HINDUSTAN AERONAUTICS LIMITED

UNDER THE GUIDANCE OF

MR. BISWENDU SAHU
SR. MANAGER(MAINTENANCE),SED

SUBMITTED BY
SOMNATH PATTNAYAK (VT NO. 23-631)
 ACKNOWLEDGEMENT

We take immense pleasure in thanking, Mr. RAVI PRAKASH GUPTA, SENIOR. Manager, for
Permitting us to carry out the vocational training.

We wish to express our deep gratitude to our project guide, Mr. BISWENDHU SAHU
Sr. Manager (Maintenance Department), SED for his able guidance and
Useful suggestions, which helped us in completing our project work in time.

Words are inadequate in offering thanks to the Employees of HAL for their
Encouragement and cooperation in carrying out the project work.

SOMNATH PATTNAYAK

VEER SURENDRA SAI UNIVERSITY OF TECHNOLOGY, SAMBALPUR

1. History of HAL
2. Description of power distribution in HAL
3. HAL Koraput 132/11KV switchyard SLD
4. Details of equipment’s used in 132 KV substation
5. Concept of power factor
6. List of installation in SED
7. 132KV Switchyard
8. 11KV Substation Details
9. Auxiliary equipment’s in 132KV substation
10. Method to verify the correct operation of protective
system
11. Tariff plan by which HAL is paying electricity bill
12. Solar
13. Conclusion
 HISTORY OF HAL

An agreement was signed in August, 1962 with the Soviet Union for
manufacture of MiG-21 E7FL Air craft under license the Aero engine Factory at
Koraput (ORISSA), the Air frame Factory at Nasik (Maharastra), and the
Avionics Factory at Hyderabad (Andhra Pradesh) have been set up to meet this
requirement on the name of Aeronautics India Limited which was formed on
April 1964 and new company under the name of Hindustan Aeronautics Limited
was formed.

The government sanction for the first phase of construct of the Aero engine
factory at Sunabeda (Koraput) was accorded March 1964 and the factory started
manufacture of R11F2-Series-III engines for fitment on MIG-21FL Aircraft from
1969 onwards. The first engines of imported category manufactured in December
1968 and various categories of engines were produced during the subsequent
years. The first raw material engine was produced in February 1971.The
production programmes for the factory also include manufacture of forging and
casting required for MIG-Aircraft.

To meet the Air force requirement for improved fight interceptor aircraft, an
agreement was signed with USSR in August1976 for manufacturing MiG-21BIS
Aircraft. The power plant of this aircraft is the R25 turbojet engine. The
government approval for setting up capital facilities was accorded in October
1977. The first engine of imported category delivered to HAL Nasik Division in
the year 1978-79.The FI raw material engine was delivered during January1983.

With signing of the inter-governmental agreement for manufacture of MiG 27M

Aircraft on 19th March 1982, this Division would be involved in the manufacture
of R-29B series of engine from the year 1984-85
 In order to attain self-sufficiency and to avoid difficulties regarding supply
of Raw Material & other layout items from USSR, it was decided to provide
indigenous supply of spares manufacturing for Overhaul/maintenance of the fleet.

The Government approval for undertaking the tax received during 1977-78 and
the indigenization plan was formed to tackle,

 ARS and first moving spares.

 Metallic material.
 Non-metallic material.
 Ready-made articles.

HISTORY GROWTH AND OBJECTIVES OF THE EARLY

YEARS

The origins of the present day Hindustan Aeronautics Limited can

be traced to the erstwhile Hindustan Aeronautics Limited, which was set up in
December 1940 by a foreign industrialist the late Seth Walchand Hirachand in
association with the government of the princely state of Mysore. The register of
joint stock companies of Mysore State registered the company on 23rd December
1940 as private limited company.

The company was registered on 23rd December 1940 as private limited company
by the register of joint stock companies of Mysore State. The company
commenced its operations with the aim manufacturing the Harlow Trainer,
Curtiess Haw Fighter the Vul Bomber in collaboration with the Inter Continentals
Aircraft company USA. The first flight handed over to the government of India
in August 1941. Aten seat glider designed by Dr.V.Ghatage was also test flown
in August 1941.
 Now there are various divisons of HAL located in different places in India.

These are:

1. Bangalore Division (Karnataka)

2. Barakpur Division (West Bengal)
3. Nasik Division (Maharashtra)
4. Hyderabad Division (Telangana )
5. Lucknow Division (Uttar Pradesh)
6. Kanpur Division (Uttar Pradesh)
7. Korwa Division (Uttar Pradesh)
8. Koraput Division (Odisha)

CORPORATE OBJECTIVES

The objectives for which the company is established are out in the memorandum of
Association of HAL. There are clauses which interlia provide for design, development,
M a n u f a c t u r e , repair and overhaul of aircraft, engines, related materials, components
And equipment.

Manufacture of Missiles and Weapons, to take or otherwise acquire and hold shares in
Other company having objective altogether or in part similar to those of HAL etc.

