INTRODUCTION

Visakhapatnam Steel Plant is an ISO certified company playing a major role in

the field of steel making domestically and internationally. Being a gigantic steel
manufacturing company, it follows lot of advanced procedures and systems in the
field of production as well as maintenance.
In any industry, material handling is the prime activity to transport

Raw

materials as well as the manufactured products from one place to another place. Some
times maintenance of the equipments require handling / transportation system.
Visakhapatnam Steel Pant is mainly using Electric Overhead Travelling cranes
of 10 Tons, 20 Tons, 50 Tons, 100 Tons, 150 Tons and 200 Tons for its material
transport / equipment maintenance.
The Light and Medium Merchant Mill is the end product manufacturing
department of the steel plant with a capacity of 7,10,000 Tons of channels, angles,
rebars, plains, etc., annually. The major function of these EOT cranes is hoisting and
lowering of the Mill products and also used at the time of equipment maintenance or
at the time of breakdowns.
The EOT crane mainly consists of three drives.
(1)

Hoist

(2)

Cross travel

(3)

Long travel

The motors used for the above drive are Slip Ring Induction motor.

PRESENT SYSTEM:
In the present system the hosting capacity is 10 Tons. The hoisting drive need
high starting torque. Hence slip ring induction motors with Rotor resistance method is
being used for speed control. Relay logic system is used to control the speed control.
By using the rotor resistance method, smooth variations of speed is not possible. The
speed can be varied in 4 steps.

The system is generating lot of problems while in operations. The problems

encountered are:
(1)

Mechanism/equipment alignment gets disturbed during operation due to

sudden jerks.

(2)

Power contactors some times not working and getting damaged

frequently due to equipment high ho. Of start/stops and vibration.

(3)

Sudden jerks in the equipment because of the step speed variations.

(4)

Manufacturing of contractors/relays.

(5)

25% speed step only possible in present system.

(6)

Danger to men and equipments/materials.

(7)

Jobs are getting delayed.

AN OVERALL VIEW OF VSP

Visakhapatnam steel plant, the first coastal-based steel plant of INDIA is
located, 16 kilometers southwest of the city of destiny. VSP has an installed capacity
of 3 million tonnes per annum of liquid steel and 2.656 million T of saleable steel. At
VSP there is emphasis on total automation. VSP products meet exalting international,
quality standards such as JIS, DIN, and BIS, BS etc.
VSP has the distinction to be the first integrated steel plant in INDIA to become
a fully 1S0-9001:2000 certified company. The certificate covers quality systems of all
operational, maintenance, services units besides purchase systems, training and
marketing functions spreading over 4 regional marketing offices, 20 branch offices
and 22 stock yards located all over the world.
VSP by successfully installing and operating efficiently Rs. 460 crore worth of
pollution control and environment control equipment's and converting barren
landscape by planting more than 3 million plants has made the steel plant, steel
township and surrounding areas into a heaven of lush greenery. This has made Steel
Township a greener, cleaner and cooler place, which brought down the temperature by
3 to 4 degrees centigrade. Even in the peak summer days compared to Visakhapatnam
City.

MAJOR FACILITIES IN VSP:

Three Batteries each of 67 ovens and 7 m
height Useful volume 41.6 m3

COKE OVENS

2 Sinter machines of area 312 m2

2 Blast Furnaces having 3200
m3 useful volume each

SINTER MACHINES
BLAST FURNACES
STEEL MELTING SHOP

3 LD Converters having 133 m3 volume each

and 6 nos. of 4 strand continuous bloom
casters

LIGHT AND MEDIUM

MERCHANT MILL

710,000 T per annum capacity

WIRE ROD MILL

850,000 T per annum capacity

MEDIUM MERCHANT
AND STRUCTURAL MILL

850,000 T per annum capacity

Besides these a captive power plant with a capacity of 247.5 MW, Oxygen
plant, Acetylene Plant, Compressed Air Plant, extensive repair, maintenance facilities
from part of the facilities available at VSP. VSP has sufficient infrastructure to expand
the plant to 10 million tons per annum of liquid Steel capacity.

MAJOR DEPARTMENTS

RAW MATERIAL HANDLING PLANT (RMHP):

VSP annually requires quality raw materials, iron ore, fluxes (limestone,
dolomite, coking and non coking coals etc.) to handle such a large value of incoming
raw materials received from different sources and to ensure timely supply consistent
quality of feed materials to different VSP consumers, raw material handling plant
serves a vital function. This unit is provided with elaborate unloading, blending, and
stacking.

COKE OVENS AND COAL CHEMICAL DIVISION:

Blast furnaces, the mother units of any steel plant requires huge qualities of

strong, hard and porous solid fuel in the form hard metallurgical coke for supplying
necessary heat for carrying out the reduction and refining reactions besides acting a
reducing agent.
Coke is manufactured by heating of crushed coking coal in absence of air at a
temperature of 1000 degree centigrade and above for about 16-18 hours. A coke oven
comprises of 2 hollow chambers mainly heating chamber and coal chamber. In the
heating chamber a gaseous fuel such as blast furnace gas, coke oven gas is burnt. The
heat so generated is conducted through, the common valve to heat and carbonize the
coking coal placed in the adjacent coal chamber. Number of ovens built in series one
after the other form a coke oven battery.
Red-hot coke is pushed out the oven and sent to coke dry cooling plants for
cooling to avoid its combustion. There are three coke dry cooling plants each having
four cooling chambers. The capacity of each cooling chamber is 50-52 T/h. Nitrogen
gas is used as the cooling medium.
The coal chemicals such as Benzyl, tar, ammonium sulphate etc. are extracted
in the coal chemical plant from CO gas. After recovering the coal chemicals the gas is
used as a by-product fuel by mixing it with gases such as BF gas, LD gas.

SINTER PLANT:
Sinter Plant Sinter is a hard and porous ferrous material obtained by
agglomeration of iron ore fines, coke breeze, limestone fines & metallurgical wastes.
Sinter is a better-feed material to FB in comparison to iron ore lumps & its usage in
blast furnaces help in increasing productivity, decreasing the coke rate & improving
the quality of hot metal-produced. Sintering is done in 2 no. of 312 m2.

