NCU PLANT

....a

brief overview

HALDIA PETROCHEMICALS LTD.

CONTENTS
Title 1.INTRODUCTION: Plants and units 2.HPL Plant capacities 3.Study on NCU plant 4.Equipments used in NCU plant 5.Lighting system in NCU plant 6.SLD of lighting system 7.Types of supply 8.Lighting panels 9.Types of lamps and rating 10.On-Off principle 11.Area of lighting 11.Protection 12.Conclusion 13.Acknowledgement Page No. 3 3 4-9 9 10 11-12 12 13-14 14 14 14 15-17 17 18

INTRODUCTION: Plants and units:

HPL has a number of plants for the production of world class petrochemical products. They are: 1. Naphtha Cracking Unit (N.C.U) 2. Naphtha cracking associated unit (N.C.A.U) 3. High Density Polyethylene (H.D.P.E) 4. Linear Low Density Polyethylene (L.L.D.P.E) 5. Polypropylene (P.P.E) 6. Integrated Offset Plant (I.O.P)

HPL PLANT CAPACITIES:UNITS Naphtha Cracker Unit Associated Units : Butadiene Extraction Unit PGH Plant Benzene Extraction Unit C4 Hydrogenation Unit Polypropylene Plant LLDPE / HDPE Plant HDPE Plant BOO Units : Captive Power Plant Nitrogen Plant Capacity (TPA) 670,000 100,000 520,000 152,000 112,000 320,000 368,000 320,000 116 MW 9000 NM3 /Hr Process License ABB Lummus Global BASF IFP Lurgi IFP Montell Montell Mitsui L&T Praxair

STUDY ON NAPTHA CRACKER UNIT

Substation 6 is feeding power to NCU to fulfill the process requirements. The loads are fed at different voltage levels as per requirement.

Voltage Levels: The following voltage levels exist in the electrical systems of NCU substation/plant :

a) 6.6 kV AC b) 415 V AC c) 110 V AC (UPS) d) 220 V DC e) 110 V DC

SINGLE LINE DIAGRAM FOR NCU PLANT
From S/S # 1, HT-203/3 From S/S # 1, HT-202/3

TR-1 1 1 1 8 M VA 6/1 33/6.9 KV ONA N/ONA F

TR-1 2 1 1 8 M VA 6/1 33/6.9 KV ONA N/ONA F

6.6KV BUS-A
630A VCB TR-221 1 M VA .25 6.6/0.433 KV 400A VC

2500A VCB

2500A VCB

2500A VCB

6.6KV BUS-B
630A VCB TR-222 1 M VA .25 6.6/0.433 KV 630A VCB TR-224 1 M VA .6 6.6/0.433 KV

630A VCB

630A VCB TR-223 1 M VA .6 6.6/0.433 KV

630A VCB

400A VC

M
170KW to 1200KW

M
2000KW

M
2000KW

M
170KW to 1200KW

3200A A CB 630A A CB

PMCC1 BUS-1A
630A A CB

3200A A CB

BUS-1B

3200A A CB 630A A CB

4000A A CB

PMCC2 BUS-2A
1 250A A CB 630A A CB

4000A A CB 630A A CB

4000A A CB 630A A CB

BUS-2B

1 250A A CB

630A A CB

G M
55 KW < M ? 1 KW 60

M
BUS-1B EPMCC
1 600A A CB

800 KVA 41 V 5

M
MCC2 BUS-2A

M
BUS-2B

MCC-1

BUS-1A

1 600A A CB

TR-401 31 KVA 5 41 5/41 V 5

M
? 55 KW

TR-402 335 KVA 41 5/41 V 5

M
B A TTERY CHA RGER UP S

TR-403 1 KVA 60 41 5/41 V 5

M
ASB
- A ux. Supply fo r Swbds (Sp. Htrs) - UP S B ypass, EOT Cranes, A C Supply fo r SRR/A nal. Sheds

PDB
- 3-P hase Welding So ckets in P lant

MLDB
- No rmal P lant Lighting - 1P hase So ckets in P lant

EMLDB
- Emergency P lant Lighting - Substatio n B uilding Lighting

Description of 6.6 kV Level S/s # 6 receives power from SS # 1 at 33 kV level through 2 step-down transformers, 16/18 MVA, 33000/6900 V, located at the transformer yard of SS # 6. These transformers are having auto tap changing facilities. There are 17 taps in each transformer and these are controlled through an AVR located in substation. The swbd is having two bus sections A & B fed independently thru' two power transformers as mentioned above with autochange over scheme between the two incomers and bus-coupler.