In April 1971, the board of directors of HAL appointed committee known as review
committee of HAL to review the functioning of the company and make its recommendations.

Committee formulated a statement of basic objective adoption by HAL, as detailed below:

BASIC OBJECTIVES

 To serve as an instrument of the national policy to achieve self-reliance in

the design, development and production aircraft and aeronautical
equipment to meet the counter changing and growing needs, with special
emphasis on millet requirement.

 In fulfillment of this objectives, the company shall regard its fundamentally

responsible for design and development, rely however, upon such relevant
facilities as are available in to national institutions, but always holding
itself basic a responsible for the growth and furtherance of the counter
aeronautics capability.

 To so conducts its business economically and efficiently it can contribute

its due share to the national effort achieving a self-reliant and self-
generating economy.

 Towards this end, to develop and maintain an organization which will

readily respond to and adopt the changing matrix of soc techno-economic
relationship and where in a climate of grow professional competence, self-
discipline, mutual understand deep commitment and a sense of belonging
will be fostered each employee will be encouraged to grow in accordance
with potential for the furtherance of the organization.

 The recommendations of the review were subsequently approved by the

board of Directors in September 1972 and forwarded government, who
informed the company in May 1973 that the may adopt these objectives.
These objectives remain essential unchanged to date except that they have
been amplified in 1983 through the medium of MD’s dated 14th 1983
emphasizing the following:
  That our products are of the highest quality and reliability.
 That our products are fully supported after sale to customer.
 That capacity utilization is optimized, restoring which is necessary
to diversification and export.
 Greater thrust towards indigenisation of materials and product toimprove
self-reliance.

MAJOR COMPLEX

HAL has five main complexes in India:-

1. Bangalore Complex.
2. MIG Complex.
3. Accessories Complex.
4. Design Complex.
5. Helicopter Complex

1. BANGALORE COMPLEX

(A) Aircraft Division • Manufacturing Jaguar Aircrafts

(B) Engine Division • Manufacturing Jaguar Engines

(C) Helicopter Division • Manufacturing Helicopters

(D Forge and Foundry Division - Manufacturing high precision

Casting and forging

(E) Overhaul Division • Overhaul of Jaguar and other

engines
 (F) Space Division • Manufacturing of launching of
pads and common satellites

(G) Servicing Division • For common services to all

Divisions
2. MiG COMPLEX

(A) Nasik Division • Manufacturing and overhaul of

Airframes.

(B) Koraput Division • Manufacturing andOverhaul of MIG engines

and SU-30 engine Overhaul and manufacturing.

3. ACCESSORIES COMPLEX

(A) Hyderabad Division - Manufacturing of electronics and

Navigational equipment

(B) Kanpur Division - Manufacturing of passenger

Aircraft and gliders.

(C) Lucknow Division - Manufacturing of hydraulic

Pumps, fuel pumps and stator Generator.

(D) Korwa Division - Manufacturing of advanced

navigational equipment.
4. DESIGN COMPLEX

Bangalore Division - Modification of any component or

unit of an engine.

5. HELICOPTER COMPLEX
Barrackpore Division - Manufacturing and Overhaul of
Helicopter components
 INDIGENOUS NAMES OF HAL PRODUCTS