BLAST FURNACE:
Hot metal is produced in blast furnaces, which are tall vertical furnaces. The
furnace is named as blast furnace as it is run with high temperature and pressure. Raw
material such as sinter iron ore lumps fluxes and coke are discharged from the top and

hot blast at 1100 C to 1300 C. The furnaces are designed for 800/0 sinter in the
burden.
VSP has two 3200 m3 blast furnaces (largest in India) equipped with Paulworth
Bell less top equipment with conveyor charging. Rightly named as Godavari and
Krishna after the two rivers of A.P. the furnaces will help VSP in bringing prosperity
to the state of A. P. The two furnaces with their novel circular cast house and four tap
holes each are capable 9720 T of hot metal daily.

STEEL MELTING SHOP:

Steel is an alloy of iron with carbon up to 1.8%. Hot metal produced in blast
furnaces contains impurities such as carbon, silicon. Manganese, sulphur and
phosphorous is not suitable as a common engineering material.
VSP produces steel employing three nos. of top blown Oxygen converters
called LD converters (L&D stand for Linz & Donawitz- two towns in Austria where
this process was first adopted). Each converter is having 133 m3 volume capable of
producing 3 million T of liquid steel annually. Besides hot metal steel scrap fluxes
such as calcined lime or dolomite form part of the charge to the converters 95.5% of
pure Oxygen at 15-16 KSCG pressure is blown in the converter through Oxygen lance
having convergent copper nozzles at the blowing end. Oxygen oxidizes the impurities
present in the hot metal, which are fixed as slag with basic fluxes such as lime. During
the process heat is generated by exothermic reactions of oxidations of metalloids.
Liquid steel produced in LD converters is solidified in the form of blooms in
continuous bloom casters.

CONTINUOUS CASTING DEPARTMENT:

Continuous casting may be defined as teaming of liquid steel in a mould with
bottom through which partially solidified ingot is continuously withdrawn at the same
rate at which liquid steel is teamed in the mould. Facilities at a continuous casting

machine include a lift and turntable for ladles, copper mould, mould oscillating system
turn dish, primary and secondary cooling arrangement to cool the steel bloom. Gas
cutting machines for cutting the blooms in required length.
At VSP we have six four strand continuous casting machines capable of
producing 2.82 million tpa blooms of size 250 x 250 mm and 250 X 320 mm. Entire
quantity of molten steel produced is continuously cast in radial bloom casters which
help in energy conservation as well as production of superior quality products.

ROLLING MILLS:
Blooms produced in SMS - CCD do not find much applications as such and are
required to be shaped into products such as billets, rounds, squares, angles, channels,
I-PE beams, HE beams, wire rods and reinforcement bars by rolling them in a three
sophisticated high capacity, high speed, fully automated rolling mills, namely light
and medium merchant a mills (LMMM). Wire rod mill (WRM) and medium merchant
and structural mills (MMSM).

LIGHT & MEDIUM MERCHANT MILL:

LMMM comprises of two units. In the billet/brake down mills 250 x 320 mm
size blooms are rolled into billets of 125 x 125 mm size after heating them into 2 nos.
of walking beam furnace of 200-turns/ hour capacity each. This unit comprises of 7
stands and five alternating vehicle and horizontal stands. Billets are supplied from
this to bar mill of LMMM and WRM.
The billets for rolling ion bar mill of LMMM are first heated in two strand
rollers hearth furnace of 200 T/h capacity to temperature of 1150 DC to 1200 Dc. The
bar mill comprises of 26 stands- 8 stands of double strand roughing train, 2 nos. of 5
stand double strand intermediate trains and 2 nos. 4 stand single strand finishing

trains.
The mill is facilitated with temp core heat treatment technology evaporating
cooling systems in walking beam furnaces, automated piling and bundling facilities,
high degree of automation and computerization. The mill is designed to produce
710,000 T p.a. of various finished products.

WIRE ROD MILL:

WRM is a 4 strand, 25 stands fully automated and sophisticated mill'. The mill
has a 4-zone combination type reheating furnace of 200 T/h capacity for heating the
billets received from billet mill of LMMM to rolling temperature of 1200 O C. The
heated billets are rolled in 4 strands. No twist continuous mills having a capacity of
8,50,000 tons of wire rod coils. The mill is equipped with standard and retarded
stelmore lines for producing high quality wire rods in 10, medium and high carbon
grade meeting the stringent national and international standards.

MEDIUM MERCHANT & STRUCTURAL MILL:

MMSM is a high capacity continuous mill consisting of 20 stands arranged in 3
trains.

Roughing train

Intermediate train

Finishing train

The feed material to the mill is 250 x 250 mm size bloom, which is heated to

rolling temperature of 1200O C in 2 walking beam furnaces each of 130 T/h capacities.
The mill is capable of producing 8,50,000 tons of various products.

THERMAL POWER PLANT-AN INTRODUCTION

The fact that thermal energy is the major source of power generation itself
shows Thermal power plants importance in India. More than 60% of electrical power
is produced by Thermal powered steam plants in India. The steep rise in the demand
for power demands a larger unit setup which requires the use of more fuel. These
plants are trying to keep the overall cost of power generation low using modern
techniques and devices.
In steam power plants the heat obtained by the combustion of fossil fuels
(coal, oil or gas) is utilized by the boilers to raise the steam to a high pressure and
temperature. The steam so produced is used in driving the steam turbines and
sometimes steam engines coupled to generators and thus in the generation of electrical
energy. The steam turbines or steam engines thus used not only act as prime movers
but also as drives for auxiliary equipments such as pumps, fans etc.
The steam power plants may be installed either only to generate electrical
energy or electrical energy generation along with steam generation for industrial
purposes such as paper mills, sugar mills, chemical works, plastic manufacture, food
manufacture etc.

Generally Thermal power plants are categorized as

Utility Power Plant:

Power is produced solely for the purpose of

generation and supplied to the various kinds of customers through grid.

Captive Power Plant:

Power is produced for supplying quality power for

the effective functioning of the actual plant. Import and export of power takes
place in accordance with the load.
The Thermal power plant seen in Vishakapatnam Steel Plant is a captive power plant.
The power requirement of VSP is met through captive generation as well as supply
from APSEB grid.

Captive capacity of TPP in VSP

3 units of 60 MW generation capacity.

1 unit of 67.5 MW generation capacity.

286.5 MW

 2 units of 7.5 MW capacity at Back Pressure Turbine Station (BPTS).

2 units of 12 MW capacity at Gas Expansion Turbine Station (GETS).
The speciality of this power plant is that the energy from the waste heat is not wasted.
The Heat of hot coke from cokeovens are used in BPTS and the gases from blast
furnace are used in GETS to generate power.

