AS WELL AS ON THE

EQUIPMENT UNDER MAINTENANCE / LINE CLEARANCE.

5. CONFARM THAT THE VALVES OR CHAINS ARE CLOSED PROPERLY.

6. RACK OUT THE BREAKER FROM ITS SERVICE POSITION TO ISOLATING POSITION.
LOCK THE BREAKER AT ISOLATING POSITION. TAKE OUT THE KEY. (TAKE OUT
POWER FUSES IN CASE OF SWITCH FUSE MODULE)

7. TAKE OUT ORIGINAL LINE CLEARANCE WITH COPY & KEYS /FUSES. KEEP IN THE
LINE CLEARANCE & FUSE KEEPING RACK. HAND OVER THE KEY TO THE OWNER
(e.g. PRODUCTION / TPS OPERATION)

8. TEST THE EQUIPMENT BY GIVING ON COMMAND FOR COMPLETE ISOLATION.

9. CHECK & ENSURE THAT LINE CLEARANCES SHOULD BE ISSUED TO ALL CONCERN
AGENCIES WHOSOVER PERFORM THE JOB EVEN ON ALREADY LINE CLEARANCE
ISSUED EQUIPMENT.

10. LINE CLEARANCE TO BE CANCELLED AFTER COMPLETION OF JOB& RETURNING OF

CLEARANCE CERTIFICATE TO ISSUING OFFICE BY AUTHORISED PERSONS.
*** ELECTRICAL AUTHORISED PERSON MUST CARRY OUT ALL ACTIVITIES ***

35
36

36
 37

ELECRRICAL EQUIPMENTS ISOLATION PROCEDURE

A) ISOLATION PROCEDURE FOR HT EQUIPMENTS

1. CHECKS & CONFIRMS THAT THE ISOLATION OF THE EQUIPMENT IS ASKED BY THE
OWNER IN THE LINE CLEARANCE FROM (OWNER: PRODUCTION IN CASE OF UNIT &
OPERATION IN CASE OF TPS).

2. INDENTIFY THE ISOLATION SOURCE CHECK THAT THE EQUIPMENT IS NOT IN OPERATION.

3. PREPARE THE ISOLATION PERMIT AND NOTE DOWN IN DETAIL ALL PTECAUTIONS TAKEN IN
THE LOG BOOK AS WELL AS IN THE ISOLATION BOOK (REGISTER) INCLUDING SL NO &
DATE. & ISOLATE EQUIPMENT FROM THE SORCE SIDE

4. PUT THE MEN AT WORK TAG ON THE PANEL AS WELL AS ON THE EQUIPMENT UNDER
MAINTENANCE / LINE CLEARANCE.

5. RACK OUT THE BREAKER FROM ITS SERVICE POSITION TO ISOLATING POSITION. LOCK
THE BREAKER AT ISOLATING POSITION. TAKE OUT THE KEY. IF APPLICABLE.

6. TAKE OUT ORIGINAL LINE CLEARANCE WITH COPY & KEYS /FUSES. KEEP IN THE LINE
CLEARANCE & FUSE KEEPING RACK. HAND OVER THE KEY TO THE OWNER (e.g.
PRODUCTION)
.
7. TEST THE EQUIPMENT BY GIVING ON COMMAND FOR COMPLETE ISOLATION.

8. DISCHARGE THE EQUIPMENT WITH EARTHING ROD.

9. CHECK & ENSURE THAT LINE CLEARANCES SHOULD BE ISSUED TO ALL CONCERN
AGENCIES WHOSOVER PERFORM THE JOB EVEN ON ALREADY LINE CLEARANCE
ISSUED EQUIPMENT

