PREPARED BY

1. 2. 3. 4. 5. ANJALI SWAIN ANUPAMA GUPTA POOJA TIWARI RUCHITA NALE SONAM DONGRE - ELECTRICAL 5TH SEMESTER

 Symbol of Indo-Soviet techno-economic collaboration One of the first 3 integrated steel plants set up by Indian Government The commissioning of first Blast Furnace on 4th Feb, 1959 by the then President of India Dr.Rajendra Prasad Commissioning of all units of 1MT by 1961 After plant expanded to 2.5 MT capacity per year

 The plant now consists of 10 coke oven batteries Steel is made through twin hearth furnace in SMS-1 & through LD Convertor (CCS) in SMS-2 Cleaner steel ensured by flame enrichment & oxygen blowing in SMS-1 & by Vacuum Arc Degassing in SMS-2 The rolling mill complex consists of BBM, Rail & Structural mill, Merchant Mill, Wire Rod Mill & Plate Mill. Sole manufacturer of rails & producer of the widest & heaviest plates Specializes in high strength UTS 90 rails, high tensile & boiler quality plates, TMT bars & electrode quality wire rods. A leader in terms of profitability, productivity & energy conservation

WELCOME TO POWER SYSTEMS DEPARTMENT

INTRODUCTION
Power Systems Department takes care of distribution of electrical power to the entire production and service units. 5 EHT substations, 42 HT substation & more than 150 LT sub station. Receives power from CSEB at 220 & 132 KV at two EHT substations. Regular maintenance of electrical equipments such as circuit breakers, transformers, HT cables, overhead lines, batteries , chargers etc.

BSP POWER SUPPLY SCHEME

MSDS-1 receives power from two 132KV lines from BRSS MSDS-2 receives power from 220KV lines from Khedamara. MSDS-1 & MSDS-2 are interconnected through 132 KV tie-line called TIE-LINE-3. PP-1 is connected to MSDS-1 through 6.9KV TL. PP-2 connected to MSDS-1 & MSDS-2 by 132KV tie-lines (TL-1 & TL-2).

 Capacities of two power generating stations at BSP: PP-1 : 3 * 12 MW + 1 * 15 MW = 51 MW PP-2 : 2 * 30 MW + 1 * 14 MW = 74 MW MSDS-3 & MSDS-6 receives supply at 132 KV from MSDS-2. MSDS-4 receives supply at 132 KV from MSDS-1. Total load of BSP including township 260 MW. Captive Power Plants( PP-1 & PP-2 ) generates 110 MW. Remaining 150 MW imported from CSEB. In case of failure PP-1 & PP-2 generates & supply power.

SALIENT FEATURES OF MSDS-1

Three 40.5 MVA , 132 KV / 7.2 KV( 1T , 2T , 3T) One 80 MVA , 132 / 11 / 11 KV ( 5T ) It supplies power to rolling mill , coke ovens , blast furnace , merchant mill etc. EQUIPMENTS AT MSDS-1 : Power Transformers 1. 80 MVA Transformer voltage ratio - 132 / 11.5 / 11.5 KV connection - star/delta/delta tap changer - On load, 15 taps cooling type - ONAN , AF & OF

2. 40.5 MVA Transformer voltage ratio - 132 / 7.2 KV connection - star/delta tap changer - on load, 9 taps cooling type - oil cooled with air forced The cooling fans automatically controlled. Remote indication of tap position & oil/winding temp is provided in control room. Provision of alarm & tripping of transformers in case of excessive temp , low oil level . 3. 132 KV SF6 Circuit Breakers high dielectric strength rated capacity - 7910 MVA rated current - 2000 Amps operating pressure - 5.6 bar lightening impulse withstand voltage 650 KV duration of S.C. 3 secs S.C. current 100 Amps

4. 132 KV Isolator current capacity - 1200 Amps operating mechanism - pneumatic/manual operating pressure - 17 Kg/sq.cm Isolators installed on both sides of 132 KV breakers & connected to both 132 KV sections. Interlocks provided in operation of isolators. Without switching off the ABCB/SF6 CB, not possible to open isolator . Isolator cannot be closed with earthing blade ON.