POWER REQUIREMENT
Integrated Steel Plants are major consumers of electricity, with specific
consumption of power at around 600-650 kWh/Ton of liquid steel. The estimated
annual power requirement of Visakhapatnam Steel Plant, at full level of production in
each shop, is 1932 million kWh. This corresponds to an average demand of 221 MW.
The demand is found to be 227 MW on an average and 260 MW peak value.
The estimated energy consumption and average demand of major shops is given
below:
SHOP
RMHP
CO & CCP
SINTER PLANT
BLAST FURNACE
SMS & CCM
LMMM
WRM
MMSM
CRMP
TPP
ASP
COM. STATION & CWP
AUXILIARY SHOPS
WATER SUPPLY
TRAFFIC & OTHERS
TOWNSHIP
LOSSES
TOTAL

Annual Energy
(106 kW Hrs.)
35
171
254
210
126
100
118
100
35
310
258
131
20
15
7
28
14
1932

AverageDemand (MW)
4.0
19.5
29.0
24.0
14.5
11.5
13.5
11.5
4.0
35.0
29.5
15.0
2.5
2.0
1.0
3.0
1.5
221.0

SOURCES OF POWER
Power requirement of VSP is met through captive generation as well as
supply from APSEB grid. The captive capacity of 270 MW is sufficient to meet all
the plant needs in normal operation time.

In case of partial outage of captive

generation capacity due to breakdown, shutdown or other reasons, the short fall of
power is availed from APSEB grid. Turbo Generators of VSP normally operate in
parallel with state grid. Excess generation over and above plant load is exported to
APSEB.The agreement with APSEB provides for a contract demand of 150 MVA and
permit export of power. Tariff for import, export, demand charges, penalties etc. are
stipulated. For purpose of billing, import and export energy is separately metered at
Main Receiving Station.

APSEB SUPPLY NETWORK

The Power Grid Corporations Sub-station adjacent to Ukkunagaram is
connected to Vijayawada by a 400 kV line. It is also being connected to Jaipur, Orissa
(Eastern Grid) through DC back to back arrangement of 500 MW capacity and by 400
kV AC double circuit line. Power is stepped down through a 315 MVA, 400/220 kV
auto transformer at Power Grid Corporation Sub-station and is fed to the adjacent
APSEB switching station. This switching station is also connected to Bommuru and
Gajuwaka sub-stations by 220 kV double circuit lines.

Bommuru sub-station is

connected to generating stations at Vijayawada, Lower Sileru, Vijjeswaram, Kakinada

and Jegurupadu. Gajuwaka sub-station is connected to Upper Sileru. Two 1000 MW
Thermal Power Stations are expected to come up in the next few years at
Visakhapatnam and close to steel plant.
Power is supplied to VSP from APSEB switching station over two 220 kV
lines on double circuit towers. Power is received at the Main Receiving Station
(MRS) located near Main gate and further distributed to various units within the plant.

EXTRA HIGH VOLTAGE DISTRIBUTION (220 kV)

Power from APSEB is received at Main Receiving Station (MRS). The entire
plant is configured as five electrical Load Blocks and Step down sub-stations are
provided in each block (designated as LBSS 1 to 5) with 220 kV transformers to step
down power to 33/11/6.6 kV and for further distribution as indicated below:

STATION DESIGNATION

AREAS COVERED

LBSS1 (220/11/6.6 kV)

LBSS2 (220/11/6.6 kV)

RMHP, CO & CCP, Sinter Plant, BF

BF, SMS, ASP, CRMP, Comp. House-1

(220/33 kV)
LBSS3 (220/11/11 kV)
LBSS4 (220/11/11 kV)

Ladle furnace in SMS

MMSM
LMMM, WRM, Aux.

Shops,

Adm.

Building and Kanithi reservoir pump

LBSS5

(220/11&220/11/11

kV)
MRS (220/33 kV)

house.
TPP, Plant essential category loads, KBR &
Township pump houses & hospital.
Plant, Township and construction network.

HIGH VOLTAGE DISTRIBUTION (33/11/6.6 kV)

Two 220/33 kV Transformers installed at MRS feed power to Township step
down Station through 33 kV cables. Here the voltage is further stepped down to 11
kV by two nos. of 33/11 kV transformers. Out going feeders from this station supply
power at 11 kV through cables to township net work. 11 kV overhead construction
power lines are connected to this
sub-station.
Electric power at 11/6.6 kV stepped down at above LBSS stations is
distributed to smaller Load Block Distribution Station (LBDS) located in each unit.
Power supply to essential category loads of various zones is extended form TPP
directly from Generator Switch Board (GSB) at 11 kV.

Cross-linked Poly

Ethylene(ELPE) cables are used for 11 kV distribution.

6.6 kV supply is mostly used for motors (of rating >200 and <200 kW
generally). Cross-linked poly ethylene cables are used for 6.6 kV distribution.
Appropriate protective relays provided to quickly isolate faulty feeders/apparatus with
suitable

discrimination.

All

varieties

of

breakers

such

as

Bulk

Oil/MOCB/VCB/SF6/Air Blast are used.

MEDIUM VOLTAGE DISTRIBUTION (BELOW 650 V)

In each shop, to cater to Medium and Low voltage load, 11 kV/415 V LCSS
are formed. Power is fed from LCSS to motors, MCC, Power Distribution Boards
(PDB), Lighting Distribution Boards (LDB), ESP transformers etc. and for further
distribution. The 3 phase 415 V distribution is solidly earthed neutral system. PVC
cables are used for medium voltage distribution generally.

LOW VOLTAGE DISTRIBUTION (250 V & BELOW)

Low voltage distribution consists of power supply on single phase to lighting
equipment, ceiling fans, portable hand tools and domestic appliances etc. For safety
reasons, 24 V distribution is also provided to cater to hand lamps etc. in some areas.
PVC cables are used.

SCADA:
The 220 kV, 11 kV and 6.6 kV distribution system is monitored by a centralized

Supervisory Control And Data Acquisition system. The plant generation,

import/export and consumption in each unit are monitored through SCADA.