10. LINE CLEARANCE TO BE CANCELLED AFTER COMPLETION OF JOB& RETURNING OF

CLEARANCE CERTIFICATE TO ISSUING OFFICE BY AUTHORISED PERSONS

*** NOTE: ELECTRICAL AUTHORISED PERSON MUST CARRY OUT ALL THE ACTIVITIES. ***

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16. LIST OF APPROVED DISPLAY BOARDS / INSTRUCTIONS

LIST OF APPROVED DISPLAY BOARDS / INSTRUCTIONS MAINTAINED AT TPS AREA

SR NO: - DESCRIPTIONS

1. SINGLE LINE DIAG. OF POWER GENERATION & DISTRIBUTION

2. TGS RELAY & MERERING DIAG

3. TGS RELAYS ALARM / TRIP SETTINGS

4. DAILY PEAK POWER GRAPH.

5 CORPORATE SAFETY POLICY.

6. GUWAHATI REFINERY QUALITY POLICY.

7. TOWER MAST LIST.

8. DOS & DONTS OF ENERGY CONSERVATION.

9. TREATMENT FOR ELECTRICAL SHOCK.

10. CRITICAL EQUIPMENTS LIST.

11. BATTERY CARE & MAINTAINCE TIPS.

12. SELECTING CORRECT FIRE EXTINGUISER.

13 FIRE & SMOKE DETECTOR LOCATION.

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17. SUDDENLY TRIPPED TGS (BLACK START)

1. INFORME TO ASEB OVER TELE PHONE/ HOT LINE ELE (ECR)

2. POWER TAKEN FROM ASEB ON BUS I & II ( 6.3 KV) ECR (OPTR)

3. OPEN BY-PASS VALVE OF TPS COOLING TOWER TPS CT (OPTR)

4. INFORM CPUM / SPUM (O) / MNMEL / SRSM DMPU (O)

4. SWITCH OFF BREAKERS OF NON ESSENTIAL LOADS ECR ( OPTR)

5. UNIT COOLING TOWER COLD PP START UTC (OPTR)

6. AIR COMPRESSOR START (13 MS/ N2) COMP (OPTR)

7. MES LINE CLOSE WTP (OPTR)

8. ONE INTAKE PUMP START INTAKE (OPTR)

9. CLEARANCE TO UNIT CT / TPS CT PUE (TPS)

10. NORMALISE BOILERS FEED PUMPS. BFP (OPTR)

11. NORMALISE BOILERS & TURBINES BLR& TG (OPTR)

12. RESETTING OF LOAD SHEDDING RELAYS& LSR-3 ELE/PUE

13. DATA OF TRIPPED RELAY/ANNUNCIATORS (RECORDED) ECR&TCR(OPTR)

14. ALL TRIPPED RELAYS RESETTING INCUDING 86T OF TG TCR&ECR (OPTR)

15. INFORM MECH/TESTING/INSTRUMENT, PERSONNEL. DMPU (O)

16. FAULTY FEEDER TO BE ISOLATED. PUE/ ELE

17. AFTER REACHING R.P.M OF TG SYNCHRONISE WITH ASEB ECR (OPTR)

** AFTER SMOOTH OPERATION ASEBTO BE ISOLATED& NORMALISATION OF LOAD SHEDDING

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18. TGS START- UP ELECTRICAL

1. RESET GEN LOCK OUT RELAY (86A), UNIT LOCK OUT RELAY
(86B) AND TRIPPING RELAY (86AX) ECR OPTR

2. CLEAN SLIP RINGS, COMMUTATOR AND BRUSHES WHEN

THE TURBINE IS ON BARRING GEAR. ECR OPTR

3. TEST GEN BREAKER IN TESTING POSITION LOCALLY AFTER

SWITCHING ON. CONTROL SUPPLY. ECR OPTR

4. SWITCH OFF D.C. CONTROL SUPPLY. PUT GEN BREAKER IN

WORKING POSITION. SWITCH ON CONTROL SUPPLY & RESET
TRIP SUPERVISION RELAY. PUT LOCAL/REMOTE SELECTOR
SWITCH ON REMOTE. ECR OPTR

5. CHECK SPRING CHARGING INDICATION HEALTHY ECR OPTR

6. SWITCH ON DOUBLE POLE SWITCH ON SWING RACK OF AVR

FOR D.C SUPPLY TO AVR/DVR ECR OPTR

7. SWITCH ON. 13 CUBICLE AUXILLIARY A.C. SUPPLY TO AVR/

DVR AT TPS AUXILLIARY SUB-STATION. ECR OPTR

8. SWITCH ON MCB-I & MCB-II OF AUTO & MANUAL CHANNEL

IN AVR/DVR PANEL. ECR OPTR

9. CHECK FOR THE FOLLOWING INDICATIONS IN GEN CONTROL DESK

a) POTENTIOMETERS IN AUTO & MANUAL CHANNEL ARE IN

MINIMUM POSITION. ECR OPTR

b) MAIN SUPPLY TO AVR/DVR FUSES ARE IN HEALTHY ECR OPTR

c) THYRISTOR FUSES ARE HEALTHY IN BOTH THE CHANNEL ECR OPTR

10. CHECK GEN FLD BRK & EXCITER FLD BRK AS BELOW

a) SWITCH ON THE GENERATOR FIELD BREAKER ECR OPTR

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b) SWITCH ON EXCITER FIELD BREAKER. ECR OPTR