SL. No. AIRCRAFT ENGINE INDIGENOUS

NAME

1 MIG-21FL R11-F2Ó BADAL

2 MIG-21M/MF R11-F2S/F2SK TRISHUL

3 MIG-21BIS R-25 VIKRAM

4 MIG-23MF R-29 RAKSHAK

5 MIG-23BN R-29B VIJAY

6 MIG-25 R-29B GARUD

7 MIG-27M R-29B BAHADUR

8 MIG-29 RD-33 VAJ

9 GNAT ORPHEUS-701 AJEET

10 HF-24 ORPHEUS-703 MARUT

11 HJT-16 VIPER-11 KIRAN

12 JAGUAR ADOUR MK-803 SHAMSHOR

13 MIRAGE-2000 M-53 VAJRA

14 HS-748 (AVRO) DART-531 CHITRA

CHE
15 ALLOUTEE ARTOUSTE-IIIB (HELICOPTER)
CHEETAH

16 AN-32 SUTLUJ

17 MI-8 PRATAP

18 MI AKBAR

19 HPT-32 PISTON ENGINE

20 SU-30 AL31FP SUKHOI

 HINDUSTAN AERONAUTICS LIMITED

The beginning of HAL can be traced to the year 1940 when a far sighted
Industrialist, the late Seth Walchand Hirachand, set up a company called Hindustan
Aircraft Limited at Bangalore with the object of establishing an aviation industry
That can manufacture, assemble and overhaul aircraft. Initially Aircraft like Curtiss
Hawk, Volte Bomber and Harlow Trainer was taken up for manufacture and
Overhaul in collaboration with Inter Continental Aircraft Company of the USA.
With the escalation of the Second World War the government of India took
Over the management of the company in 1942 and handed it over to US Air force for
Repair and overhaul of various aircraft. The main activity for the next few years after
The war was reconditioning and conversion of war surplus aircraft for the use of IAF
And Civil Operators.
To fulfill the fresh mandate of the post independent India and to meet the
Challenges of open market economy of recent times the mission of the company has
Been redefined as:
To become a globally competitive Aerospace industry while working as
Instrument for achieving self-reliance in design, manufacture and maintenance of
Aerospace defense equipment and diversifying to related areas, managing the
Business on commercial lines in a climate of growing professional competence."
In the six decades, HAL has spread its wings to cover various activities in
The areas of design, development, manufacture and maintenance. Today HAL has 14
Production divisions spread over at Bangalore, Nasik, Koraput, Kanpur, Lucknow,
Korwa, Hyderabad and Barrackpore. These divisions are fully backed by 9 design
Centers, which are co-located with the productive divisions. These centers are
Engaged in the design and development of combat aircraft, helicopter, aero engine,
Engine test beds, aircraft communication and navigation systems and accessories of
Mechanical and fuel systems and instruments.
The current program include production of Dhruv an Advanced Light Helicopter,
Jaguar, LCA, Su-30MKI and upgrades of MIGs, Jaguar and Avro HS-748.
NIC.

KORAPUT ENGINE DIVISION

Engine Division - Koraput, a unit of HAL's vast network, was set up in April 1964 to
Manufacture R11-f2 turbo jet engine of MiG-21 FL aircraft under licence from the erstwhile
USSR. Subsequently, the division took up, under various licence agreements, manufacture of
R-11 series engines of MIG-21 FL and MiG- 21M aircraft, R-25 series engines of MiG-21
BI’s aircraft and R-29B engines for Mig-27M aircraft. Simultaneously, facilities were set up
For overhaul of R-11 and R-25 series engines, which started in 1971 and 1983 respectively.
Starting from 1997 - 98 overhaul of RD - 33 Engines of MiG-29 aircraft were also conducted.
 INTRODUCTION TO SU-30 MKI

Sukhoi SU-30 MKI, (Russian: Modernizirovannyi KommercheskiyIndiski;

Modernized Commercial India), is the variant of the Sukhoi SU-30. The SU-
30 MKI a highly specialized aircraft developed for the Indian Air Force. It is
a heavy class, long-range, multi-role, air superiority fighter and strike
fighter. The variant also consists of French, Israeli and Indian subsystems. The
MKI variant is a much more advanced fighter jet than the basic K and MK
variants and is considered a 4.5 generation aircraft. The MKI variant is considered
to be the most advanced fighter aircraft of Russian origin in service.

Aircraft SU-30MKI is a multipurpose twin seated supersonic fighter

designed: to destroy air targets in free space and against the earth background
both by day and at night under visual and adverse weather conditions and to
engage ground and surface targets within tactical and operational depths under
heavy noise conditions as well.
To destroy aerial targets, a provision is made for employment of all angle
medium-range missiles (active, semi-active radar and infra-red guided missiles)
and short-range missiles (infra-red guided missiles) capable of high target hit
probability.
To destroy ground targets, use is made of unguided bombs, guided bombs and
missiles. The aircraft is also equipped with a rapid fire gun mount with caliber
of 30 mm.
The aircraft is also intended for training, acquisition (perfection) of skills in flying
techniques, air navigation and combat employment including participation in
group combat actions.

Introduction to AL-31FP Engine

The Saturn AL-31FP is a high-temperature fully-ducted turbofan

of modular design. It is the AL-31F derivative with all advantages of the
predecessor retained.

The AL-31FP engines power the advanced multi-purpose 4+ generation Su-

30MKI fighters.

The AL-31FP design feature is a variable asymmetric vectoring nozzle with a

thrust vector angle of ±15° ensuring aircraft maneuvering performances.
The AL-31FP manifests stable operation under all possible changes of aircraft
attitude under super-maneuvering conditions, including zero and negative
airspeed. The variable thrust vector is of a great efficiency, which considerably
surpasses efficiency of the aircraft aerodynamic rudders. The systems of surge
destruction, in-flight automatic start, combustor and afterburnerrelight provide
the power plant stable operation, with airborne weapon application. The seal
at the thrust vectoring nozzle-to-afterburner end part transition area is one of the
AL-31FP most complex assemblies, where the temperature attains 2000°С, and
pressure is 5 to 7 atmospheres.