MAIN EQUIPMENTS IN TPP:

The following are the equipments involved in TPP
Boilers
Turbo-generators
Transformers
Turbo-blowers
Chemical water treatment plant
Coke Dry Cooling Plant (CDCP) boilers
Back Pressure Turbine Station(BPTS) and Cooling Water Plant (CWP) -1 and 2
Gas Expansion Turbine Station (GETS)

PROCESS FLOW CHART OF TPP & BH

BOILERS:
No. of boilers

5 (4 working+1 standby)

Steam capacity

330Tons/Hr

Pressure

101 ata

Temperature

540oC

Fuel

Coal, Furnace Oil, Coke Oven

gas, Blast Furnace gas

Type

Water tube, suspended type,

Multi fuel type

Coal for the plant is obtained from Talcher, Orissa. Lignite coal is
obtained. Lignite is porous, has 30-50% moisture, light weight. It is stored in
coal bunkers (Immediate stock bins) and then ground in coal mills i.e.
pulverized to increase the surface area of combustion. Then Primary Air fan
sweeps the pulverized coal for combustion to occur. The heat resulting due to
this combustion is used to raise the steam in boiler to the required temperature
and pressure.

FUEL COMPARISON:
Fuel

Calorific Value

Coal

3200 4500 KCal / KG

Coke-Oven gas

Blast Furnace Gas

800 KCal / NM3

Fuel Oil

10000 KCal / KG

4425 KCal / NM3

The water input given to the boiler is demineralized before sending into the boiler,
to prevent the corrosion and damage of boiler tubes and turbine blades. There are

super-heaters which are used to increase the steam temperature to 540oC. The heat
from flue gas is used for the same.

TURBO-GENERATORS
GENERATOR (60 MW)- TG#1,2,3
No. of units

Make

BHEL

Type & description

TARI 930-36P

Rated power Active

60000 kW

Rated power Apparent

75000 kVA

Power factor

0.8

Rated stator voltage

11000 5% Volts

Rated stator current

3936 Amp

Rated rotor voltage

300 Volts DC

Rated rotor current

596 Amp

Rotational speed

3000 RPM

Frequency cycles

50 HZ

Critical speed

1765 n1, >4500 n2

Class of insulation of winding

Air gap between stator and rotor

55 mm

Type of cooling

Air cooling indirectly

Maximum temp. rise of stator winding

120O C

Maximum temp. rise of rotor winding

130O C

Winding type

double layer-with 36 slots

Turbine type

impulse-reaction (1:40)

GENERATOR(67.5 MW)- TG#4

No. of units

Make

BHEL

Type & description

TARI 930-36P

Rated power Active

67500 kW

Rated power Apparent

84375 kVA

Power factor

0.8

Rated stator voltage

11000 5% Volts

Rated stator current

4429 Amp

Rated rotor voltage

300 Volts DC

Rated rotor current

625 Amp

Rotational speed

3000 RPM

Frequency cycles

50 HZ

Critical speed

1765 n1, >4500 n2

Class of insulation of winding

Air gap between stator and rotor

55 mm

Type of cooling

Air cooling indirectly

Maximum temp. rise of stator winding

120O C

Maximum temp. rise of rotor winding

130O C

 SYNCHRONISATION:
A generator requires to be synchronised if it is to be run in parallel with
others. Before it is connected electrically to energised busbar, the following
conditions must be satisfied.
(a)

Equality of voltage

(b)

Equality of frequency

(c)

Synchronisation of phases

With these requirements fulfilled, there will be no voltage difference between any
corresponding pairs of terminals of machines and busbars, so that points can be
electrically connected without disturbance.

ASYNCHRONOUS OPERATION:
Asynchronous operation of the generation on field failure is allowed
depending upon the permissible degree of the voltage dip and acceptability of
the system from the stability point of view. During field failure there are
important points to be noted.
Field failure with under-voltage
Field failure without under-voltage
Field failure with under voltage will be sensed and the machine will get tripped
without any delay.
During field failure without under voltage, active load on the generator shall be
decreased to 40% of rated load immediately. The generator can operate at 40% of the
rated load asynchronously for a total period of 15 minutes from the instant of failure

of excitation. Within this period, steps should be taken to establish the reasons of field
failure to restore normalcy. If it cannot be restored then the set has to be switched off.
Then the set should switched over to the reserve excitation.

TURBO BLOWERS
BLOWERS

3 (2 Working + 1 Standby)

CAPACITY

6067 m3 /min

SPECIAL FEATURES:
Constant Speed with EHTC (Electro Hydraulic Turbine Governing system)
Inlet Guide Vane Control
Axial type largest blowers in India.
VSP has 2 blast furnaces. To meet the blast air requirement, 3 turbo blowers, each of
6067 nm3/min capacity, are installed at TPP. These blowers are of axial type and are
the largest blowers installed in India.
These blowers are provided with suction filters, pre-coolers and inter-coolers.

AUXILIARIES OF TPP:
These include coal conveyors, cooling towers and pump house#4 for cooling
water system, pump house for ash water, ash slurry, fire water and fuel oil and
emergency diesel generators, electric switch gear for power distribution, ventilation
and air conditioning equipment etc. The entire power generated at Back Pressure
Turbine Station (BPTS) and Gas Expansion Turbine Station (GETS) is transmitted

over 11 kV cables to power plant, stepped up through a 220 kV transformer at LBSS5

and transferred to plant grid.

TRANSFORMERS

TRANSFORMERS CONNECTED TO 60 MW GENERATORS

Type Of Cooling
Vector group
Class of insulation
Power rating
Primary voltage
Secondary voltage

:
:
:
:
:
:

ONAN
YNd11
F
63 MVA
11 kV
220 KV

TRANSFORMERS CONNECTED TO 67.5 MW GENERATORS

Type Of Cooling
Vector Group
Class of insulation
Power rating
Primary voltage
Secondary voltage

:
:
:
:
:
:

ONAN
YNd11
F
90 MVA
11 kV
220KV

There are 2 main types of transformers present in a Thermal Power Plant viz.
Generator transformer
Auxiliary transformer
A Generator Transformer is one which steps up the voltage to the grid for the
purpose

of

distribution.

50,63,90MVA,220/11KV rating.

There

are

generator

transformers

of

An Auxiliary transformer is one which steps down the voltage for the plant
purposes.

The

auxiliary

transformers

include

32

LT

transformers

of

1.6MVA,11KV/415V rating and 6 LT transformers of 20MVA,11/6.6KV rating.

