IIIT BHUBANESWAR

A Project report for Industrial Training Taken In

TATA STEEL

Project Title :- Study of power System and their Protective devices at New BPP
of BATTERY 10&11
Project Guide :- Mr. Subhash Chakraborty
By:-
SOMNATH BANERJEE
VT20192562
4 Weeks
About TATA STEEL
Tata Iron and Steel Company was founded by Jamset ji Tata and established by Dorab ji Tata on 26
August 1907, and began producing steel in 1912 as a branch of Jamsetji's Tata group . By 1939, it
operated the largest steel plant in the British Empire. The company launched a major
modernization and expansion program in 1951. Later, in 1958, the program was upgraded to
2 million metric tonnes per annum (MTPA) project . By 1970, the company employed around
40,000 people at Jamshedpur, and a further 20,000 in the neighbouring coal mines .

In 1971 and 1979, there were unsuccessful attempts to nationalise the company . Tata Steel on Thursday, 12 February 2015 announced
buying three strip product services centres in Sweden, Finland and Norway from SSAB to strengthen its offering in Nordic Region. The
company, however, did not disclose the value of the transactions . Tata Steel is headquartered in Mumbai, Maharashtra, India and has its
marketing headquarters at the Tata center in kolkatta , west bengal. It has a presence in around 50 countries with manufacturing operations
in 26 countries including: India, Malaysia, Vietnam, Thailand, UAE, Ivory Coast, Mozambique, South Africa, Australia, United Kingdom, The
Netherlands, France and Canada . Tata Steel primarily serves customers in the automotive, construction, consumer goods, engineering,
packaging, lifting and excavating, energy and power, aerospace, shipbuilding, rail and defence and security sectors
The steel plant produces:
 Iron
 Soft iron
 Cast Iron
 Alloy
They also produce:
 Locomotive parts
 Agricultural equipment
 Machinery, tinplate
 Cable and wire
 Re bars
 Branded products and solutions like Pravesh Doors
 About
Coke oven
Plant
The coke oven by-product plant is an integral part of the by-product coke making process. During the production of coke by coal carburization in
a coke oven battery a large amount gas is generated due to the vaporization of volatile matter in the coal. The gas is generated over most of the
coking period, the composition and the rate of evolution changing during this period and being normally complete by the time coal charge
temperature reaches 700 deg C. This gas is known as raw coke oven gas and is processed in the by-product plant. The functions of the by-
product plant are to process the raw gas to recover valuable coal chemicals and to condition the gas so that it can be used as a clean,
environmentally friendly fuel gas.
After leaving the coke oven chambers, the raw coke oven gas is sprayed with flushing liquor so as to reduce its temperature to a reasonably low
level and to condense the most easily condensable (high boiling point) components. The raw gas is cooled by adiabatic evaporation of some of
the spray liquor to around 80 deg C and is water saturated. The temperature of the gas becomes sufficiently low so that it can be handled in the
gas collecting mains. From the gas collecting main the raw coke oven gas flows into the suction main. The amount of flushing liquor sprayed into
the hot gas leaving the oven chambers is far more than is required for cooling, and the remaining flushing liquor which is not evaporated
provides a liquid stream in the gas collecting main. At this stage there are two streams namely a liquid condensate stream and a gas stream. The
two streams pass through a butterfly control valve before leaving the coke oven battery area. This control valve is set to maintain a slightly
positive pressure in the collecting main to provide safe working conditions in the coke oven chambers.
The liquid stream in the gas collecting main flushes away condensed tar and other
compounds. The stream of flushing liquor flows under gravity into the suction main
along with the raw coke oven gas. The raw coke oven gas and the flushing liquor are
separated using a drain pot (the down comer) in the suction main. The flushing liquor
and the raw coke oven gas then flow separately to the by-product plant for
treatment . Saturated raw gas coming from the coke oven battery contains around 46
% to 48 % water vapour. Other component of raw gas contains hydrogen, methane,
nitrogen, carbon monoxide, carbon dioxide , high paraffins and unsaturated hydro
carbons (ethane, propane etc.), and oxygen etc. Raw coke oven gas also contains
various contaminants, which give coke oven gas its unique characteristics. These
consist of :-
Tar components
Benzene, toluene and xylene (BTX)
Naphthalene
Ammonia gas
Hydrogen sulfide gas
Hydrogen cyanide gas
Ammonium chloride
Carbon di-sulphide