The various department present in engine division are:

1. Forge
2. Foundary
3. Tool room
4. Small parts & fuel
5. Sheet metal & welding
6. Blades
7. Electroplating
8. Heat treatment
9. Compressor
10.Turbine
11.CNC
12.Assembly
13.Overhaul
14.Gear
15.Test house
16.Maintenance

Sukhoi Engine Division has 6 workshops, called as Hangar. Each Hangar has
different work for engine.
1. HANGAR – 101
a. Compressor Shop – 611
b. Turbine Shop – 610
c. Blade Shop - 615
2. HANGAR – 102
a. CNC Shop – 616
b. Gear Casing Shop – 609
3. HANGAR – 103
a. Heat Treatment Shop – 603
b. Electroplating Shop – 604
 4. HANGAR – 104
a. Assembly – 620
b. Jet Nozzle Assembly – 620A
c. Fuel & Small Parts – 614
d. Rig Room – 614A
5. HANGAR – 105
a. Sheet Metal Shop – 612
b. Special Equipment Shop
6. HANGAR – 106
a. Aggregate Overhaul Shop – 613

Description of power distribution in HAL:

The 132 kV power from Odisha Power Transmission Corporation Limited

(OPTCL) is received at HAL 132 kV switchyard through 132 kV double circuit
Transmission line.

The 132 kV power received is stepped down to 11kv by 2 no. of 25 MVA,

132/11KV Transformer. The 11 kV supply from the transformer is fed through
11kV bus Ducts to 25 panel board located in control room. The 11 kV supply is
fed to Various substations located in each hanger by through double line of
XLPE Cables.

All the equipment’s in the substation like VCB, LT, ACB, MCCB, along with the
Equipment in 132 kV substation will be controlled from the central control panel
(CCP) located in the control room.

The various substations are connected in ring main through ring network.

Substations are connected in ring main as given below:

1. Substation 8 is interconnected to substation 2
2. Substation 1 is interconnected to substation 5
3. Substation 3 is interconnected to substation 4
4. Substation 6 is interconnected to substation 7
5. Substation 7 is interconnected to substation 9
6. Substation 10 is interconnected to old factory substations
 132 kV HAL GRID DETAIL:

Incoming supply from OSEB : 132kv, 3 phase, 3 wire, 5000MVA

Distribution Voltage : 11Kv, 3 phase, 3 wire, 25Ka, Earthed
Operating voltage for Auxiliary System : 415v, 3 phase, 4 wire, 50KA
Operating Voltage for receptacles : 230 v, 1 phase AC
DC control supply : 220v
Details of equipment’s useD in 132 KV substation:

1. LIGHTNING ARRESTER:
Lightning arrester gives protection to substation equipment’s by discharging
lightning & switching over voltages to earth. It consists of a series of spark
gaps and several non-linear resistances like thyrite, metrosil, etc. A non-linear
resistor is one whose resistance is not constant but inversely proportional to
applied voltage, it decreases rapidly as the voltage across it is increased, i.e. it
has an extremely low value when the high surge voltage appears & allows the
flow of heavy currents of the order of thousands of amperes & dissipates
energy quickly & recovers again, presents a high resistance value to the
normal line voltage as soon as surge has disappeared, so that any tendency of
the arc to continue is immediately suppressed. In a system which has its
neutral solidly earthed, the rated voltage of the arrester is usually taken as
80% of its maximum line to line voltage. In an unearthed system it is taken as
100% of line-to-line voltage since under fault conditions when one line is
earthed, the arrester connected to the other two lines would be subjected to
full line-to-line potential.

Surge Counter Lighting Arrestor

 Surge Counter

Testing: -

 IR Testing between Stack to stack & between each Stack to earth by suitablemegger.
 Surge Counter Test - Apply 230V AC supply across the counter & check pointer
movement in clockwise direction.
Maintenance: -

 Insulator cleaning
 Connections tightness
 Checking of Earthing connections
 Reading of leakage current on daily basis to be taken. If current shoots in red
zone, then that particular LA is to be replaced as early as possible.

2. ISOLATOR AND EARTH SWITCH:

Isolator is the device, which makes & breaks circuits in no load condition.
Electrical Isolator Working Principle:
The working of an isolator is very simple and it can be operated in various ways
such as fully automatic, semi-automatic, or manually operated. Isolators are
sometimes used as switches that can be opened or closed based on the
requirement. But many times, isolators are used permanently in a fixed position
to keep isolation such as in electrical transmission lines, transformers, and grid
stations.
 This figure shows isolators being used as insulators in transmission lines to
Isolate transmission towers from the conductor. And here isolators are particularly
Useful in eliminating grounding loops, such as lowering the risk of accidental paths
For electric current to flow towards the ground.

Isolator switches, in particular, are used in power grids and substations to efficiently isolate very
high voltage apparatuses such as transformers and circuit-breakers when they are due for
maintenance. Commonly used isolators are not intended to stop current during a fault to eliminate
high voltage arcs, which occur due to disturbance in electric conductors. In high-voltage power
systems, isolators are used in conjunction with circuit breakers to provide an extra layer of safety.
A first circuit breaker is opened which disconnects the circuit then the isolator is also opened
And for the reverse process, the first isolator is closed then the circuit breaker is closed and the
circuit is reconnected. It can be seen that it is a physical and mechanical system. And It can be
operated manually or it can be actuated automatically. The isolators which operate manually can
be operated by using the system with up to 145 kV whereas, for high voltage systems using 245
kV otherwise 420 kV, motorized isolators are utilized.