CHEMICAL WATER TREATMENT PLANT

The Chemical Water Treatment Plant located in TPP produces high quality
purified Demineralised Water and soft water. There are 6 streams of de-mineralising
units each capable of producing 125 m 3/hr. 2 softening units of 125 m3/hr each is
present. Demineralisation is done by the Cation and Anion Exchange process. This
DM water is supplied to TPP, Steel Melt Shop (SMS), CDCP Boilers at Coke Ovens
and Rolling mills. Soft water is supplied to Chilled
Water Plant-I, II and SMS mould cooling.
BACK PRESSURE TURBINE STATION (BPTS)
BPTS GENERATOR (7.5MW)
No. of units

Make

BHEL

Type & description

TGN 218226/2

Rated power Active

7500 kW

Rated power Apparent

9375 kVA

Power factor

0.8 lag

Rated stator voltage

11000 5% Volts

Rated stator current

492 Amp

Rated rotor voltage

140 Volts DC

Rated rotor current

596 Amp

Rotational speed

3000 RPM

Frequency cycles

50 HZ

Critical speed
Class of insulation of winding

:
:

1900 n1

B(Stator &Rotor)

Type of cooling

Closed Circuit Air cooling

Short Circuit Ratio

0.610

Generator field Resistance

0.334 at 20C

Moment of Inertia of Rotor

GD = 101tm

Max. Short Circuit Torque(for Coupling) :

15368 kg-m

No. of Generator Terminals

Generator Phase Connection

Generator Brushes
Size

4 for Ring (2 Rings)

32 x 32 mm

Grade

Minimum Permissible dia of Slip Ring

Star

HM6R

370mm

Max. out put with one cooler out of service :

6562 kVA

Volume of cooling Air

28800m/hr

Designed for

Tropical Climate

GETS GENERATOR (12MW)

TG-1

TG-2

Make

RUSSIA

RUSSIA

Type & description

T-122-3

T-12-2T3

Rated power Active

12000 KW

12000KW

Rated power

15000 KVA

15000KVA

Power factor

0.8 lag

Rated stator voltage

6300/10500 Volts

11000 Volts

Rated stator current

1375/825 Amp

787Amps

Rated rotor voltage

230/232 Volts DC

232 Volts DC

Rated rotor current

268/270 Amps

270Amps

Rotational speed

3000 RPM

3000 RPM

Frequency cycles

50 Hz

50Hz

Critical speeds

1720 n1, 4720 n2

1700n1, 4800n2

Efficiency

97.6

97.6

Type of cooling

Closed Circuit Air cooling

Mass of Rotor

0.8 lag

6980kg

7500kg

Stator Mass

14500/15300kg

15300kg

Rotor fly wheel Moment

1.42 tm

1.42tm

POWER GENERATION AND DISTRIBUTION

Each generator of group 1, 2 and 3 is connected to one section of Generator
Switch Board (GSB). Each section of GSB-1 is in turn connected with each other by a
bus coupler with reactor and without reactor scheme.
The TG#4 which was added later on to augment power position of the plant
and to utilize full capacities of 4 running boilers, is connected through a power
transformer to 220 kV side of the Load Block Sub-Station (LBSS)-5.In addition, the
plant has got total of 4 small generator sets (2 at coke ovens [CO] and 2 at blast
furnaces) which utilize the waste heat and blast furnace top pressure respectively to
produce power.
Sets operating at CO area have a capacity of 7.5 MW each and at BF area
have a capacity of 12.5 MW each. One set each from CO and BF areas are connected
to GSB-2 and GSB-3 respectively.
GSB-1 is connected to the plants 220 kV circuit at LBSS-5 with 3- 11/220 kV,
50/63 MVA transformers. GSB-2 and GSB-3 are connected to plants 220 kV circuit at
LBSS-5 via a 3 winding 11/11/220 kV transformer. Power requirement of power plant
is et by 2 switch boards namely 5LBDS7 and 05HVLC-1 connected to 3 section of
GSB-1.
5LBDS-7is mainly a 11 kV switch-board with 3 sections and caters to the
need of various load centres throughout TPP. 05HVLC1 is a 6.6 kV load centre which
meets the requirement of HT drives.

ISLAND OPERATION SCHEME

A scheme has been envisaged at TPP to get isolated from the grid in case of
system disturbance or low frequency condition with ABB make relay type FCX 103b
relay for some conditions. Frequency is considered as the main parameter for this
operation as it is highly reliable compared to voltage and current.
The conditions are
When a frequency of 47.5 Hz or goes above 51.5 Hz is sustained for 0.5
seconds, the mainline breaker will trip, isolating the plants 220 kV from grid.
This is called first stage of isolation.
When the frequency further drops down to 46.9 Hz and is sustained for 1
second, the 11 kV section is cut off from the grid. This is called second stage
of isolation.
If the rate of change of frequency is 2 Hz/second, sustained for 100 ms,
isolation occurs

INTRODUCTION TO ERS
Electrical equipment repair shop is popularly known as ERS. It is located on the plant
plaza by the side of central stores. ERS carries medium and capital repair of different
type of LT and HT AC motors, DC motors, lifting magnets, transformers, coils etc.
ERS also carries out large equipment at sites. ERS renders support to all shops during
emergencies to ensure uninterrupted production. These are the activities carried out
by the ERS.
To maintain the standards the ERS is divided into different sections they are as
follows.
1. Planning section
2. Assembling and dismantling section
3. Pre rewinding section
4. Low tension AC winding section
5. High tension AC winding section
6. DC section
7. Varnish and impregnation section
8. Testing section
9. Machine section
10. Electrical maintenance section
11. Stores and material planning section

These are several sections of ERS to perform a job completely and up to the standards
after giving a job the job is being performed by an systematic order in one by one
section wise, for the performance of the job the ERS is equipped with different
equipment.
To assemble and dismantle an motor the section is provided with bearing cleaning
equipment, bearing puller, bearing heaters, small dynamic balancing machine etc, For
dismantling, assembling and over hauling equipment is also provided.
To carry out pre rewinding activities it is equipped with stator coil puller, charring
oven, hot water jet cleaning machines, hot water tank, blowing chamber etc., are being
provided in this section.