5. 132 KV Current Transformer rated primary current - 400/800/1200 Amps no. of windings -3 CT ratio - 400/5,800/1,1200/1 CTs used for metering & protection of 132 KV system. CTs are outdoor type, oil filled, single phase. 6. 132 KV Potential Transformers rated voltage - 132 KV nos. installed - 24 no. of secondary windings - 2 PT ratio - 132KV/100V , 132/100/3 PT are of oil filled type & outdoor type. Used for metering & protection of 132KV system.

6. 132Kv Lightening Arrestors Protects main power transformers & 132KV section against lightening surges. In normal conditions works as perfect insulator In case of high voltage surge breakdown of insulating gas occurs passing surge to ground 7.Arc Suspension Coils ( Peterson coils ) Three arc suspensions 1DK, 2DK, 3DK Connected between auxiliary transformer neutral & earth fault current in 6.9 KV system Coils have 5 taps to adjust current from 54 Amps to 104 Amps

TRS ( Transformer Repair Shop ) & OIL SUPPLY FACILITY AT MSDS-1

TRS facilitates capital repair & overhauling of all types of transformers. An electrical winch- 75T capacity provided for lifting core & material handling For purification of transformer oil centrifuge filter press & streamline filters Oil storage three tanks of 60 cu.m & three tanks of 30 cu.m capacities Major breakdown gases CH4, C2H6 , CO, acetylene & ethylene. Major suppliers are EMCO, NGEF, BHEL.

MSDS - 2, 3 & 4 ( 4 MT EXPANSION)

Three Main Step Down Substation ( MSDS -2, 3, & 4) provided for 4 MT expansion MSDS-2 receives power through 220 KV double circuit line from Khedamara Each line rated 115 KV MSDS 3 & 4 fed from MSDS-2 at 132 KV by double ckt line for Plate Mill & OP-2 area Captive Power Plant -2 : for emergency essential loads Two Step Up transformers: 50 MVA capacity & 11/132 KV rating for interconnection

MAIN SCHEME AT MSDS-2

Two different HT distribution voltages 11 KV for all motors above 1000 KW 6.6 KV for motors between 200 1000 KW All distribution transformers are 11 KV /400V rating Two 220 KV lines coming from MPEB connects two 132 KV sections through 220 / 132 KV Auto-transformers Two 132 KV sections paralleled through Bus coupler Two 132 KV feeders to MSDS3 & other two to MSDS-6 (Oxygen Plant -2) Two Tie-lines connects PP-1 & MSDS-1 Two 80 MVA capacity transformers : to step down voltage to 11 KV & 6.6 KV

 Duplex Reactors provided between transformers & 6.9 KV sections to reduce fault level 1T feeds 11 KV Bus-1 & 6.9 KV sections 1 & 4 2T feeds 11 KV bus-2 & 6.9 KV sections 2 & 3 MSDS -2 supplies power to various shops at 11 KV & 6.6 KV through underground cables Two transformers 400 KVA capacity & 11KV / 400V voltage rating : for auxiliaries of MSDS-2 & TRS Two neutral earthing transformers provided to neutralize earth fault current

TRS : MSDS 2
Facilitates repair & overhauling of all transformers in 4MT area. Additional facilities : oil storage, filtration, testing Drying chamber with heating & temprature monitoring arrangement Drying & heating of windings of higher rating transformers facilitated through hot air circulation by heaters Electrically operated winch for pulling transformer on rail track between TRS & 132KV yard

MAIN EQUIPMENTS IN MSDS-2 SWITCHING YARD

POWER TRANSFORMERS : Two auto transformers 160 MVA, 220KV/132KV Two 80 MVA transformers: star/delta, split secondary with 132KV/11.5KV/6.9KV Oil cooled type transformers with ON/OB/OFB cooling MVA rating corresponding to : ON : 45 MVA, OB : 63 MVA, OFB : 80 MVA Transformers provided with ON load tap changers at primary for voltage regulation : +/- 10%

OTHER EQUIPEMENTS IN THE YARD ARE:

AIR BLAST CIRCUIT BREAKERS 132 KV ISOLATORS AIR COMPRESSORS CURRENT TRANSFORMERS ( CT ) POTENTIAL TRANSFORMERS ( PT ) WAVE TRAP LIGHTENING ARRESTOR DUPLEX REACTORS STORAGE BATTERIES CHARGERS CABLE BUSHINGS