Opening Operation of Electrical Isolator

 In the beginning, open the major circuit breaker.

 Then divide the load from a system with an isolator opening
 Close the earth switch. Earth switch can become an interlock system with an isolator.
That’s means when the isolator is open only that time earth switch can be closed.
 Closing Operation of Electrical Isolator

 Detach the earth switch.

 Shut the isolator.
 Shut the circuit breaker.

Types of Isolators:
I. Centre Break Rotating Type Isolator.
II. Double Break Rotating Type Isolator
III. Pantograph Type Isolator
IV. Tandem Isolator

Earthing Switch is provided for safety purpose to work on Dead Lines and is
Electrically & mechanically interlocked with Isolator.
Isolator Testing: -
 IR Testing – Phase to phase & Phase to earth by 5 KV megger
 Contact Resistance check - Measure contact resistance by suitable micro-ohmmeter.

Isolator Maintenance: -
A. Checking of the male / female contacts for good condition and proper connections.
B. Checking proper alignment of male & female contacts & rectify if required.
C. Cleaning of Insulators
D. Lubrication of all moving parts on regular basis
E. Tightness of all earthing connections
F. In case of Isolator with Earth switch, check electrical and mechanical interlock i.e.
Isolator can be closed only when E/switch is in open condition & vice versa.
G. As Isolators are operated on No load, hence check the interlock with Circuit Breaker, if
provided i.e. Isolators can be operated when Breaker is in OFF condition.
H. The motor operating mechanism box, in case of motor operated isolators,should be checked
for inside wiring, terminal connectors, etc.
I. Check the Panel indications i.e. semaphore & bulbs if provided (Isolator and Earth switch -
close and open condition) and rectify if required.

3. INSTRUMENT TRANSFORMERS:

These transformers are minimum oil type & hermetically sealed. They are expected to be
Maintenance free during their service life. They transform the high current or high voltage
Connected to their primary windings to the standard low values in the secondary that feed the
Metering and protection apparatus. It also isolates the secondary circuits from very high
Voltages of power system. From the application point of view, these are divided into mainly
two categories 1) Metering 2) Protection type.

Metering Type – The specified performance of CT is to be maintained in therange

Normally 5% to 120% of the rated current. The CT cores should be suchthat it saturate at
Its instrument security factor (ISF) for safeguarding the instrument from getting damaged
Under fault condition. The VT designed for metering is required to perform as specified
Within the voltage range near to the rated voltage normally 80% to 120% of the rated
Voltage.
 Protection Type – Main requirement of performance of protection class CTs is that its
cores should not getSaturated below its Accuracy Limiting Factor (ALF) up to, which the
primary current should be faithfully Transformed to the secondary, maintaining the
specified accuracy. During fault conditions, the primary of CT carvery high current and
the first few cycles of wave have the D.C. component, which may sature the core.
Behavior of the cores in such condition should be such as to avoid getting magnetized &
to come to normalcy (Demagnetized stage) soon after clearing fault.

Outdoor Type Instrument Transformer – These are used in Substations and Power stations
where high voltages are employed. While designing for their performance, following factors
should be considered.

A. Effect of atmosphere environment:-Use of porcelain insulators for external isolation

between Live and Ground. These insulators provide outer casing for allthe
atmospheric conditions like rain, dust, chemical contamination, wind, sun, etc
B. The insulation between primary & secondary windings has to be suitable for
withstanding the disturbance in the network system such as switching surges,
lightning surges, temporary over voltages, fault currents, over load currents, etc.
C. These transformers are normally oil filled with paper insulation and are hermetically
sealed to avoid ingression of moisture.

Instrument Transformer has the following major components:-

I. Primary Winding
II. Secondary Winding
III. Major Insulation
IV. Insulator
V. Transformer Oil
VI. Metal Tank

PT CT
 CT is connected in series with the supply line & PT is connected across the supply line. The
CT secondary should never be open circuited and no fuse should be inserted. In a PT the
Secondary should never be short-circuited and a fuse is used in PT secondary circuit.

Current Transformer: Types

Window CT: - This is constructed with no primary winding and is installed around the
Primary Conductor.

Bushing CT: - This is window CT specially constructed to fit around a bushing and it cannot be
Accessed.

Bar CT: - It is window CT but has a permanent bar installed as a primary conductor.

Wound CT: - This CT has a primary & secondary winding like a normal transformer. This
CT is Rare and is used at very low ratios and currents, typically in CT secondary circuits to
Compensate For low currents, to match different CT ratios in summing applications, or to
Isolate different CT Circuits.
The type of primary winding depends upon the type of CT insulation i.e. whether dead tank or
Live tank (Inverted Type) Design.

