A REPORT ON

INDUSTRIAL TRAINING
TITLED
POWER DISTRIBUTION SYSTEM
TAKEN AT
“Bharat Heavy Electricals Limited, HERP, VARANASI”

Submitted in partial fulfilment for the award of degree of Bachelor of

Technology from MEERUT INSTITUTE OF ENGINEERING AND
TECHNOLOGY,MEERUT

2016-2020
Submitted to: Submitted by:
PANKAJ KUMAR AYUSH
(BRANCH-EE)
3 rd Year
Roll no.1606820011
 CERTIFICATE

Certified that Ayush (B.Tech, EE), student of 3rd year 6th semester in Electrical
Engineering,Meerut Institute 0f Engineering And Technology,Meerut has
prepared this industrial summer practical training project report on “Power
Distribution System” taken at “Bharat Heavy Electricals Limited, HERP,
VARANASI” from 10 June 2019 to 8 July 2019. The report has been found
Excellent and it is approved for submission.

Pankaj Kumar
Dy. Engr.
(Electrical Engineering)
 Acknowledgement

I feel happiness in forwarding this summer industrial training report as a

sincere effort. It is almost inevitable to ensure indebtedness to all generally
help by sharing their valuable experience and devoting their precious time with
and without whom this summer industrial report would never have been
accomplished.
Foremost and first of all I extend my thanks gratitude to the entire unit of
“Bharat Heavy Electricals Limited, HERP, and VARANASI”along with “Mr
ASHUANI KUMAR AGM (Maint. & mod. /MM) and Mr PANKAJ KUMAR
(trainer)” whose guidance, teaching and invaluable suggestions provided me a
deep insight in my chosen field of technology, enhanced my knowledge and
support in widening my outlook toward communication industry. I am also
very thankful to engineer of the department for their kind and support
throughout the training.
We perceive as this opportunity as a big milestone in our career development.
We shall strive to use gained skills and knowledge in the best possible way, and
will continue to work on their improvement, in order to attain desired career
objectives. Hope to continue cooperation with all of you in the future.
 TABLE OF CONTENT

1) Introduction
2) About HERP
3) Line Diagram of Power Distribution System
4) Components of Power Distribution System

a) Incoming feeder
b) Metering cubicle
c) Circuit Breaker
d) XLPF Cable
e) Transformer
f) Diesel Generator Set
6) Power Factor System
7) Power Factor Correction
8) Summary
 INTRODUCTION

In this project, we have studied the Power Distribution System at BHEL HERP.
The Plant has a 33 KV Substation which receives power from Independent
feeder at Tarna Substation of UPPCL located inside BHEL premises. The single
line diagram of distribution system up to distribution Panel has been prepared
which also incorporates the relevant ISO standards. The technical specification
of the critical electrical installation has been noted & used for load & fault
analysis.
The detailed working & operational characteristics of VCB, Oil & air cooled
transformers, ACBs, etc. has been studied and analysed in this report.A
comparative study citing the advantages & disadvantages of different types of
switch gears, relays and controllers has also been carried out as a part of this
industrial training. The safety & protection of installations, equipment and
operators has also been studied to understand the best industry practices.
 ABOUT HERP

In line with BHEL's objective of providing consistent service at doorstep, HERP

was established in the vicinity of power stations at Varanasi. The foundation
stone of HERP sprawling in 29.8 acres area at Varanasi was laid on 26th
September 1984. Within a short span of 21 months, production activities were
started in the plant from 1st April'1986. Having achieved break-even point in
the second year of its existence itself, HERP progressed by leaps & bounds.
Starting as a manufacturer of O&M spares for boiler auxiliaries, repair activities
took off on firm footing in 1990 when rebabbitting of TG set bearings was
taken up. Since then, rabbiting of different kinds of bearings including import
substitution (NCL Bearings) as well as bearings of unconventional synchronous
condenser have been carried out to the entire satisfaction of the customers.
HERP Varanasi has taken up various critical jobs from nearby power plants viz:
NTPC Tanda, Unchahar, UPRVUNL Obra, Anpara, Parichha and helped them to
achieve maximum availability of their units.
Now apart from conventional spares of Bowl Mills & boiler auxiliaries, HERP is
manufacturing and supplying turbine fasteners for different power plants,
turbine tools and tackles (required for erection and commissioning/ major
overhaul of turbines) for various power projects. This year, we will be
manufacturing steam turbine strainer assembly, sealing rings & small
governing assembly also.
Line Diagram of Power Distribution System of BHEL
(Varanasi)
Components of Power distribution system

A) IFT: Incoming feeder: This receives power from the metering cubicle. This
has microprocessor based Relay installed for tripping & protection during
fault.