The winding section is divided in to three parts they are 1) low tension ac winding
section 2) high tension ac winding section 3)dc section and these equipped with
different equipment such as small coil winding machines, coil winding forming
machines taping machine, insulation cutter, wedge cutter, brazing transformer, rotor
banding machine are the equipment being provided.
In the section of the varnish and impregnation two varnish tanks are provided for
varnishing electrical equipment winding with different grades of varnish, two ovens
are provided for curing and during. Testing section is one of the most important
section, this section is provided with checking of healthiness of winding of the
equipment, special test equipment like surge comparison tester, high voltage tester,
millivolt drop tester etc., are available. To carry out minor technical mechanical
repairs there is a machine section equipped with lathe, hack saw machine, grinders,
drill machines., etc are provided. Two EOT cranes, one of 15/3T capacity and the
other of 5T capacity are provided in the main bay. Two jib cranes, of 1T are provided
for assembling and dismantling work. One 5T single girder crane is available in PRA
section and one 3T crane in varnish section. So these are the various sections in the
electrical repair shop to perform different tasks.

ASSEMBLING AND DISMANTLING

The job is dismantled and sent to the testing as well as PRA section. Any fault ie.,
burn out, cracks in the winding can be easily found out by physical inspection.
Special care is taken for bearings while dismantling the job. The nameplate details are
noted down after dismantling. An FDR test (First Dismantling Report) is prepared
which explains the condition of bearings and other parts of the motor. The end covers
are marked for identification while dismantling the motor, the first dismantling report
is prepared. The entire condition of the motor is checked. The Stator and the Rotor
are sent to corresponding section.
Steps in dismantling the motor:
1. Removing Fan cover
2. Removing Fan
3. Removing outer grease cup
4. Removing end shield
5. Removing inner grease cup after removing bearings
Following the same procedure for the other side also. Remove the rotor from the
stator before assembling grease is applied to the bearings. The type of grease applied
depends on the operating temperature. For high temperatures, Servo Gen 3 (-20 to
140 deg c ) is generally used.
Generally, while dismantling care is taken so that bearings are not damaged. Sylguard
compound or paint is used for hot crane magnet and dobefil in cold magnets. This
compound is removed by punching.
Steps in assembling the motor:
1. Align the motor correctly inside the stator
2. Fix the end cover

3. Fix the outer grease cap

4. Fix fan and fan cover
5. The bearings are heated before fixing then on to the shaft so that they can
be fixed easily (the bearings are heated using a bearing heater).
Generally, ball bearings are used on non-drive end and roller bearings on drive
end.
The bearing heater consists of a primary supply. The bearing is placed on the
board provided and a laminated steel block is placed inside it. The steel block
acts as the core and the bearing as the secondary winding.
Since the secondary is short circuited (bearing) current flows in it and over a
period of time t heat energy I * Rt is generated in the secondary (bearing),
thus heating and expanding it.
Fan key is inserted in key way and fan is fixed. Fan has a groove for inserting
the tray.
Ring spanner, DE spanner, handle spanner are used.
Oxy acetylene torch is used to heat the parts and cut the bearings.

Dismantling of a transformer:
1. First the connection of the terminal box is removed.
2. The transformer oil is to be drained out either partially or completely if
possible.
3. The top cover is to be removed by removing the bolts provided.
4. The connections of the LT and HT side are to be removed.
5. The core is to be carefully lifted without hitting in onto the walls.
After assembling it is again sent to testing section for final testing.

PRE REWINDING ACTIVITIES

After dismantling the job, in the dismantling section, the job is sent for pre-rewinding
activity. The main role of PRA is to collect the winding data from the job and to get it
prepared for further re-winding work.
The activities carried out in PRA are:
1. First, the job is inspected physically for any fault in winding, the stator core.
2. If the winding is burnt, the stator is heated in charring over (up to 250 deg
.c) for 2 to 3 hours
3. This heating is done for diffusing the becktol paint coated over the varnish.
Also the varnish looses its properties at this temperature.
4. After heating, the job is heated from the oven and the coils are removed
from the stator slots.
5. During the removal, data regarding the winding i.e, coil pitch, no. of slots,
name plate details, end connection details etc, are taken and are sent to
rewinding section.
6. The core slots are cleaned by inserting the wire brushes to remove the
material after the coil is burnt..
7. Then the job is blowed with compressed air and cleaned with cleaning agent
called orion. (thinner)

After dismantling the job, in the dismantling section, the job is sent for pre-rewinding
activity. The main role of PRA is to collect the winding data from the job and to get it
prepared for further re-winding work.

REWINDING SECTION
Rewinding section is again divided into two 1) AC winding section and 2) DC
winding section. So let us study in brief about each of the above.
AC WINDING SECTION
1) AS winding section: After the pre-rewinding activities the motor is sent to
rewinding section if there is a problem in windings only. In this section they
follow the following procedure after receiving the motor.
As per the data sheet the coils are wound on universal formal machine and this
machine will wound the coil with conductors as per the given details.
b) The coils prepared in the former machine are set in an order so that they can be
placed easily on one by one order.
c) Now the insulation material is placed in the bottom part of the slot and then the
coil is placed in it and as per the pitch the another part of the winding is placed in
the required slot. In this way they finish the placing of coils in the slots with
specified insulation as per the data given in the data sheet.
d) The out put terminals of each coil are cover with fiberglass coated insulating
materials to provide insulation to the out put terminals of the coils.
e) Wedge is being placed on the already placed coils in the slots, the wedge will
provide the coil not to move from the place where it has been placed this is
because that when supply is given the forces developed inside the motor will
disturb the coil due to attractive or repulsive forces that were developed in the
machine generally this wedge is made up of texolite material.
f) Now the out put terminals are taken out and they are given connection as per the
details given in the data sheet.
The general possible windings that occur in AC machines are of two types they are 1)
Concentric type winding and 2) Symmetrical type winding.
Concentric type winding: For this type of winding, the number of slots is equal to
twice the number of coils are equal to the number of coil sides. It is has one coil per
pair of poles per phase. It would be noted that the polar group of each phase is 360
degrees a part, in this type of winding.