SALIENT FEATURES OF MSDS - 6

Part of OP2 expansion to cater additional power supply requirement Mainly steps down voltage from 220 KV to 132 KV 1T & 2T : 160 MVA rating & 220KV/132KV voltage rating Two 50 MVA transformers installed to feed two 11 KV sections & one 6.6KV section Entire SIEMENS equipments : based on PROFIBUS Protocol

MSDS-5 220KV/132KV GAS INSULATED SUBSTATION

GIS is electrical substation with major structures contained in sealed environment Insulating medium : SF6 gas Originated in Japan due to need of compact substation Circuit breakers in GIS employ SF6 gas as interrupting medium & insulating medium Modern equipment uses PUFFER technique SF6 gas forced into space between breaker contacts opening , increasing gas pressure to support interrupting

SF6 INSULATING MEDIUM GAS PRESSURE : Normal pressure : 5.2 Bar Alarm : 4.6 Bar Tripping pressure : 4.4 Bar SF6 CIRCUIT BREAKER GAS PRESSURE : Normal pressure : 6.3 Bar Alarm : 5.5 Bar Tripping pressure : 5.3 Bar MAIN ADVANTAGES : In desert & arctic areas : can be installed in a building with environment control High voltage installations Provides environment containment Totally shields substation from lightening

SPECIFICATION OF WORK AT ERS

Repairs all kinds of electrical machines Motors, generators, welding & control transformer Load lifting magnets, brake, control coils, switches On average per month ERS repairs 380 motors & generators, Manufactures 535 coils Repairs 17 load lifting magnets 28 welding & control transformers.

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

DIFFERENT SECTIONS OF ERS TO FACILITATE SYSTEMATIC REPAIR PROCESS R & I Section

Assembly & dismantling section Winding section Varnishing section Testing section Machine section Spare parts manufacturing section Commutator repair section Shop maintenance Magnet & transformer repair shop (MTRS) Motor overhauling & repair shop (MORS)

ASSEMBLY & DISMANTLING SECTION

After dismantling preliminary check-up -meggering -visual inspection Healthy components - cleaned & varnished Detective components to winding sections for repair/rewinding All windings meggered to ensure healthy IR & continuity

WINDING SECTION
Rewinding or partial repair FLUX TEST to ensure soundness of core laminations Abnormal heating detected core repaired Components rewinded until soundness ensured After rewinding high voltage test, current balance test, magnet field test, check all joints Finally preheated & varnish covering

TESTING SECTIONS
Conducts tests on all repaired machines on No Load :1. AC Squirrel Cage Induction Motor: meggering, physical inspection, HV test, No load running test (30 mins), inter turn insulation test (2 mins ) 2. AC Slipring motors:

 Meggering , PI, HV test, ratio test, no load running test 3. DC MOTOR Meggering, PI , no load running test(30 mins), over speed running test, load test During no load test if all machines should proper currents , no abnormal heating, vibration, sound declared fit. Megger test to determine IR , check for proper insulation & test continuity

MTRS
Repairs load lifting magnets , control transformers & rectifiers Fabricates load lifting magnets PTD designs drawing of shell, center of pole, coil & non magnetic plates Shell testing by Ultrasound testing techniques Insulating & curing the shells coils assembled Heat resistant compound added

MORS
Does overhauling of traction motors Overhauls roll table motors from various rolling mills

MM 350 mm SEMI CONTINOUS HIGH CAPACITY MILL

Capacity 5 MT Product mix : round bars , TMT bars , angles , channels Raw materials : billets ( 100*100 , 110*110 ) from yards , shaped billets ( 122*135*80) Merchant Mill consists of 3 sections : 1. Re-heating furnaces 2. Mill stands 3. finishing zone & shipping

RE-HEATING FURNACES
3 reheating furnaces installed to heat billets Furnaces continuous , end charging / discharging type. 3 zones of heating : heating , pre-heating , heating & soaking zones Preheating & heating zones billets move over water cooled skids & heated by burners While rolling beams soaking zone temp 12501280 C While rolling rounds 1220 -1250 C

MILL STANDS