c) SWITCH OFF GEN FIELD BREAKER & THEN EXCITER FIELD BRK
SHOULD TRIP. ECR OPTR

11. SELECT MANUAL CHANNEL OF AVR/DVR IF IT IS IN AUTO

CHENNEL. ECR OPTR

12. WIRH DUE PERMISSION FROM TURBINE SIDE EXCITE GEN

BY CLOSING GEN FIELD BREAKER THEN EXCITER FIELD
BREAKER. RAISE VOLTAGE SLOWLY UP TO 6.3 KV THTOUGH
MANUAL CHANNEL ECR OPTR

13. RESET FOLLOWING RELAY, IF FOUND OPERATED ECR OPTR

a) GENERATOR VT FUSE MONITORING RELAY (60P) ECR OPTR

b) AVR/DVR PT FUSE MONITORING RELAY (60A) ECR OPTR

c) FIELD UNDER VOLTAGE RELAY (81-1, 81-2) & THEIR TIMERS. ECR OPTR

d) FIELD UNDER VOLTAGE RELAY (27 / 40A) ECR OPTR

14. RAISE AUTO CHANNEL POTENTIOMETER TILL BALANCING

VOLTMETER READS ZERO ECR OPTR

15. CHANGE OVER TO AUTO CHANNEL ECR OPTR

16. ALEART TURBINE OPERATOR. SPUE/ PUE

17. SYNCHRONISE GEN AFTER SWITCHING ON SYNCHRONISING

KEY. ECR OPTR

18. INCRESE LOAD TO 0.5 MW IMMIDIATELY AND MAINTAIN

POWER FACTOR AROUND 0.85 ECR OPTR

*************************

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19. SYNCHRONISATION OF TG WITH ASEB

1. SELECT THE GRID TRANSFORMER BY PUTTING S 2 SWITCH IN TR I OR

TR 2 (SELECT TR 1 IN CASE OF SYNCHRONISE AT GRID TR 1) ECR ( OPTR)

2. INFORM TURBINE OPERATOR THAT TG IS GOING TO BE SYN WITH ASEB ELE (ECR)

3. CHECK THAT OLTC ( ON LOAD TAP CHANGER) IS OPERATING FROM ECR) ECR (OPTR)

4. INSERT THE SYNCHRONISING KEY INTO ASEB SYN KEY SEC I, ASEB
33/6.3KV SEC I SOCKET OF THE 6.3KV SIDE CONTROL KEY OF 33KV
TRANSFORMER OF THE PERTICULAR SECTION (PRESENTLY TR I SIDE) ECR (OPTR)

5. PUT SI POSITION TO S2 TO BRING SYNCHRONISING RELAY IN CIRCUIT. ECR (OPTR)

6. SWITCH ON THE SYNCHRONOSCOPE IN ECR PANEL ECR (OPTR)

7. ADJUST THE INCOMING TG VOLTAGE TO MATCH WITH THE GRID VOLTAGE

BY INCREASING OR DECREASING WITH AUTO RAISE/ LOWER FROM PANEL. ECR (OPTR)

8. ADJUST THE TG FREQUENCY TO MATCH WITH THE GRID FREQUENCY BY

RAISE OR LOWER THE RPM FROM GOVERNOR CONTROL FROM PANEL. ECR (OPTR)

9. OBSERVE THAT THE CHECK SYNCHRONISING RELAY IS IN SERVICE. ECR (OPTR)

10. OBSERVE THE POINTER OF THE SYNCHRONOSCOPE. AS SOON AS POINTER

IS STANDSTILL OR APPROACHING SLOWLY TOWARDS THE ZERO POINT IN
CLOCK-WISE DIRECTION, SWITCH ON THE CIRCUIT BREAKER OF 6.3KV SIDE
OF GRID TR I. (IF THE BREAKER IS NOT CLOSING IT MEANS THE POINTER IS
NOT MATCHED PROPERLY. ECR (OPTR)