 Rating of HT transformer:Makers name Bharat bijlee Ltd. Connection symbol Dyn1 Phase displacement = -30deg KVA = 16000/18000 Volts at no load HV=33000, LV=6900 Amps = HV=280/315, LV=1339/1506 Frequency=50 Hz Generated maximum temp. rise in oil / winding over an ambient of 40 deg celcious 50/55deg celsius Type of cooling ONAN/ONAF Percentage impedance at 75 deg celsius 9.73 The following major loads are fed from the HT board : 28 motors > 160 kW 6 outgoing transformer feeders feeding the downstream 415 V PMCC boards through 6600/415 V step-down transformers Description of 415 V PMCC Level There are two 415 V PMCC boards designated as PMCC1 and PMCC2 receiving power from the HT board thru distribution transformers 1.25 MVA, 6600/415 V ( for PMCC 1 ) & 1.6 MVA,6600/415 V ( for PMCC 2 ). These transformers are having off load tap changers. The number of taps is 5. Rating of 1.25 MVA transformer:Makers name-Voltamp Transformer Ltd. Vector group- Dyn11 Rating- 1250KVA Noload voltage-HV 1.6KV, LV 0.433KV Current- HV 109.34A, LV 1666.71A Cooling ONAN Max temp rise oil / winding = 50/55 deg Celsius Impedance voltage =6.20% Rating of 1.6 MVA transformer:Makers name-Voltamp Transformer Ltd. Vector group- Dyn11 Rating- 1600KVA Noload voltage-HV 6.6KV, LV 0.433KV
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Current- HV 139.96A, LV 2133.39A Cooling ONAN Max temp rise oil / winding = 50/55 deg celsius Impedance voltage =6.01% These buses are also having two incomer and one bus coupler with auto changeover scheme. Incomers are protected with over current and earth fault protection. The major loads supplied by these boards are : Motor loads > 55 kW and 160 Kw MCC 1 & 2 EPMCC Main distribution board for lighting ( normal ) commonly called MLDB thru TR 402 and NEW MLDB-thruTR 404 Main distribution board for lighting ( emergency ) commonly called EMLDB thru TR 403 Power distribution board commonly called PDB - thru TR 401( feeding welding receptacles ) Description of 415 V EPMCC Level This board is having two normal incomers and one Emergency Diesel Generator (EDG) incomer supplied from emergency DG (800 kVA, 0.8 p.f ). The scheme of operation is as follows : The normal incomer 2 feeds the bus under healthy power conditions. Under conditions of power failure ( no line voltage ), EDG controller senses the u/v condition & starts the DG on auto & assumes the bus load. On voltage restoration, again the controller senses healthy line voltage condition, synchronises with mains, runs in parallel, slowly ramps off load (soft transferring of load to mains) & shuts downs automatically after engine cooldown period. Description of 415 V MCC Level There are two MCCs in S/s # 6 ( MCC 1&2 ). All the motors 55 kW are fed from MCC. There are two incomers and one bus coupler with mechanical interlocking arrangement ( no auto-changeover for MCCs ).

110 V UPS System : There are two 110 V UPS installed in S/s # 6. 80 kVA Gutor make UPS for Instrumentation and ECMS loads. 10 kVA Tata Liebert make UPS for paging system. V DC System: The 220 V DC supply is used for control circuits of switchgears and for critical lighting. The 220 V DC battery charger is supplied by GUTOR and provides the control supply of switchgears and feeds critical lighting of the plant. The system configuration is : 2 Rectifiers 1 Battery fuse box 1 Battery bank 1DCDB 1 DC Distribution Section (Voltage dropper section)

110 V DC System : 110 V DC is used to feed the instrumentation loads - generally the solenoids for the SOVs. This system is identical as the 220 V DC system except the matching transformer where the secondary voltage is matched with 110 V.

Equipments used in NCU plant:

1. Induction motors 2. Distribution Transformers 3. Lighting transformer 4. Battery charger 5.EOT crane 6.MOVS 7.UPS 8. Elevator

Lighting System In NCU Plant:

There are three types of lighting in NCU plant: Normal lighting Emergency lighting DC critical lighting The philosophy of lighting followed in NCU : The normal lighting is for plant area and fed from normal distribution board with a timer connected to the panels.The timer is set manually.When the manually set time arrives plant lighting is switched ON.

The emergency lighting is divided into : Substation lighting always on Plant emergency lighting - The critical lights in the plant and substation are fed from 220 V DCDB. These lights will glow when there is no power available even in EPMCC ( total blackout ). There are two parts of DC critical lighting - one is for daytime and other is for night. The typical scheme is as follows:
Bus coupler for Day Light

DP switch
Bus Coupler for Night-light

Incoming from 220V DC charger

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SLD OF LIGHTING SYSTEM:

33KV SWGR SF6 36KV,16/18MVA,1250A TR-112 33KV/6.6KV NGR %Z=9.327% VCB 7.2KV,630A,25KA 6.6KV BUS VCB 7.2KV,630A,25KA TR-222 6.6KV,433/250V,1250KVA %Z=6.17% ACB 415V,3200A,50KA PMCC BUS B 440V BUS ACB 415V,800A,50KA TR-402 415/240V,335KVA,%Z=4.55% 3N-415/240V,500A,50KA 415V,630A TIMER MLDB NIGHT AND DAY LIGHTS EMLDB NIGHT LIGHTS CRITICAL LIGHTS

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SLD OF EMLDB:

TYPES OF SUPPLY: a)ac supply-normal and emergency lighting works under ac supply b)dc supply-The 220 V DC supply is used for control circuits of
switchgears and for critical lighting. The 220 V DC battery charger is supplied by GUTOR and provides the control supply of switchgears and feeds critical lighting of the plant.