B) Metering cubicle: This section has CT & PT for metering. This section also
has 33 KV Fuse of 6A rating for protection of metering PT.

C) Circuit Breaker: A circuit breaker is an automatically operated electrical

switch designed to protect an electrical circuit from damage caused by an
overload or short circuit. Unlike a fuse, which operates once and then has
to be replaced, a circuit breaker can be reset (either manually or
automatically) to resume normal operation.

TWO TYPES OF CIRCUIT BREAKERS WHERE THERE

i) Vacuum Circuit Breaker.
ii) Air Circuit breaker.
 Vacuum Circuit Breaker
A vacuum circuit breaker is a kind of circuit breaker where the arc quenching
takes place in vacuum medium. The operation of switching on and closing of
current carrying contacts and interrelated arc interruption takes place in a
vacuum chamber in the breaker which is called vacuum interrupter.

Construction of Vacuum Circuit Breaker

It is very simple in construction as compared to any other circuit breaker. Their
construction is mainly divided into three parts, i.e., fixed contacts, moving
contact and arc shield which is placed inside the arc interrupting chamber.

The outer envelope of vacuum circuit breaker is made up of glass because the
glass envelope help in the examination of the breaker from outside after the
operation. If the glass becomes milky from its original finish of silvery mirror,
then it indicates that the breaker is losing vacuum.
The fixed and moving contacts of the breaker are placed inside the arc shield.
The pressure in a vacuum interrupter at the time of sealing off is kept at about
10-6 torr. The moving contacts of the circuit breaker are move through a
distance of 5 to 10 mm depending upon the operating voltage.
The metallic bellows made of stainless steel is used to move the moving
contacts. The design of the metallic bellows is very important because the life
of the vacuum circuit breaker depends on the ability of the component to
perform repeated operations satisfactorily.

Working of Vacuum Circuit Breaker

The sectional view of vacuum circuit breaker is shown in the figure below when
the contacts are separated due to some abnormal conditions, an arc is struck
between the contacts, the arc is produced due to ionization of metal ions and
depends very much on the material of contacts.

The arc interruption in vacuum interrupters is different from other types of

circuit breakers. The separation of contacts causes the release of vapor which
is filled in the contact space. It consists positive ions liberated from contact
material. The vapor density depends on the current in the arc. When the
current decreases, the rate of vapor release decreases and after current zero,
the medium regain its dielectric strength if the vapor density is reduced.
When current to be interrupted is very small in a vacuum, the arc has several
parallel paths. The total current is divided into many parallel arcs which repel
each other and spread over the contact surface. This is called diffused arc
which can be interrupted easily.
At high values of current, the arc gets concentrated in a small region. It causes
rapid vaporization of the contact surface. The interruption of the arc is possible
if arc remains in diffused state. If it is quickly removed from the contact
surface, the arc will be re-strike.
Arc extinction in vacuum breakers is greatly influenced by material and shape
of the contacts and the technique of considering metal vapor. The path of the
arc is kept moving so that temperature at any one point will not be high.
After the final arc interruption, there is rapidly building up of dielectric
strength which is peculiar of the vacuum breaker. They are suitable for
capacitor switching as it will give a re-strick free performance. The small
current is interrupted before natural current zero, which may cause chopping
whose level depends on the material of contact.

Applications of Vacuum Circuit Breaker:-

a) The vacuum circuit breaker is today recognized as most reliable
current interruption technology for medium voltage switchgear. It
requires minimum maintenance compared to other circuit breaker
technologies.
b) The technology is mainly suitable for mainly medium voltage
application. For higher voltage vacuum technology has been
developed, but it is not commercially feasible. Vacuum circuit
breakers are used in metal clad Switchgear and also in porcelain
housed circuit breakers.
ACB (Air Circuit Breakers)
It is an electrical device used to provide Overcurrent and short-circuit
protection for electric circuits over 800 Amps to 10K Amps. These are usually
used in low voltage applications below 450V. We can find these systems in
Distribution Panels (below 450V).
Air circuit breaker is circuit operation breaker that operates in the air as an arc
extinguishing medium, at a given atmospheric pressure.