11. IF REQUIRED VOLTAGE CAN ALSO BE ADJUST WITH ONLC ECR (OPTR)

12. INFORM THE PANEL OPTRS OF THE TURBINE THAT THE SYSTEM HAS BEEN
SYNCHRONISED WITH ASEB ELE (ECR)

13. REDUCE LOAD ON TURBO GENERATOR AND IMPORT THE POWER FROM
ASEB AS REQUIRED. ECR (OPTR)

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PRE SRART CHECKS

b) ACTION BY ELECTRIAL CONTROL ROOM OPERATOR UNDER SUPERVISION

OF ELECTRIAL ENGINEER.

1) CHECK THAT NO LINE CLEARANCE IS PENDING TO ANY AGENCY FOR ANY OF THE
BREAKERS (PANEL NO. 10 & 42 IN GEN BUS SEC I & II AND NO. 6 AT NE BUS).
2) RACK-IN TO ANY OF THE BREAKERS TO ITS SERVICE POSITION & LOCK THE BREAKER
AT SERVICE POSITION (PANEL NO 10 IN GEN BUS SEC I, PANEL NO 42 IN GEN BUS SEC
II FOR SYNCHRONIZING DGS WITH GUWAHATI REFINERY SYSTEM OR PANEL NO. 6 AT
NE BUS FOR SYNCHRONIZATION WITH ASEB).
3. SWITCH ON THE DC CONTROL SUPPLY & AC SUPPLY OF THE SELECTED BREAKER (AS
PER POINT NO. 2).
4. RESET ALL THE OPERATED RELAYS.
5. ENSURE THAT THE SPRING OF THE BREAKER IS CHARGED.
6 CHECK AND ENSURE THAT NO DG BREAKER IS CLOSED.
7. CHECK AND ENSURE THAT DG CONTROL PANEL MAIN ISOLATING BREAKER (4.0 MVA, 6.3 /
0.415 KV) AT LT SIDE IS OFF.
8. NOW CLOSE THE BREAKER IN SERVICE POSITION (PANEL NO 10. IN GEN BUS SEC- I,
PANEL NO 42 IN GEN BUS SEC II FOR SYNCHRONIZING DG S WITH GUWAHATI
REFINERY SYSTEM OR PANEL NO 6 AT NE BUS FOR SYNCHRONIZING WITH ASEB).

2. SYNCHRONAZATION PROCEDURE

A) IN RUN ( MANUAL MODE )

a) ACTION TO BE TAKEN BY DG SET OPERATOR

1. SELECT THE FOLLOWING IN CONTROL PANEL

a) SELECT RUN/OFF SWITCH IN OFF POSITION.
b) SELECT DG BREAKER CLOSE INHIBIT/CLOSE PERMIT POSITION.
c) SELECT DG LOAD / UNLOAD SWITCH IN LOAD POSITION.
2) SELECT THE DG BUS / TG BUS SELECTOR SWITCH AT TG BUS AT MAIN LT DG POWER
OUTGOING BERAKER PANEL.
3) CLOSE BREAKER AND CHARGE THE 0.415KV LT DG BUS (FROM CONTROL PANEL)
4) SELECT RUN / OFF / AUTO SELECTION SWITCH IN RUN POSITION AT DG PCC.
AS SOON AS RUN IS SELECTED IN DG PCC, DG SET WILL START& VOLTAGE BUILD UP
WILL TAKE PLACE AUTOMATICALLY.

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5) SCROLL THE MANUE ON DG PCC, AND BRING IT TO BUS FREQUENCY & ANGLE MANUE.
CLOSE THE DG BREAKER FROM DG PCC WHEN ** APPEARS AHEAD OF ANGLE.
6) NOW LOAD THE DG BY ADJUSTING REGULATOR VOLRAGE SLOWLY & SLEADILY IN
CONTROL PANEL AS PER DEMAND OF LOAD ON THE DG.
7) IF THE RAGULATOR VOLTAGE IN CONTROL PANEL IS ADJUSTED BEFORE ACTION AT SL.(5)
& (6), DG WILL GENERATE POWER UP TO PRESET LOAD IN 120 SECONDS.