Dead Tank: - In this design, the secondary core windings are housed in metallic tank, which is
Lower part of the CT and solidly earthed. The leads of the primary winding are brought at top
Chamber for termination. The primary winding in the shape of ‘hair pin’ or ‘bolt’ is passed
Through the secondary cores and full insulation is provided on primary windings.

Live Tank (Inverted): - In such design, the secondary cores and the primary windings are
Assembled in the metal tank located at the top of the Current Transformer. Here the secondary
Cores assembly is insulated fully for high system voltage & primary winding is looped through
The core assembly. The primarywinding can be single bar primary or multi-turn primary.

Hermetically Sealing: - The Instrument Transformer is supposed to be maintenance

Free and hence there is no scope of filtering or change of oil duringits life. This makes it
Essential to hermetically seal the transformer to avoid breathing of atmospheric air.
Sealing with Metallic Bellows: - It is fitted in expansion chamber mounted at the top of the
Instrument Transformer, which separates oil with any external environment. This allows the
Expansion and contraction of oil volume, as thebellow is free to expand and contract.

Sealing by Nitrogen Cushion: - Expansion chamber on top of the CT isevacuated first

Applying vacuum and then vacuum is filled with dry Nitrogen. The chamber is then sealed
Thus avoiding breathing with outer atmosphere.

If CT and Protective devices located within same switchgear, 5 Amp secondary current is
Used. If CT lead goes out of the switchgear, 1 Amp secondary current is preferred.

Accuracy Class: - It is the rated ratio accuracy in percent.

Accuracy Limit Factor (ALF): - It is the ratio of largest value of current to CTrated
current up to which CT must retain the specified accuracy. Example: - CT - 5P20, 5 VA,
ALF = 20

It means error < 5 % up to 20 times rated current for burden of 5 VA Accuracy class

1% means max. Ratio error < 1% at rated current & burden.

CT Core Identification as per class: -

A. Class - 0.2s, 0.5s, and 1.0s: - Metering Core
B. Class - 5P10, 5P20, etc.: - Backup protection core (O/C & E/F Protection)
C. Class - PS: - Primary protection core (Differential, Distance, REF etc.)

CT Testing: -

1. IR Testing –

A. Primary to earth by 5 KV megger

B. Secondary each core to earth by 500 V megger
C. Primary to secondary by 5 KV megger
Secondary core to core by 500 V megger
 2. Polarity Test - For carrying out this test, we require one 1.5 V cell, DCanalogue
ammeter.

P1 P2

S1  S2
Analogue Ammeter
 

CELL

By making above connection, if there is positive deflection of ammeter, thenpolarity is

confirmed.

3. Ratio Test - Inject current in primary winding & measure induced secondary current
for different current readings and verify with CT Ratio.

4. Knee point check for PS class core - Inject 230 V variable AC voltage in secondary
core with ammeter in series. At certain stage, with 10% increase in voltage, current
shoots up almost 50%. This is the Knee point voltage. Afterperforming this test,
Voltage is gradually reduced to Zero to demagnetize the CT.

5. Winding Resistance Test - Measure secondary winding resistance by micro- ohm

meter.

Tan Delta Measurement – For getting concept of Tan Delta (Tan ), weconsider the
insulation of equipment as Capacitor
Ideal Ic = V/Xc

Actual Ic

Loss Angle
Xc V
 Phase Angle
 CT Maintenance: -
 Checking of Oil level & leakage, rectify the same immediately.
 Checking of Insulation Resistance.
 Power connection tightness.
 Secondary connection tightness.
 Cleaning of Bushings / Insulators.
 Check the proper earthing of Body connection.
 Check the earthing of CT Secondary core star points.
 Check the working of stainless steel bellows.
 Check the nitrogen pressure in case of Nitrogen filled CT.

Potential Transformer: - There are two types of PTs as mentioned below:

Electromagnetic Voltage Transformer – Its construction largely depends on the rated

Primary voltage. Primary & secondary windings are wound on magnetic core like in usual
Transformer. For voltages up to 3.3 KV, dry type transformer with varnish impregnated taped
Winding is quite satisfactory. For higher voltages, it is a practice to immerse the core and
Winding in oil. It is used up to 66 KV level.

Capacitor Voltage Transformer – For voltages above 66 KV, CVT is used. It consists of a
Capacitive potential divider & inductive medium voltage circuit. Primary voltage is applied
To a series capacitor group. The voltage across intermediate capacitor is taken to primary of
Auxiliary voltage transformer. The secondary of auxiliary voltage transformer is taken for
Measurement or protection. The inductive part is immersed in oil and sealed with an air
Cushion inside a steel tank. Fuses are provided in secondary box. Voltage Factor of PT is
Maximum system voltage, PT can withstand & is expressed in % i.e.120% continuous &
150% for 30 seconds.

PT Testing: -

IR Testing –
A. Primary to earth by 5 KV megger
B. Secondary each core to earth by 500 V megger
C. Primary to secondary by 5 KV megger
D. Secondary core to core by 500 V megger.