Working of Air Circuit breaker

Air Circuit breakers normally have two pairs of contacts. The main pair of
contacts carries the current at normal load and these contacts are made of
copper. The additional pair is the arcing contact and is made of carbon.
When circuit breaker is being opened, the main contacts open first and during
opening of main contacts the arcing contacts are still in touch with each other.
As the current gets. a parallel low resistive path through the arcing contact
during opening of main contacts. there will not be any arcing in the main
contact. The arcing is only initiated when finally, the arcing contacts are
separated. The each of the arc contacts is fitted with an arc runner which
helps. the arc discharge to move upward due to both thermal and
electromagnetic effects as shown in the figure. As the arc is driven upward it
enters in the arc chute, consisting of splatters.
The arc in chute will become colder, lengthen and split hence arc voltage
becomes much larger than system voltage at the time of operation of air circuit
breaker, and therefore the arc is quenched finally during the current zero.
Air Circuit breakers (ACBs) are available which can be Electrically Operated or
Manually Operated. This means electrically operated Air Circuit Breaker Can be
Opened (switched OFF) and Closed (Switched ON) using external power supply.
The Electrically operated motor is used to operate spring charging mechanism
for closing and opening the Circuit Breaker. The power supply could be single
phase 230V AC Supply or low voltage 24V-110V DC supply for operation during
no availability of power.
Types of Air Break Circuit Breaker
⦁ Plain air circuit breaker
Plain air circuit breaker is also called as Cross-Blast Circuit Breaker. In this, the
circuit breaker is fitted with a chamber which basically surrounds the contacts.
This chamber is known as arc chute.

Plain Air Circuit Breaker

This arc is made to drive in it. In achieving the cooling of the air circuit breaker,
an arc chute will help. From the refractory material, an arc chute is made. The
internal walls of arc chute are shaped in such a way that arc is not forced into
close proximity. It will drive into the winding channel projected on an arc chute
wall.
The arc chute will have many small compartments and has many divisions
which metallic separated plates are. Here each of small compartments behaves
as a mini arc chute and metallic separation plate acts like arc splitters. All arc
voltages will be higher than the system voltage when the arc will split into a
series of arcs. It is only preferable for low voltage application.
⦁ Air blast Circuit Breaker
Air blast circuit breakers are used for system voltage of 245 KV, 420 KV and
also even more.Air blast circuit breakers are of two types:
(i) Axial blast breaker
The moving contact is in contact. There is a nozzle orifice in fixed contact at
normal closed condition of breaker. When a fault occur, high pressure is
introduced into the chamber. High-pressure air will flow through nozzle orifice
voltage is sufficient to sustain.
 Axial blast breaker

(ii) Axial blast with sliding moving contact

The moving contact is fitted over a piston supported by a spring. The blast
transfers arc to arcing electrode.

Axial blast with sliding moving contact

Applications of Air Circuit Breakers

1. Air Circuit Breakers are used for controlling the power station auxiliaries
and industrial plants. They offer protection to industrial plants, electrical
machines like the transformers, capacitors, and generators.
2. They are mainly used for protection of plants, where there are possibilities
of fire or explosion hazards.
3. The air brake principle of the air breaker circuit arc is used in DC circuits
and AC circuits up to 12KV.
 4. The air circuit breakers have high resistance power that helps in increasing
the resistance of the arc by splitting, cooling and lengthening.
5. Air circuit breaker is also used in the Electricity sharing system and NGD
about 15kV.

Advantages of ACB
1. There is no chance of fire hazard caused by oil.
2. The breaking speed of circuit breaker is much higher during operation of air
blast circuit breaker.
3. Arc quenching is much faster during operation of air blast circuit breaker.
4. The duration of arc is same for all values of small as well as high currents
interruptions.
5. As the duration of arc is smaller, so lesser amount of heat realized from arc
to current carrying contacts hence the service life of the contacts becomes
longer.
6. The stability of the system can be well maintained as it depends on the
speed of operation of circuit breaker.
7. Requires much less maintenance compared to oil circuit breaker.

Disadvantages of ACB

1. In order to have frequent operations, it is necessary to have sufficiently high

capacity air compressor.
2. Frequent maintenance of compressor, associated air pipes and automatic
control equipment is also required.
3. Due to high speed current interruption there is always a chance of high rate
of rise of re-striking voltage and current chopping.
4. There also a chance of air pressure leakage from air pipes junctions.

D)XLPE CABLE
 XLPE is an abbreviated designation of “cross-
linked polyethylene”.

 Polyethylene has good electrical properties

and in particular a low dielectric loss factor,
 which gives it potential for use at much higher voltages than PVC.