B) IN RUN (AUTO MODE)

b) ACTION TO BE TAKEN BY DG SET OPERATOR

1) SELECT THE DG BUS / TG BUS SELECTOR SWITCH AT TG BUS AT MAIN LT DG POWER

OUTGOING BREAKER PANEL.
2) CLOSE THE BREAKER AND CHARGE THE 0.415KV LT DG BUS (FROM CONTROL PANEL).
3) SELECT RUN / OFF/ AUTO SELECTION SWITCH IN AUTO POSITION AT DG PCC.
4) SELECT THE FOLLOWING IN CONTROL PANEL
a) SELECT RUN/OFF SWITCH IN RUN POSITION.
b) SELECT DG BREAKER CLOSE INHIBIT/ CLOSE PERMIT IN CLOSE PERMIT POSITION
c) SELECT DG LOAD/ UNLOAD SWITCH IN LOAD POSITION.
5) NOW LOAD THE DG BY ADJUSTING REGULATOR VOLTAGE SLOWLY & SLEADILY IN
CONTROL PANEL AS PER DEMAND OF LOAD ON THE DG.
6) IF THE REGULATOR VOLTAGE IN CONTROL PANEL IS ADJUSTED BEFORE ACTION AT SL.
(5), DG WILL GENERATE POWER UP TO PRESET LOAD IN 120 SECONDS.

3) SHUT DOWN PROCEDURE

c) ACTION TO BE TAKEN BY DG OPERATOR

1) DECREASE THE RAGULATOR VOLTAGE SLOWLY & STEADIDILY IN CONTROL PANEL UP TO

1.00 V . THIS WILL UNLOAD THE DG SET.
2) OPEN THE DG BREAKER FROM DG PCC.
3) SELECT RUN / OFF / AUTO SWITCH IN DG PCC IN OFF POSITION AFTER ~ 2.0 MINUTETS.
THIS WILL SHUT DOWN THE DG SETS.

****************** ******************* *********************

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21. UPS OPERATION OF HT SUB- STATION OPERATORS

1. CAUTION
a) RED SWITCHES AND RED PUSH BUTTONS AFFECT SYSTEM OPERATE ONLY
WHEN SURE ABOUT IT.
b) BLAKE SWITCH AND BLACK PUSH BUTTON PERFORM MONITORING THE SYSTEM.

2. STARTING MODULE I / II
a) CLOSE CONTROL SUPPLY SWITCH (S3) ON THE MODULE (INSIDE).
a) CHECK GREEN LIGHT INDICATIONS OF CB1, CB2, AND CB3.
c) CLOSE CB1 SWITCH AND SEE RED LIGHT INDICATION ON CB1. OBSERVE FOR 10 TO
15 SECONDS AND SEE THAT DC AND AC OUT PUT VOLTAGE RAISE GRADUALLY.
d) CLOSE BATTERY CIRCUIT BREAKER CBB AND SEE RED LIGHT LAMP INDICATION ON
MODULE MIMIC CHECK BATTERY CHARGING CURRENT ON (M5)
e) CLOSE OUT PUT CIRCUIT BREAKER CB1 AND SEE RED LAMP INDICATION ON OF
MODULE MIMIC.

3. TRANSFER FROM BY-PASS (K3) TO UPS (K2)

a) CHECK UPS VOLTAGE AND BY-PASS VOLTAGE BY MEANS OF S1 & M1. BOTH
VOLTAGE SOULD BE SAME.
b) OPERATE TRANSFER SWITCH (S8) TO K2 POSITION. SEE RED INDICATION ON K2
MIMIC AND GREEN INDICATION ON K3 MIMIC.