1) It is necessary to used two different shapes of coils to avoid fouling of end

connections.
2) Since polar groups are of each phase are 360 degrees a all such groups are
connected in the same direction
3) The disadvantage is that short pitched coils cannot be used
Symmetrical type winding: This is an simple and continuous winding generally seen
In single layer windings to get maximum emf, two sides of a coil should be one pole
pitch a part i.e, coil span should be equal to one pole pitch, if one side of the coil is
under the center of a N-pole, then the other side of the same coil should be under the
center so S-pole i.e, 180 degrees a part in that case, the emf induced in the two coils
adds together so this is about the symmetrical type winding.
The winding can also be classified as !) single layer winding 2) double layer winding
3) mixed layer winding.
1) Single layer winding: Through out the winding there is only one layer of
bunch of coil that is, in one slot only one winding is placed this is called as
single layer type winding.
2) Double layer winding: This type of windings are ;quite common and efficient
to develop more flux in this case two coils are placed in one slot and this is
carried out through out the winding ;and result in double layer windings.
3) Mixed layer winding: This type of winding which is an mixture of single layer
and double layer, that is some slots will have one coil and some slots will have
double coil this is called mixed layer winding.
Procedure: In this section all the machines, which are of high voltage ratings are
brought to this section and all AC machines which are of high voltage ratings a only
are delt there. In this section a lot of care is taken while the job is carrying out since
these are huge machines and carry out huge currents these machines are treated very
care fully the following steps are followed in this section.
1. First the machine is checked out for any physical problems are their and they
go for identification if any problem is their physically.
2. They go for the data sheet which is going say the problem of the machine and
they rectify it as per the details.
3. If there is any problem in windings then it is sent for re winding this part is also
done in this section only until and unless if their machine cannot be brought up
here they go to the site and repair the machine their itself.

4. Separate machines are allotted in this case for making of the coils and
arranging them in the machine.
5. Then it sent to the testing section for confirmation of the machine healthiness
of the machine if it certified by the testing section then it is sent to the
corresponding section.
So these are general steps followed by the HT section in maintaining the high tension
motors the material used there are maximum of H class and F class type classification
so this about the high tension section.

TESTING OF MOTORS
.
There are two types of MOTORS.
They are 1. AC Motors
2. DC Motors
Testing of AC Motors
For AC Motors we will conduct three types of tests. They are
1. Preliminary tests
2. Intermediate test
3. Final test
Preliminary test:
It is sub divided into 7 types
1. IR test
2. Resistance test
3. Surge test
4. Current balance test
5. Flux test
6. Pole test
7. Temperature test
IR Test:
1. IR means Insulation Resistance. This will be measured in M .This test will be
conducted by using MEGGER
2. This test will be conducted to both stator and rotor parts of AC motors.
3. In this test we connects the leads of MEGGER to phase to phase and line to
neutral and we have to check the IR value/
4. For LT we have to use 500V capacity MEGGER.
5. For HT we have to use 2.5KVcapacity MEGGER.
6. The body is said to be efficient if the IR value should be greater than 1M.
7. The given body is aid to be more satisfactory if its value is to be 50 and above
M.
8. The range for this
G-G
This reading should be in zeroM.
G-P
This reading should be in less than or equal to 100M.
P-P
This reading should be greater than or equal to 100M.
Resistance Test:
1. This test can be conducted by using the micro ohmmeter.
2. This test will be conducted by connecting the leads of ohmmeter in between the
terminals in the terminal box of the body.
3. The connection will be taken in between the terminals like R-Y, Y-B & R-B or
A1-A2,B1-B2,C1-C2.
4. After connecting like these we have to check the resistance value in between
those three.
5. The allowable difference should be less than 5%.

SURGE Test:
1. In this test we will use surge test kit.
2. In this kit there will be four terminals.
3. In these four terminals earth terminal (green cable) is connected at any place of
the body and the other three terminals are connected to the terminals on the
terminal box.
4. After connecting, we will observe the waveforms.
5. By observing these waveforms we will conclude the efficiency of given body.
6. And these waveforms are as follows

CURRENT BALANCE TEST

1. In this test we will pass the full load current of the machine flowing by
applying variable voltage.
2. The connection will be given in between the terminals like R-Y, Y-B & R-B.
3. This test will be conducted by using the auto transformer/induction regulation.
4. If the currents flowing in between these phases the motor said to be running in
good condition otherwise it will be sended to AC motor section.

FIELD ROTATION TEST

1. This test is performed by observing whether the field rotation is produced or
not when the supply is given to the body.
2. This test will be connected by using the principle of FARADAYS LAW OF
ELECTROMAGNETIC INDUCTION.
3. It states that whenever a current carrying conductor is placed in a static
magnetic field it experiences a torque.
4. First of all we will take a magnetic needle.
5. After giving supply to the stator we will put this needle inside the stator.
6. If the flux is produced in the stator the needle will rotates as per the
FARADAYS LAW OF ELECTROMAGNETIC INDUCTION.

POLE FORMATION TEST

1. This test will be used to check the number of poles formed in the stator.
2. In this test we will use the magnetic needle for checking the number of poles.
3. In this test we will give the two phase supply by disconnecting the 3rd phase.
4. After giving the 2- supply we will put this needle into the stator.
5. At the presence of the poles the needle will rotates.
6. By counting the number of rotations we will calculate the number of poles in
the stator.
TEMPERATURE TEST
1. This test will be conducted by using the RATEK instrument.
2. By using this instrument we will put light on each and every winding.
3. It indicates he temperature of that particular winding in the instrument.
4. The temperature of al the windings should be in balanced condition.
5. If the temperature of any winding is not in the balanced condition the entire
body will be defected.

6. That defected body will be sended to the winding section.

INTERMEDIATE TEST:
In addition of all the tests which are performed in preliminary tests high voltage test
will be conducted in this test.
HIGH VOLTAGE TEST
1. In this test we will check whether the coil is good or not and how much leakage
current is drawing by the coil.
2. The requirement is to test the coil is high tension testing kit.
3. The input of the high tension testing machine is AC 230v 50HZ and it will
convert as DC supply and that DC supply is given to the coil.
4. A 230v AC supply is given to the testing machine then the high tension knob is
kept in ON.
5. The leakage current knob is pressed and at the same time then the 21KV DC
voltage is given to the coil.
6. The leakage current should be exceeded then the 1mA when knob is at 1mA.
7. When the leakage current increasing the knob is changed to 10mA.
8. After giving the 21KV DC supply to the coil we have to wait for a minimum
time because if there is no fluctuation in the leakage current in the coil means it
is good coil.
9. Then the voltage is decreased by varying the voltage varies and high tension kit
is switched off.

Final Test
1. In this final test after all the test, repairing and varnishing of the body it will be
again sended to the testing section.
2. In this testing section the final test will be performed.
3. In the final test the no load test will be conducted on the AC motor.
4. In this test we will give the rated voltage to the motor and we will check
whether we are getting the rated current or not.
5. If we obtain the rated current the motor is said to be good otherwise it will be
resented to checking.
MOTORS
Motor:
Motor is an electrical device which converts electrical energy into mechanical
energy by electro magnetic induction principal or simple by farday laws of electro
magnetic induction. So the motor will run when an supply is given to it, this is about
the motor.