 Cross-linking is the effect produced in the

vulcanization of rubber and for materials.
The effect of the cross-linking is to inhibit
the movement of molecules with respect to
each other under the stimulation of heat
and this gives the improved stability at elevated temperatures compared
with the thermoplastic materials. This permits higher operating
temperatures, both for normal loading and under short-circuits
conditions, so that an XLPE cable has a higher current rating than its
equivalent PVC counterpart.

 Cross linked polyethylene is produced from polyethylene under high

pressure with organic peroxides as additives. The application of heat and
pressure is used to effect the cross linking. This causes the individual
molecular chain to link with one another which in turn causes the
material to change from a thermoplastic to an elastic material.

 In the manufacture of medium and high voltage XLPE cable, plant uses
the latest technology available in the field by using an integrated high
performance extrusion line which consists of a triple-layer crosshead
and a water-free Completely Dry Curing and Cooling(CDCC) gas-
vulcanizing process. This type of extrusion minimizes the risk of
introducing external contaminants and produces high quality XLPE cable.

 It is used predominantly in building services pipework systems, hydronic

radiant heating and cooling systems, domestic water piping, and
insulation for high tension (high voltage) electrical cables.

 It is also used for natural gas and offshore oil applications, chemical
transportation, and transportation of sewage and slurries.

CHARACTERISTICS AND ADVANTAGES OF XLPE CABLE

1. Excellent Electrical and Physical Properties:XLPE cable constitutes the

best cable for transmission and distribution lines because of its excellent
electrical and physical properties.
 2. Capability of carrying large currents:The excellent resistance to thermal
deformation and the excellent ageing property of XPLE cable permit it to
carry large current under normal (900C) and emerging (1300C) or short
circuit (2500C) conditions.

3. Ease of installation:XPLE cable withstands smaller radius bending and is

lighter in weight, allowing easy and reliable installation. Furthermore, the
splicing and terminating methods for XPLE cable are simpler in
comparison with other kinds of cable.

4. Free from height limitation and maintenance: XPLE cables can be

installed anywhere without special consideration of the route profile
(height limitations) since it does not contain oil and thus is free from
failures due to oil migration in oil-filled cables.

5. No metallic sheath required:XPLE cable does not generally demand a

metallic sheath. Thus it is free from the failures peculiar to metallic-
sheathed cables, such as corrosion and fatigue.

E)Transformer:
A transformer is an electrical device that transfers electrical energy between
two or more circuits through electromagnetic induction. A varying current in
one coil of the transformer produces a varying magnetic field, which in turn
induces a voltage in a second coil. Power can be transferred between the two
coils through the magnetic field, without a metallic connection between the
two circuits. Faraday's law of induction described this effect. Transformers are
used to increase or decrease the alternating voltages in electric power
applications.

These are the basic components of a transformer.

 1. Laminated core:The core is used to support the
windings in the transformer. It also provides a low
reluctance path to the flow of magnetic flux. It is made
of laminated soft iron core in order to reduce eddy
current loss and Hysteresis loss. The composition of a
transformer core depends on such factors as voltage,
current, and frequency. The diameter of the
transformer core is directly proportional to copper loss
and is inversely proportional to iron loss.

2. Windings:There are two windings wound over the transformer core that are
insulated from each other. Windings consists of several turns of copper coils
bundled together, and each bundle is connected in series to form a winding.
Following type of windings are there mainly present in a transformer:

 Primary winding:
The primary winding is the coil that draws power from the source.
 Secondary winding:
The secondary winding is the coil that delivers the energy at the
transformed or changed voltage to the load.
 Tertiary winding or stabilizing winding:
An auxiliary delta connected winding used particularly in star connected
transformer or autotransformer for following purpose:
1. To facilitate the flow of zero phase sequence current.
2. To reduce third harmonics voltage of the transformer.
3. To stabilize the neutral point of the fundamental frequency voltages.

3. Insulating materials:Insulating paper and

cardboard are used in transformers to isolate primary
and secondary windings from each other and from
the transformer core.
4. Transformer oil:Transformer oil is another insulating material. Transformer
oil can actually have two functions: in addition to insulating it can also work to
cool the core and coil assembly. The transformer's core and windings must be
completely immersed in the oil. Normally, hydrocarbon mineral oils are used as
transformer oil. Oil contamination is a serious problem because contamination
robs the oil of its dielectric properties and renders it useless as an insulating
medium.