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LIGHTING PANELS: a)MLDB(L,LN): This board is fed from PMCC 1 through TR 402, which is
335-kVA 1:1 transformer. It feeds to the single-phase sockets and plant lighting. This transformer is having off load tap changers. The number of taps is 5. Rating of 335KVA transformer:Makers name-Indcoil Bombay. Vector group- Dyn11 Rating- 335KVA Noload voltage-primary 0.415KV, secondary 0.415KV Current- primary 466A, secondary 466A Cooling AN Max temp rise in air = 115 deg celsius Impedance voltage =4.55% b) EMLDB(LE,LEN): This board is fed from EPMCC through TR 403, which is 160-kVA 1:1 transformer. It feeds to the emergency plant lighting and substation lighting. This transformer is having off load tap changers. The number of taps is 5. Rating of 160KVA transformer:Makers name-Indcoil Bombay. Vector group- Dyn11 Rating- 160KVA Noload voltage-primary 0.415KV, secondary 0.415KV Current- primary 222.59A, secondary 222.59A Cooling AN Max temp rise in air = 115 deg celsius Impedance voltage =3.81% c)NEW MLDB(L,LN):This board is fed from PMCC3 through TR 404,which is 200 KVA 1:1 transformer.This transformer is having off load tap changers.The number of taps is 5.
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c)CRITICAL LIGHT(LC,LCN):This board is fed from DCDB.This board supplies the DC control loads ( dc control supply for HT Swbd & PMCCs ), dc critical lighting & is fed from 220 V DC battery charger

TYPES OF LAMPS AND RATING: HPMV(high pressure mercury vapour) lamp Rating-80W,125W,250W,400W GLS(General light) Rating-100W,200W Flourescent lamp Rating-36W Aviation lamp Rating-10W,15W,20W

On-Off principle: In the earlier times photo sensor was used for the on-off function of the lighting system in NCU plant.But now-a-days
there is a timer connected with the panels which helps in the on-off function of the lamps in the NCU plant.The timer is set manually.In this plant the timer is set from 6pm to 5:30am.

Area of lighting in NCU plant:

1. 2. 3. 4. 5. 6. 7. Heater Quench polisher Compressor Hot Cold EBR

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Protection:
Different circuit breakaers and relay are used for the protection of the lighting system in NCU plant.

ELCB(Earth leakage circuit breaker)- An Earth Leakage Circuit Breaker (ELCB) is a safety device used in electrical installations with high earth impedance to prevent shock. It detects small stray voltages on the metal enclosures of electrical equipment, and interrupts the circuit if a dangerous voltage is detected. Once widely used, more recent installations instead use residual current circuit breakers which instead detect leakage current directly.

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 RCCB(Residual current circuit breaker)- A Residual-Current Circuit Breaker (RCCB) is an electrical wiring device that disconnects a circuit whenever it detects that the electric current is not balanced between the energized conductor and the return neutral conductor. Such an imbalance may indicate current leakage through the body of a person who is grounded and accidentally touching the energized part of the circuit. A lethal shock can result from these conditions. RCCBs are designed to disconnect quickly enough to prevent injury caused by such shocks. They are not intended to provide protection against overcurrent (overload) or short-circuit conditions.

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 ELR(Earth leakage relay)- An earth leakage relay is an electronic or electromechanical device that detects the current flowing to earth. If this earth leakage current is above a preset level (and carries on for a preset time) the relay is "tripped" - this may switch on an alarm signal - or more usually it simply disconnects the supply. Currents may flow to earth due to a fault condition or because of lots of individual items connected to the supply have a small "leakage" to earth.

Conclusion
I consider myself very lucky that I could gather the required technical skills from Haldia Petrochemicals Limited, a pioneer in petrochemical arena. I have learned a lot of things after coming to HPL. The discipline, the environment, the technology and the system is really impressive.Moreover, it is really a great experience to have my training in HPL, Haldia.

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Acknowledgement
I am very much thankful to Mr. Gopal Chakrabarty, Head Of The Electrical Department Mr. Kamalesh Das , Training Co-ordinator Mr.Sudipta Debnath,Manager-Electrical Mr.Sabyasachi Mahata,Deputy Manager-Electrical & All the other members of NCU for helping me whenever needed.

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