CLASSIFICATION OF MOTORS:

MOTORS

Ac motors

dc motors

Synchronous motors

permanent magnet type

electro magnet

type

Induction motors
plane

super

separately

excited

single phase motor

3 phase motor

self excited

slip ring
series
capacitor capacitor shaded repulsion
start

run

pole

shunt

compound

INDUCTION MOTOR
As a general rule, conversion of electrical power into mechanical power takes place in
the rotating part by induction method just like primary and secondary coils of a
transformer. Since the conduction through by induction, this motor is called as
induction motor
Advantages:
2. It is very simple and extremely rigid.
3. Its cost is low and also highly reliable.
4. It has sufficiently high efficiency, in normal running conditions, no brushes
are provided so no frictional losses and more efficiency mechanically.
5. It require minimum maintenance
6. It starts up from rest and needs no external prime mover to start the motor
and this motor need not be synchronized.

Disadvantages:
1. Its speed is cannot be varied with out sacrificing its efficiency.
2. Its speed decreases with increase of load.
3. Starting torque is very low compared to dc motors.
Constructional Details:
As per the construction of induction motor its design is easy and most rigid its design
is economical and handling of the machine is easy while assembling or dismantling
the motor these motors are most generally used since they are economical and easy
handling, as per details of construction this motor has mainly two parts they are as
follows 1) stator 2) Rotor let us see them in detail.
Stator:
It is made up of a number of stampings, which are slotted to receive the windings.
The stator carries a 3-phase winding and is fed from a 3-phase supply poles are
determined by the required speed. The flux developed is of constant magnitude and it
revolves at synchronous speed given by Ns=120*f/p this induces emf in the rotor by
mutual induction.

Rotor:
In this case there are two types of rotors they are a) Squirrel cage rotor and b) Slip ring
rotor or phase wound rotor let us explain them in brief.
i.Squirrel cage rotor:
This is simple and rigid it consists of a cylindrically laminated core with parallel slots
for carrying the rotor conductors called bars.

These bars are permanently short

circuited on themselves and these are featured with small thin lines marked with some
angel to avoid inter locking with main flu so these are some of the important
constructional details of squirrel cage rotor.
ii.Slip ring or phase wound rotor.
This rotor is provided with 3-phase, double layer, distributed winding consisting of
coils as used in alternators. The rotor is wound as many poles as the number of stator
poles. The 3-phase are starred internally and connected to slip rings externally.
Which are mounted on the shaft with brushes connected high care is taken for this
typ0e of windings and some insulation is provided to the wire carrying to the rings,
carbon brushes are provided to make the contact with the slip rings and provide
constant contact with the terminals so this is about the construction details of the slip
ring or phase wound rotor.

DC MOTOR
When a current carrying conductor is placed in a magnetic field it experiences a
mechanical force whose direction is given by the Flemings left hand rule and its
magnitude is given by f=bx1x1 Newton in this motor the input supply is dc so as a
general working principle these motors will have field winding and armature winding
now this current carrying conductor called armature is placed in the ;magnetic field
developed by the field coil, now this armature experiences a mechanical force so this
is about the working principle of dc motor.
Advantages:
2. Have grater speeds compared to the other motors.
3. Speed of these motors can be varied easily.
4. They start immediately and no external driven machines are required.
5. Many number of classifications are available in this dc motors as per the
requirements.

Disadvantages:
1. The construction of these motors is quite difficult.
2. These motors are expensive and has to be handled with care.
3. These motors require additional windings to compensate some of the losses
developed in the dc motors.

Constructional details:
Dc motor have the most complicated winding construction special care has to be taken
in the windings of the motor this motor construction is different compared to
induction motor this motor has many parts and they play vital role in the performance
of the motor the general details of the motor construction are as follows.

1. Yoke
2. Poles-core and poles shoes
3. Pole coils and field coils
4. Armature core
5. Armature windings and conductors
6. Commutator
7. Brushes and bearings

These are different parts of a dc motor so let us see them in brief of each part
functioning.
1)Yoke is the frame that conducts magnetic path through it, it also supports the coils to
be placed, simply it provides shape and mechanical strength to the motor.
2) The field magnets consists of poles core and poles shoes. The pole shoe serves
two purposes a) they spread out the flux in the air gap, and also being in the larger
cross section, they reduce the reluctance of the magnetic path b) they support the
exciting coils so these are the functioning of the pole shoe in the case of dc motor.
3) The field coils or pole coils, consists of copper wire or strip wound in former
dimension and the wound coils is placed in the core when current passes in the
through the field coil magnetic flux will be developed just like an electro magnet
so in this way this field foil will develop flux in the motor.
4) Armature core houses the armature conductors and this will cause the conductors
to rotate hence these conductors will cut the magnetic flu of the field windings this
armature core plats a vital role in holding the conductors so it should hold the
conductors in such away that they cannot move so that their will be no damaging
of the motor physically, this armature core is generally made up of silicon steel and
is being laminated so this about the armature core.
5) Armature windings are usually former wound. These are first wound in the form
of flat rectangular coil and then pulled in to their shape these windings will

conduct the current through them and will develop magnetic field which will cut
the main magnetic flux and this cause the armature to rotate so this about armature
winding.
6) The function of commutator is to faciliate collection of current from the armature
conductors it rectifies, that is it converts the alternating current induced ;in the
armature conductors into unidirectional current in the external load circuit in the
so this about the functioning of the commutator in the dc motor .
7) Brushes function is to collect current from commutator, they are usally made up of
carbon or graphite and these are housed in brush holders and bearings provide free
and easy rotation of armature they provide mechanical support to the armature so
there are different types of bearings available so depending up on the purpose
bearings are used generally ball bearings and roller bearings are used in the dc
motors so this about the brushes and bearings.
So these are the different parts of dc motor and their role in the dc motor construction
and the type of material used for the construction are mentioned in the above details.
And the structures of the armature coil and the diagrams of armature core, brushes,
pole shoe, yoke can be seen.
This is about the different types of motors and about their constructional details of the
motors and the advantages and disadvantages of the motor are also being mentioned
and their basic working principles are also stated so this is about the different types of
motor.