5. Tap changer:The output voltage may

vary according to the input voltage and
the load. During loaded conditions, the
voltage on the output terminal
decreases, whereas during off-load
conditions the output voltage increases.
In order to balance the voltage
variations, tap changers are used. Tap
changers can be either on-load tap
changers or off-load tap changers. In an
on-load tap changer, the tapping can be
changed without isolating the
transformer from the supply. In an off-load tap changer, it is done after
disconnecting the transformer.

6. Conservator:The conservator
conserves the transformer oil. It is an
airtight, metallic, cylindrical drum
that is fitted above the transformer.
The conservator tank is vented to the
atmosphere at the top, and the
normal oil level is approximately in
the middle of the conservator to
allow the oil to expand and contract
as the temperature varies. The
conservator is connected to the main
tank inside the transformer, which is completely filled with transformer oil
through a pipeline.

7. Breather:The breather controls the moisture level in the transformer.

Moisture can arise when temperature variations cause expansion and
contraction of the insulating oil, which then causes the pressure to change
inside the conservator. Pressure changes are balanced by a flow of
atmospheric air in and out of the conservator, which is how moisture can
enter the system. If the insulating oil encounters moisture, it can affect the
paper insulation or may even lead to internal faults. Therefore, it is
necessary that the air entering the tank is moisture-free.

The transformer's breather is a cylindrical

container that is filled with silica gel. When
the atmospheric air passes through the silica
gel of the breather, the air's moisture is
absorbed by the silica crystals. The breather
acts like an air filter for the transformer and
controls the moisture level inside a
transformer. It is connected to the end of
breather pipe.

8. Cooling tubes:Cooling tubes are used to cool the transformer oil. The
transformer oil is circulated through the cooling tubes. The
circulation of the oil may either be natural or forced. In
natural circulation, when the temperature of the oil rises the
hot oil naturally rises to the top and the cold oil sinks
downward. Thus the oil naturally circulates through the
tubes. In forced circulation, an external pump is used to
circulate the oil.

9. Buchholz Relay:The Buchholz Relay is a protective device container

housed over the connecting pipe from
the main tank to the conservator tank.
It is used to sense the faults occurring
inside the transformer. It is a simple
relay that operates by the gases
emitted due to the decomposition of
transformer oil during internal faults.
 It helps in sensing and protecting the transformer from internal faults.

10. Explosion vent:The explosion vent is used to expel boiling oil in the
transformer during heavy internal faults in order to avoid
the explosion of the transformer. During heavy faults, the
oil rushes out of the vent. The level of the explosion vent is
normally maintained above the level of the conservatory
tank.

No transformer is truly an 'ideal transformer' and hence each will incur some
losses, most of which get converted into heat. If this heat is not dissipated
properly, the excess temperature in transformer may cause serious problems
like insulation failure. It is obvious that transformer needs a cooling system.
Transformers can be divided in two types as (i) dry type transformers and (ii)
oil immersed transformers. Different cooling methods of transformers are -

 For dry type transformers

1. Air Natural (AN)
2. Air Blast
 For oil immersed transformers
1. Oil Natural Air Natural (ONAN)
2. Oil Natural Air Forced (ONAF)
3. Oil Forced Air Forced (OFAF)
4. Oil Forced Water Forced (OFWF)

Cooling methods for Dry type Transformers

A. Air Natural or Self air cooled transformer: This method of transformer
cooling is generally used in small transformers (upto3 MVA). In this method the
transformer is allowed to cool by natural air flow surrounding it.

B. Air Blast:For transformers rated more than 3 MVA, cooling by natural air
method is inadequate. In this method, air is forced on the core and windings
with the help of fans or blowers. The air supply must be filtered to prevent the
accumulation of dust particles in ventilation ducts. This method can be used
for transformers upto 15 MVA.
Cooling methods for Oil Immersed Transformers:
A. Oil Natural Air Natural (ONAN): This method is used for oil immersed
transformers. In this method, the
heat generated in the core and
winding is transferred to the oil.
According to the principle of
convection, the heated oil flows in
the upward direction and then in
the radiator. The vacant place is
filled up by cooled oil from the
radiator. The heat from the oil will
dissipate in the atmosphere due to
the natural air flow around the
transformer. In this way, the oil in
transformer keeps circulating due
to natural convection and
dissipating heat in atmosphere due to natural conduction. This method can be
used for transformers upto about 30MVA.