4. TRANSFER FROM UPS (K2) TO BY-PASS (K3)

a) CHECK UPS VOLTAGE AND BY-PASS VOLTAGE BY MEANS OF S1 & M1. BOTH
VOLTAGE SOULD BE SAME.
b) OPERATE TRANSFER SWITCH (S8) TO K3 POSITION. SEE RED INDICATION ON K3
MIMIC AND GREEN INDICATION ON K2 MIMIC

5. SHUT DOWN OF UPS SYSTEM

a) TRANSFER THE UPS SYSTEM TO BY-PASS AS MENTION IN SL NO 4
b SWITCH OFF THE STATIC BY-PASS ISOLITOR (S9)
b) PRESS TRIP PUSH BUTTONS ON CB2, CBB AND CB1 RESPECTIVELY IN THAT ORDER
c) SWITCH ON THE CONTROL SUPPLY SWITCH (S3) LOCATED IN SIDE THE PANEL.

6. EMERGENCY SHUT DOEN

a) PRESS EMERGENCY STOP PUSH BUTTOM.

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22. PROCESS OF ELECTRICAL SHUT DOWN OF TURBO GENERATORS

PROCESS OF DISCONNECTION OF ASEB FROM TURBO GENERATORS

PROCESS OF ELECTRICAL SHUT DOWN OF TURBO GENERATORS

a. PUT OF SS-1 AND SWTG OF L/S PANEL IF IT IS ON ECR (OPTR)

b. SLOWLY REDUCE THE LOAD UP TO 0.5 MW ECR (OPTR)
c. ALART TURBINE OPERATOR BOTH PANEL & FIELD AND
SWITCH OFF GENERATOR MAIN BREAKER ECR (OPTR)
d. SWITCH OFF D.C SUPPLY TO AVR/DVR ECR (OPTR)
e. KEEP GENERATOR BREAKER IN TESTING POSSITION. ECR (OPTR)
f. SWITCH OFF CONTROL SUPPLY OF GEN BKR FROM PANEL. ECR (OPTR)
g. SWITCH OFF AUXILLIARY SUPPLY TO AVR/DVR FROM TPS AUX. ECR (OPTR)

PROCESS OF DISCONNECTION OF ASEB FROM TURBO GENERATORS

a. INFORM THE PANEL OPERATOR OF TURBO GENERATOR THAT

THE SYSTEM IS GOING TO BE DISCONNECTED FROM A.S.E.B. ECR (OPTR)
b. GRADUALLY REDUCE LOAD ON ASEB SYSTEM ECR (OPTR)
c. WHEN BOTH ACTIVE AND REACTIVE LOADS OF THE ASEB
SYSTEMS ARE OK. SWITCH OFF THE 6.3KV CIRCUIT BREAKER
OF 33KV TRANSFORMER. ECR (OPTR)
d. REMOVE THE SYNCHRONISING PLUG FROM THE SOCKET ECR (OPTR)
e. INFORM THE PANEL OPERATOR OF THE TURBINES THAT
THE SYSTEM HAS BEEN DISCONNECTED FROM ASEB ELE (ECR)

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INSTRUCTION TO ELECTRICAL CONTROL ROOM OPERATORS & OFFICERS

1. IF TG-3 & TG-5 ARE IN OPERATION.

PUT OR ENSURE TG-4 SWITCH OFF (VERY VERY IMPORTANT)

PUT SELECTOR SWITCH TG-3/4 & TG-5 ON & OTHER SELECTION SWITCHES ARE
OFF
PUT TG-3 AND TG-5 SWITCH ON.
PUT LOAD SHEDDING AUTO-MANUAL SWITCH IN AUTO MODE.
AS SOON AS LOAD SHEDDING OPERATES, A BUZZER WILL SOUND IN
ELECTRICAL CONTROL ROOM. SOUND CAN BE MUTED BY PRESSING THE
ALARM RESET SWITCH.
PUT OFF THE SWITCH OF TG WHICH HAS TRIPPED (IF TG-3 TRIPS, PUT OFF
TG-3 SWITCH AND IF TG-5 TRIPS PUT OFF TG-5 SWITCH.
THEN PRESS THE PLC RESET PUSH BUTTON FOR RESETTING LOAD SHEDDING
FROM RESET BUTTON.
PUT THE LOAD SHEDDING AUTO MANUAL SWITCH IN MANUAL MODE.
GIVE CLEARANCE TO TURBINE SECTION TO RESTART THE TURBINE WHICH
HAS TRIPPED.