Ratio Test - Inject A.C. variable voltage in primary winding & measure induced secondary
voltage at different voltages & verify the same with PTR.

PT Maintenance: -
 Checking of oil level & leakage, rectify the same immediately.
 Checking of Insulation Resistance.
 Power connection tightness.
 Secondary connection tightness.
 Cleaning of Bushings / Insulators.
 Check the proper earthing of Body connection.
 Check the secondary fuse condition & replace if required by proper rating.
 Check the working of stainless steel bellows.
 Check the nitrogen pressure in case of Nitrogen filled PT.

4. BUSBARS:
 A metallic strip or bar, typically housed inside switchgear, panel boards, and
bus way for local high current power distribution. They are also used to connect
high voltage equipment at electrical switchyards, and low voltage equipment in
battery banks.

 Rating: 11 KV, 2000A, 25 KA , 1 sec – copper bus

11 KV, 1500A, 25 KA, 1 sec – copper bus

 Standard: IS-5082

5. Circuit breakers:
Circuit Breaker is used to close or isolate the circuit in normal and abnormal condition and to
Protect the electrical equipment against the fault. The parts of a circuit breaker include –
1) Poles with interrupter, support porcelain, arc quenching medium, etc.
2) Operating mechanism
3) Support structure
4) Control circuit
 SF6 Circuit Breaker

The part of the breakers assembled in one phase is called a pole. A circuitbreaker suitable
for three-phase system is called a triple pole circuit breaker. Allthe three poles operate
simultaneously. Each pole comprises one or more interrupters or arc quenching chambers. The
interrupter is mounted on support insulators. The interrupter encloses a pair of fixed and
moving contact. The moving contact can be drawn apart by means of the operating
mechanism. The operating mechanism gives the necessary energy for opening and closing of
contacts of the breakers. The arc produced by the separation of current carrying contacts is
extinguished by a suitable medium.

When a fault occurs in the protected circuit, the relay connected to the CT actuates and closes
its contacts. D.C. current flows from the source in the trip circuit. As the trip coil of the breaker
is energized, the circuit breaker operating mechanism is actuated & it operates for the opening
operation automatically. The spring in the operating mechanism is charged by electrically or
manually. Breaker auxiliary switches are mechanically attached with the operating mechanism
ofbreaker. The contact changeover takes place as per breaker operation. Auxiliary contacts are
used for breaker operation circuit, indication circuit, and trip circuit supervision circuit.

The Circuit breakers are classified on the basis of arc extinction medium:

1) Bulk Oil type

2) Minimum Oil type
3) Air Blast type
4) SF6 Gas type
5) Vacuum type
 In short, difference of individual breaker is listed below:

1) Bulk Oil Circuit Breaker – Contacts are separated inside a steel tank filledwith
transformer
Oil used for arc quenching.

2) Minimum Oil Circuit Breaker – Contacts are separated in an insulated housing

(interrupter)
Filled with transformer oil used for arc quenching. In the caseof MOCBs after certain number of
Tripping, oil is to be replaced as recommendedby the manufacturer. After 2 to 3 times of oil
Replacement, or after certain numbers of serious faults, it is necessary to overhaul the complete
Breaker.

3) Air Blast Circuit Breaker – It utilizes high-pressure compressed air for arc extinction.

4) SF6 Gas Circuit Breaker – Sulphur-Hexa-fluoride gas is used for arc extinction in this
breaker. It is must to monitor the SF6 gas pressure inside the breaker pole and check
periodically the contact Resistance of each pole or the travel of eachpole. This is helpful
to prevent the problem of bursting of poles. The SF6 breaker has an advantage that the rate of
restricting voltage is zero & hence the burning of male / female contacts is less. Operating
mechanism is of two types:
Movement of contacts is controlled by spring mechanism. (Spring Operated)
Movement of contacts is controlled by air pressure. (Pneumatic operated)

5) Vacuum Circuit Breaker – In this breaker, the contacts are housed inside a permanently
sealed vacuum interrupter. The arc is quenched as the contacts are separated in high vacuum.
For VCBs, the vacuum bottle is hermetically sealed and as such no maintenance is required.
However to ascertain the failure ofvacuum bottle, it is necessary to check the contact resistance
of each pole or the travel of each pole as specified by the manufacture. VCBs are generally
used upto 33 KV voltage systems.
Definition of Some Common Terms related with
Circuit Breaker
Fault clearing time – It is the time elapsed between the instant of the occurrence of a fault
And the instant of final arc extinction in the circuit breaker. It is the sum of relay time and
Breaker time.

Relay time – It is the time elapsed between the instant of occurrence of fault & the instant of
Closure Of relay contacts, i.e. closure of trip circuit.

Breaker time – It is the time elapsed between the instant of closure of tripcircuit and the
instant of Final current zero.