B. Oil Natural Air Forced (ONAF):

The heat dissipation can be improved further by applying forced air on the
dissipating surface. Forced air provides faster heat dissipation than natural air
flow. In this method, fans are mounted near the radiator and may be provided
with an automatic starting arrangement, which turns on whentemperature
increases beyond certain value.

This transformer cooling method is generally used for large transformers upto
about 60 MVA.

C.Oil Forced Air Forced (OFAF):

In
this method, oil is circulated with the help of a pump. The oil circulation is
forced through the heat exchangers. Then compressed air is forced to flow on
the heat exchanger with the help of fans. The heat exchangers may be
mounted separately from the transformer tank and connected through pipes
at top and bottom as shown in the figure. This type of cooling is provided for
higher rating transformers at substations or power stations.
D. Oil Forced Water Forced (OFWF):

This method is similar to OFAF method, but here forced water flow is used to
dissipate hear from the heat exchangers. The oil is forced to flow through the
heat exchanger with the help of a pump, where the heat is dissipated in the
water which is also forced to flow. The heated water is taken away to cool in
separate coolers. This type of cooling is used in very large transformers having
rating of several hundred MVA.
At BHEL (HERP), Varanasi, there are two off load tap
changingTransformers(Same Specification) of Crompton Greaves.
Transformer Specification:
 Power: 1 MVA
 Volt(No Load) : HV=33KV, LV=433V
 Ampere: HV=17.5A, LV=1333.4A
 Frequency: 50Hz
 Phase: 3
 Type of cooling: ONAN
 Impedance Voltage: 5.78%
 Connection Symbol: Dy11
F) Diesel Generator:
It is the combination of diesel engine with an alternator to generate electrical
energy.

Diesel Generator Set:-

A diesel generator set (genset) is the combination of a diesel engine, alternator
and supporting components, with the primary purpose of converting fuel into
electricity.

Diesel generating sets are used in places without connection to a power grid,
or as emergency power-supply if the grid fails, as well as for more complex
applications such as peak-lopping, grid support and export to the power grid.

At BHEL(HERP), Varanasi, there are two Diesel Generator sets(500kVA and

750kVA) of Cummins India Limited; used for emergency power supply.

Components of Diesel Generator Set:-

1. Diesel Engine:It is an internal combustion engine in which ignition of the fuel
which is injected into the combustion chamber is caused by the elevated
temperature of the air in the cylinder due to mechanical compression
(adiabatic compression).

The diesel engine used in Cummins Genset is Cummins K19 Series, 6 cylinder,
In-line, 4 stroke, radiator cooled engine.

2. Alternator: An alternator is an electromechanical device that converts

mechanical energy to electrical energy in the form of alternating current. It
may be called an AC, synchronous generator or generator end.

The specifications of alternator used in Cummins Genset is Brushless type,

Revolving field, self-excited alternator, with 12 terminals brought out for
connection.

3. Control Panel:It sends start signal to engine's starter motor.

4. Circuit Breaker:It is an automatically operated electrical switch designed to

protect an electrical circuit from damage caused by overload or short circuit.

Molded case Circuit Breakeris used in Cummins Genset for protection from any
damage.

Molded Case Circuit Breaker:

Molded case circuit breakers are interrupting devices with self-contained,
current-responsive elements. These breakers are assembled as an integral unit
in a supported and enclosed housing of insulating material.

Depending on the amount of protection required, these breakers can sense

internally and then clear under-voltage, overcurrent, and short circuit
conditions.

Molded case circuit breakers use is restricted to low voltage and medium
voltage systems.

Molded Case Circuit Breaker Principle Components

5. Cooling System:Internal combustion engines are often cooled by passing a

liquid called engine coolant through the engine block, where it is heated, then
through the radiator itself where it loses heat to the atmosphere, and then
back to the engine in a closed loop. Engine coolant is usually water-based, but
may also be oil.

Fans are also used as a part of the cooling system. The fan blows the hot air
out of the engine.

6. Coolant Tank (Cooling Tower):A coolant is a fluid which flows through a

device to prevent its overheating, transferring the heat produced by the device
to other devices that use or dissipate it.

A cooling tower is a specialized heat exchanger in which air and water are
brought into direct contact with each other in order to reduce the water's
temperature. As this occurs, a small volume of water is evaporated, reducing
the temperature of the water being circulated through the tower.

Cooling Tower
A cooling tower with water as a coolant and fans are used as a part of cooling
system in Diesel Generator set at BHEL(HERP), Varanasi.