Content of impurity in CO gas

BPP Plant process
Power Distribution Diagram
 33 KV Bus Section , MPDS # 6
SubStation X
X X
MRSS Fdr # MRSS Fdr #
1 1
X X
X
33 KV MRSS Bus
X X

33 KV => 6.6 KV Trf

33 KV => 6.6 KV Trf
#1
#2

6.6 KV MRSS
Bus X
X X

X X X X
BPP Main
X
SubStation

6.6 KV RCPH
X X
SbStation X
Single line diagram of CCR MCC
 Emergency Feeder
I/C#1 From MRSS P-18 I/C# 2 From MRSS P-35

Relay REF 615 Relay REF 615

Relay REF 542 plus Relay P143
X X
X X
BT NO. #1 BT NO.# 2
Relay REF Relay REF Relay REF
Relay REF 615 615 Relay REF 615

Bus Pt no # 3
615 615
Spare # 1

Relay REF
Relay REF

Exhauster # 2

Spare # 5
615
615
X

Exhauster
X X

=>415 V
6.6KV
Exhauster
=>415 V
6.6KV
=>415 V
6.6KV

=>415 V
6.6KV
I/C TRF # 2

I/C TRF # 4
I/C TRF # 3
X
1
I/C TRF #

X
X X
x x
MCC NAPTHALEIN

MCC H2S / NH3

EM40
EM40
0
EM40
0
X 0 X X
Relay Relay
EOCR Relay Relay
EOCR EOCR EOCR
MLDB
ACDB

ACDB

MOTOR MOTOR MOTOR MOTOR

Single line diagram of RCPH Substation
 From 6.6 KV At MRSS -> RCPH
Substation

Relay P127 Relay P127

Relay
X P143
X
X
BUS
COUPLER

Relay Relay Relay Relay Relay Relay Relay Relay Relay Relay Relay Relay Relay
P220 P220 P220 P122 P220 P220 P122 P220 P220 P122 P220 P220 P220

X X X X X X X X X X X X
X
CP4A CP3B CP3A TRAFO CP5A ACP# TRAFO ACP# CP4B TRAFO CP3C CP3D CPB
350KW 650KW 650KW 2MVA 350KW 2 2MVA 3 350KW 2MVA 650KW 650KW 350KW
250KW 250KW
Energyconsumption by the different Plant of New BPP of
Battery 10 & 11
Day 1
To BPP (KWh) To ESS (KWh) To Process To MRSS(Kwh) Total Total Power
Chiller(KWh) energy(KWh) (KW)/ day

Feeder # 38011 12805 13580 25206 BPP 117414 4893

1
MRSS 77426 3227
Feeder # 79403 27183 35718 52220
2
Day 2
To BPP (KWh) To ESS (KWh) To Process To MRSS(Kwh) Total Total Power
Chiller(KWh) energy(KWh) (KW)/ day

Feeder # 56660 34161 15780 22499 BPP 137641 5736

1
MRSS 62202 2592
Feeder # 80981 41278 32875 39703
2

Day 3
To BPP (KWh) To ESS (KWh) To Process To MRSS(Kwh) Total Total Power
Chiller(KWh) energy(KWh) (KW)/day

Feeder # 47850 37475 18825 10375 BPP 126395 5267

1
MRSS 49488 2062
Feeder # 78545 39432 33473 39113
Protecting Relays used in the High Tension side at MRSS
1. Micom REF 615 :-
Over – Current Protection.
Earth Fault Protection.
Over/Under Voltage Protection.
Thermal Over-Load.
Phase unbalance.
Breaker Failure.
P.T Fuse Failure.
Fault Trip.