2. IF TG-4 AND TG-5 ARE IN OPERATION

PUT OR ENSURE TG-3 SWITCH OFF (VERY VERY IMPORTANT)

PUT SELECTOR SWITCH TG-3/4 & TG-5 ON & ENSURE THAT OTHER SELECTION
SWITCHES ARE OFF.
PUT TG-4 AND TG-5 SWITCH ON.
PUT LOAD SHEDDING AUTO-MANUAL SWITCH IN AUTO MODE.
AS SOON AS LOAD SHEDDING OPERATES, A BUZZER WILL SOUND IN
ELECTRICAL CONTROL ROOM. SOUND CAN BE MUTED BY PRESSING THE
ALARM RESET SWITCH.
PUT OFF THE SWITCH OF TG WHICH HAS TRIPPED (IF TG-4 TRIPS, PUT OFF
TG-4 SWITCH AND IF TG-5 TRIPS PUT OFF TG-5 SWITCH.
THEN PRESS THE PLC RESET PUSH BUTTON FOR RESETTING LOAD SHEDDING
FROM RESET BUTTON.
PUT THE LOAD SHEDDING AUTO MANUAL SWITCH IN MANUAL MODE.
GIVE CLEARANCE TO TURBINE SECTION TO RESTART THE TURBINE WHICH
HAS TRIPPED.

3. IF TG-3 & TG-4 ARE RUNNING (TG-5 OFF)

PUT OR ENSURE TG-5 SWITCH OFF (VERY VERY IMPORTANT)

PUT SELECTOR SWITCH TG-3 & TG-4 ON & ENSURE THAT OTHER SELECTION
SWITCHES ARE OFF.
PUT TG-3 AND TG-4 SWITCH ON.

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PUT LOAD SHEDDING AUTO-MANUAL SWITCH IN AUTO MODE.

AS SOON AS LOAD SHEDDING OPERATES, A BUZZER WILL SOUND IN
ELECTRICAL CONTROL ROOM. SOUND CAN BE MUTED BY PRESSING THE
ALARM RESET SWITCH.
PUT OFF THE SWITCH OF TG WHICH HAS TRIPPED (IF TG-3 TRIPS, PUT OFF
TG-3 SWITCH AND IF TG-4 TRIPS PUT OFF TG-4 SWITCH.
THEN PRESS THE PLC RESET PUSH BUTTON FOR RESETTING LOAD SHEDDING
FROM RESET BUTTON.
PUT THE LOAD SHEDDING AUTO MANUAL SWITCH IN MANUAL MODE.
GIVE CLEARANCE TO TURBINE SECTION TO RESTART THE TURBINE WHICH
HAS TRIPPED.

.
4. IF ALL THE THREE TGS (TG-3, 4 & 5) ARE IN OPERATION

UNDER THIS CONDITION AUTO LOAD SHEDDING WILL NOT TAKE PLACE
DURING TRIPPING OF ANY ONE TG.
KEEP THE SELECTION SWITCH FOR TG-3, 4 & 5 ON AND OTHER SWITCHES OFF.
SWITCHES OF TG-3, TG-4 & TG-5 SHOULD BE KEPT ON.
PUT AUTO-MANUAL SWITCH IN MANUAL MODE
IF TG-3 OR TG-4 TRIPS NO LOAD SHEDDING IS REQUIRED.
HOWEVER IF TG-5 TRIPS MANUAL LOAD SHEDDING GROUP-1 CAN BE
OPERATED BY PRESSING COMMON BUTTON AND GROUP-1 BUTTON
SIMULATANEOUSLY.
SWITCH OF TG (WHICH HAS TRIPPED) SHOULD BE PUT OFF.
SELECT BALANCE TWO TGS IN OPERATION BY SWITCHING ON EITHER TG-3/4
&5 OR TG3&4 AS THE CASE MAY BE AND SWITCH OTHER TWO-SELECTION
SWITCH OFF.
PUT THE AUTO MANUAL SWITCH IN AUTO POSITION.
BEFORE PUTTING THE LOAD SHEDDING SWITCH IN AUTO MODE, PLEASE
ENSURE ALL THE SWITCH POSITIONS ARE IN CORRECT POSITION AS PER
SYSTEM REQUIREMENT.