Cummins Diesel Generator Set Specification(500kVA)

Cummins Diesel Generator Set

 POWER FACTOR SYSTEM

Power Factor Definition:

Power factor is the ratio between the KW and the KVA drawn by an
electrical load where the KW is the actual load power and the KVA is the
apparent load power. It is a measure of how effectively the current is being
converted into useful work output and more particularly is a good indicator
of the effect of the load current on the efficiency of the supply system.

P.F (Cos Ǿ)= True Power / Apparent Power.

 All current flow causes losses both in the supply and distribution system.
A load with a power factor of 1.0 results in the most efficient loading of
the supply. A load with a power factor of, say, 0.8, results in much higher
losses in the supply system and a higher bill for the consumer. A
comparatively small improvement in power factor can bring about a
significant reduction in losses since losses are proportional to the square
of the current.

 When the power factor is less than one the ‘missing’ power is known as
reactive power which unfortunately is necessary to provide a
magnetizing field required by motors and other inductive loads to
perform their desired functions. Reactive power can also be interpreted
 as wattles, magnetizing or wasted power and it represents an extra
burden on the electricity supply system and on the consumer’s bill.

 A poor power factor is usually the result of a significant phase difference

between the voltage and current at the load terminals, or it can be due
to a high harmonic content or a distorted current waveform.

 A poor power factor is generally the result of an inductive load such as

an induction motor, a power transformer, and ballast in a luminary, a
welding set or an induction furnace. A distorted current waveform can
be the result of a rectifier, an inverter, a variable speed drive, a switched
mode power supply, discharge lighting or other electronic loads.

What Causes Low Power Factor?

Since power factor is defined as the ratio of KW to KVA, we see that low
power factor results when KW is small in relation to KVA. Inductive loads.
Inductive loads (which are sources of Reactive Power) include:
a. Transformers
b. Induction motor
c. Induction generators (wind mill generators)
d. High intensity discharge (HID) lighting

 These inductive loads constitute a major portion of the power consumed

in industrial complexes.

 Reactive power (KVAR) required by inductive loads increases the amount

of apparent power (KVA) in your distribution system .This increase in
reactive and apparent power results in a larger angle (measured
between KW and KVA). Recall that, as increases, cosine (or power
factor) decreases.

Why Should I Improve My Power Factor?

 You want to improve your power factor for several different reasons. Some
of the benefits of improving your power factor include:
1) Lower utility fees by:
(a) Reducing peak KW billing demand:
 Inductive loads, which require reactive power, caused your low power
factor. This increase in required reactive power (KVAR) causes an increase
in required apparent power (KVA), which is what the utility is supplying. So,
a facility’s low power factor causes the utility to have to increase its
generation and transmission capacity in order to handle this extra demand.
 By lowering your power factor, you use less KVAR. This results in less KW,
which equates to a dollar savings from the utility.
(b). Eliminating the power factor penalty:
 Utilities usually charge customers an additional fee when their power factor
is less than 0.95. (In fact, some utilities are not obligated to deliver
electricity to their customer at any time the customer’s power factor falls
below 0.85.) Thus, you can avoid this additional fee by increasing your
power factor.
2) Increased system capacity and reduced system losses in your electrical
system
 By adding capacitors (KVAR generators) to the system, the power factor is
improved and the KW capacity of the system is increased.
 For example, a 1,000 KVA transformer with an 80% power factor provides
800 KW (600 KVAR) of power to the main bus.
 By increasing the power factor to 90%, more KW can be supplied for the
same amount of KVA.
2 2 2
 (1000 KVA) = (900 KW) + ( ? KVAR)
 KVAR = 436
 The KW capacity of the system increases to 900 KW and the utility supplies
only 436 KVAR.
 Uncorrected power factor causes power system losses in your distribution
system. By improving your power factor, these losses can be reduced. With
the current rise in the cost of energy, increased facility efficiency is very
desirable. And with lower system losses, you are also able to add additional
load to your system.
3) Increased voltage level in your electrical system and cooler, more efficient
motors.
 As mentioned above, uncorrected power factor causes power system losses
in your distribution system. As power losses increase, you may experience
voltage drops. Excessive voltage drops can cause overheating and
premature failure of motors and other inductive equipment. So, by raising
your power factor, you will minimize these voltage drops along feeder
cables and avoid related problems. Your motors will run cooler and be more
efficient, with a slight increase in capacity and starting torque.
 POWER FACTOR CORRECTION
An inductive load requires a magnetic field to operate and in creating such a
magnetic field causes the current to be out of phase with the voltage (the
current lags the voltage).
Power factor correction is the process of compensating for the lagging current
by creating a leading current by connecting capacitors to the supply.
Automatic Power Factor Correction (APFC) Panel

 It’s an automatic system adjusting itself to control the power factor

above a desired value by a bank of capacitors switched by means of
contractors.
 Contractors are controlled by a regulator that measures PF in the
network.
 Depending upon the load PF the controller will adjust the PF by
switching the necessary no of capacitors from the bank.