2. Micom REF 542 Plus :-

 Device Trip.
 Over-Current Trip.
 T.C(Trip Coil) Healthy.
 Earth fault Trip.
3. Micom P143 :-
 Fault Trip.
 T.C (Trip Coil ) Healthy.
 Over-Current Trip.
 Instantaneous Earth Fault.
 Trip circuit Supervision .
 Under Voltage Protection.
Different Specification of dry type transformer at CCR MCC

Dry Type Transformer of Capacity 1 MVA

Dry Type Transformer of Capacity 1.6 MVA
VCB used in CCR MCC
Protecting Relays used in the High Tension side at MRSS
1. Relay P127 :-
 Fault Trip.
 P.T Healthy.
 Under / over Voltage.
 PT Fuse Fail.
 T.C Healthy.
Over – Current Protection.
Earth fault Protection.
Phase unbalance.
Breaker Failure.

2. Relay P220 :-
 Common Trip.
 T.C Healthy.
 Motor Winding & Bearing Temperature.
 Minimum Starting Time between 2 Starts.
 Thermal Over-Load.
 Fault Trip.
 Instantaneous Earth Fault
 Over- Current Protection.
3. Micom P143 :-
 Fault Trip.
 T.C (Trip Coil ) Healthy.
 Over-Current Trip.
 Instantaneous Earth Fault.
 Trip circuit Supervision .
 Under Voltage Protection.

4. Micom P122 :-
 Common Trip.
 T.C Healthy.
Earth fault Protection.
Over / Under Voltage Protection.
Thermal Over-Load.
Phase unbalance.
Earth Fault Protection.
Instantaneous Earth Fault.
Standby Earth Fault Protection.
Instantaneous Over- Current.
Differential Earth-Fault.
Different Specification of VCB and Transformer at RCPH

VCU at RCPH Substation Transformer #1 (2MVA) at RCPH

Transformer # 3 (2MVA) at RCPH Transformer # 3 (2MVA) at RCPH
 Common Protection
devices
Used in Low Tension Side.
DIFFERENT PROTECTIVE DEVICES USED IN INDUSTRIES

Miniature circuit breaker

There is a bi-metallic strip which becomes over heated when circuit is overloaded for long time. Overheating results in deformation of the
strip and causes displacement of latch point. Even a slight movement of latch causes release of spring and makes the moving contact to move for
opening the MCB. During short circuit the MMF of current coil causes its plunger to hit the latch point and displaces the latch, which results in the
opening of the MCB. Arc generated by high currents will reach the arching chamber through the guide plate. The arc is separated into smaller arcs
by the arc splitter and extinguished there.
Fuses
Fuse is a protection device which melts and breaks the circuit when the current rating exceeds the rating of the fuse. Fuse must be replaced
ones it has melted.
 Isolators
Electrical isolators isolates a part of the system from rest this is useful when circuit breaker trip the circuit but the open contacts are not
visible from the outside so it’s not safe to touch the circuit just by switching of the circuit breaker. Therefore the isolator is opened only after the
circuit breaker is opened and closed before the circuit breaker is closed. Electrical isolators must be operated only when there is no current flowing
through the circuit. Isolator can be operated by hand as well as by motorized setup.
RCBO
When there is need of combined protection against over current (over load and short circuit) and protection against earth leakage current
then RCBO is used. It has wide range of breaking capacities and can be used for industrial and residential purposes. it has the combined effect of
MCB and RCCB in one device. Every circuit has its own RCBO therefore if any device is tripped due to residual current, only the faulty circuit is
disconnected. The internal residual current detecting element will trip the circuit when there is a current leakage fault. The internal
thermal/magnetic circuit breaker parts are able to trip the device when the circuit is over loaded. RCBO come in single pole and dual pole
variations. The single pole is used as a direct replacement for MCB.
ELCB
An ELCB is a voltage sensing device which is used to prevent shock threats as well as protection of instruments. Earlier it was widely used
but now a days RCCB’s are in use for protection. An ELCB has a relay coil one of the terminals is connected to the equipment and other terminal is
given to ground directly. In case of faulty conditions like if insulation of the equipment fails or live phase wires touches the metal part of the
equipment, a voltage difference appears across the coil which is connected to device and earth. After this voltage reaches a limit, current
developed in the relay trips the circuit breaker and the power supply to the device is stopped.
Thank
you