5. MANUAL MODE OF LOAD SHEDDING:

IN MANUAL MODE OF LOAD SHEDDING, THERE ARE FOUR GROUPS. USUALLY

GROUP-1 & GROUP-2 CAN BE OPERATED IMMEDIATELY AS PER NEED.
HOWEVER BEFORE PRESSING GROUP-3 OR GROUP-4, SHIFT ENGINEERS
CLEARANCE SHOULD BE TAKEN.

MANUAL LOAD SHEDDING CAN BE ACTIVATED BY PRESSING

SIMULTANEOUSLY THE COMMON PUSH BUTTON AND THE CORRESPONDING
GROUP PUSH BUTTON.

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LOAD SHEDDING INCASE OF BOILER TRIPS :

1. IF BOILER 5, 6 & 7 ARE IN OPERATION :

SWITCH ON THE SELECTION SWITCH FOR BOILER 5, 6 & 7 & ENSURE OTHER
SELECTION SWITCHES ARE OFF.
SWITCH ON BOILER 5, BOILER-6 & BOILER-7 AND ENSURE THAT BOILER 4 &
BOILER-3 SWITCHES ARE OFF.
PUT AUTO MANUAL LOAD SHEDDING SWITCH IN AUTO MODE.
AS SOON AS ANYONE BOILER TRIPS AUTO LOAD SHEDDING WILL TAKE
PLACE.
AFTER ADJUSTING LOAD ON RUNNING TWO BOILERS, SWITCH OFF THE
TRIPPED BOILER SELECTION SWITCH OFF AND ADVISE THE ELECTRICAL
CONTROL ROOM TO RESET PLC.
PLEASE NOTE THAT LOAD SHEDDING PLC CAN BE RESET ONLY FROM
ELECTRICAL CONTROL ROOM.

2. IF BOILER 3,4,5,6/7 ARE IN OPERATION :

SWITCH ON THE SELECTION SWITCH FOR BOILER 3,4,5,6/7 & ENSURE

OTHER SELECTION SWITCHES ARE OFF.
SWITCH ON BOILER 3, BOILER-4, BOILER-5 & BOILER-6/7 (WHICHEVER IS
RUNNING) AND ENSURE THAT THE IDLE BOILER SWITCH IS OFF.
PUT AUTO MANUAL LOAD SHEDDING SWITCH IN AUTO MODE.
AS SOON AS ANYONE BOILER TRIPS AUTO LOAD SHEDDING WILL TAKE
PLACE.
AFTER ADJUSTING LOAD ON RUNNING BOILERS, SWITCH OFF THE TRIPPED
BOILER SELECTION SWITCH OFF AND ADVISE THE ELECTRICAL CONTROL
ROOM TO RESET PLC.

3. IF BOILER-3,4,6 & 7 ARE IN OPERATION :

SWITCH ON THE SELECTION SWITCH FOR BOILER 3,4,6 & 7 & ENSURE
BOILER-5 SELECTION SWITCHES IS OFF.
SWITCH ON BOILER 3, BOILER-4, BOILER-6 & BOILER-7 AND ENSURE THAT
THE IDLE BOILER SWITCH IS OFF.
PUT AUTO MANUAL LOAD SHEDDING SWITCH IN AUTO MODE.
AS SOON AS ANYONE BOILER TRIPS AUTO LOAD SHEDDING WILL TAKE
PLACE.

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AFTER ADJUSTING LOAD ON RUNNING BOILERS, SWITCH OFF THE TRIPPED

BOILER SELECTION SWITCH OFF AND ADVISE THE ELECTRICAL CONTROL
ROOM TO RESET PLC.

4. SIMULTANEOUS TRIPPING OF TWO BOILERS :

WHEN AT A TIME TWO BOILERS TRIPS, AUTO LOAD SHEDDING WILL TAKE
PLACE AS PER REQUIREMENT.
PLEASE NOTE THAT PLC LOAD SHEDDING CAN BE RESET ONLY AFTER
PUTTING THE TRIPPED BOILERS SWITCHES IN OFF POSITION.

5. MANUAL SHEDDING OF OM&S & ETP STEAM.

IN ADDITION TO AUTO LOAD SHEDDING, THE OM&S STEAM AND THE ETP
STEAM CAN ALSO BE SHEDDED BY INDIVIDULA SWITCHES PROVIDED ON
LOAD SHEDDING PANEL.

S.C.GHOSH.
ELE (TPS)

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