Parts of APFC:
1. Reactive power control relay
 Capable of measuring the reactive and active power of the network.
 Works in conjunction with a capacitor bank.
 Controls the programmed target PF by activating /deactivating the
capacitors.

The main functions of the reactive power control relay:

 Automatic connection detection (Star or Delta)
 Automatic detection of capacitor stages
 Patented characteristics avoiding compensation of very low active power.
 Reactive power requirement-switching delay time
 Alarm signals for :
 Failure to reach the target PF
 Overcurrent in the capacitor
 Defects at capacitor stages
2. Network connection point

Since the power factor of the loads is to be compensated hence the connection
of the APFC unit is always done in parallel with the supply connection.
Generally Y- connection of the capacitor bank is preferred because the
transmission distribution of three phase distribution system above 132 KV is Y
connected always.
3. Slow-blow switches

Slow blow switches are always used because of the following requirements:
 To sustain the inrush and starting current surges due to vehicular loads.
 It offers a time delay between overloading and fusing.
 They can withstand heavy currents (about ten times the rated).

4.Inrush current contactors

 Used for damping the inrush current arising due to:
 Remaining capacitor voltage due to fast switching
 Short circuit power of supply
 Fault level of supply networks
 The contractors also protect the welding of the main contacts of the
contactors.
 Prevent the capacitors from high stress

5. Capacitor Bank
 The capacitor bank is the main part of the APFC units.
 Large capacitor banks are installed in the APFC’s which switch in order to
meet the desired power factor requirement.
 Each capacitor is individually fused with appropriately sized current limit
fuse.

6. Control Transformer
 Monitors the switchboard load (or load to be corrected).
 Placed physically above (towards the supply) the connections for the PFC
system.
 In case more than one transformers are fitted they are always connected in
series as they work as CT.
 Summary
Power comes from UPPCL (Uttar Pradesh Power Corporation Limited) which is
nearly at 1 km distance from BHEL HERP. For power transfer 33kv XLPE cable is
used, power comes from 33kv (secondary side of transformer), 5MVA
transformer. Firstly, cable reaches metering cubicle which gives all relevant
information like voltage, current, unit used etc.
Then, cable goes to incoming feeder after that it gets connected to feeder PT
panel, which is adjacent to incoming feeder. There are two different types of
power transformers at BHEL HERP, which differs from each other on the basis
of their cooling method. One of them is oil cooled (ONAN) and the other is air
cooled (AN). They are connected to the system in such a way only one
transformer operates that at a time, and the other is removed from the
system. Oil cooling transformer is set at high tapping value and air cooling
transformer is set at low tapping value. When there is high voltage, low
tapping transformer is connected to the system, and when voltage is low, high
tapping transformer is connected to the system. After feeder PT panel, two
separate feeders are connected to two different types of transformers which
are interlocked with each other in such a way that only one transformer is ON
at a time. Each transformer is connected with an air circuit breaker (ACB) of its
own. Then, both these transformers are connected to a single bus bar of 433 V.
A current transformer (CT) is connected to this bus bar. A current
transformer (CT) is a type of transformer that is used to measure AC Current. It
produces an alternating current (AC) in its secondary which is proportional to
the AC current in its primary. Current transformers, together with voltage
transformers (VTs) or potential transformers (PTs), which are designed for
measurement, are known as an Instrument transformer. The current
transformer, is then connected to twelve stage capacitor, which is connected
in delta configuration, and it is used to control the power factor. There is a
certain mechanism, which senses the increase or decrease in power factor, and
maintains the power factor above 0.95. The power factor should be above
0.95, and if it falls below that value, the government may charge the BHEL
authority. After twelve stage capacitor bank, there is a 2000 Ampere capacitor
bank connected in series, which is further connected to a bus bar from which
load is taken.
In case, if the supply goes OFF, there are two alternate diesel generators for
emergency power supply. Both these diesel generators have their own ACBs
and the whole setup is connected to the same bus bar from which the load is
taken.