Anti-Pumping of a circuit breaker – It blocks the repeat closing pulse when breaker is already
In Closed condition.

Auto- reclosing of a circuit breaker – Auto-reclosing is provided to restore the supply after
Interrupting a transient fault on overhead lines.

Rated short circuit breaking current – It is the highest value of short circuit current, which
A Circuit breaker is capable of breaking under specified conditionsof recovery voltage and
Power Frequency recovery voltage.

Rated short circuit making current – It may so happen that circuit breakermay close on
Existing fault. The circuit breaker should be able to close without hesitation as contact touch. The
Rated short circuit making current should be atleast 2.5 times the R.M.S. value of a.c. component
of rated breaking current.

Operating sequence of a circuit breaker – The operating sequence denotes the sequence
Of Opening and closing operations, which the circuit breaker can perform under specified
conditions. The operating mechanism experiences severe mechanical stresses during the
auto-reclosure duty.

O-t-CO-T-CO where O = opening operation, C = closing operation, CO = closing followed

By Opening, t = 0.3 second for breaker to be used for rapid auto- reclosure, T = 3 minute.

CO-t’-CO where t’ = 15 seconds for breaker not to be used for rapid auto- reclosure.
 Maintenance of Circuit Breaker
i. Tightness of power connections & control wiring connections
ii. Cleaning of Insulators
iii. Lubrication of moving parts
iv. Checking of contact resistance, close-open timing, Insulation resistance
v. Checking of gas pressure for SF6 circuit breaker (leakages if any)
vi. Checking of air pressure for pneumatic operated breaker (leakages if any)
vii. Checking of Controls, Interlocks & Protections like checking of pole discrepancysystem
i.e. whether all three poles are getting ON – OFF at the same time
viii. Cleaning of Auxiliary switches by CTC or CRC spray and checking its operation

 MCCB (Molded Case Circuit Breaker):-

 Description & Function:

 MCCBs are Molded Case Circuit Breaker, with protection facilities of over
current, earth fault.

 It has a variable range of 50% to 100% operating current.

 Used for application related with large power flow requirement.

 Types Of MCCB:

 SP – Single Pole
 SPN – Single Pole and Neutral
 DP – Double Pole
 TP – Triple Pole
 TPN – Triple Pole and Neutral
 4P – Four Pole

 MCB (Miniature Circuit Breaker) :

 Description & Function :

 The main function of an MCB is to switch the circuit, to open the circuit
automatically when the current passing through it exceeds the value for which
it is set.
  Types Of MCB:

1) On the basis of no. of poles :

 SP – Single Pole
 SPN – Single Pole and Neutral
 DP – Double Pole
 TP – Triple Pole
 TPN – Triple Pole and Neutral
 4P – Four Pole
Type Tripping Current Operating Current
Type B 3 to 5 time full load current 0.04 to 13 sec
Type C 5 to 10 times full load current 0.04 to 5 sec
Type D 10 to 20 times full load current 0.04 to 3 sec

Reason SF6 circuit breaker is used now a days:

SF6 circuit breakers are mainly used for the protection of very high voltage circuits up to 800
kV from fault current. it can safely break and depower a high voltage circuit for any kind of
inspection or maintenance. Each interrupter unit is capable of handling 60 kA in the range of
80 kV.

6. RELAY:

Relay is a device by which electrical circuit is indirectly controlled during a fault condition.
The purpose of relay is to operate the correct circuit breaker, so as to disconnect only the faulty
Equipment from the system as quickly as possible, thus minimizing the trouble and damage
Caused by faults when they do occur.
There are only four main parts in a relay. They are:
1. Electromagnet
2. Movable Armature
3. Switch Point Contacts
4. Spring
Types of Relay:

1) Over Current relay

2) Inverse definite minimum time relay
3) Distance relay
4) Current differential protection relay
5) Directional relay

• Overcurrent relay: An overcurrent relay is a type of protective relay which

operates when the load current exceeds a pickup value.
• It is of two types: instantaneous over current (IOC) relay and definite time
overcurrent (DTOC) relay

Over current relay

• Inverse definite minimum time relay: IDMT relay is inverse definite

minimum time relay. It is one in which Time of operation is inversely
proportional to magnitude of fault current near pickup value and
becomes substantially constant slightly above the pick up value of the
relay
 Inverse definite minimum time relay

• Distance relay: A distance relay is a type of protection relay most

often used for transmission line protection. Distance relays measure
the impedance from the installation side to the fault location and operates
in response to changes in the ratio of measured current and voltage.

Distance Relay

• Current differential protection relay: Directional overcurrent

relays respond to excessive current flow in a particular direction in
the power system. The relay typically consists of two elements. One is a
directional element, which determines the direction of current flow with
respect to a voltage reference.

Current differential protection relay

 • Directional relay: The relay whose operation depends on the phase
difference of two or more electrical quantities is known as the
differential protection relay. It works on the principle of comparison
between the phase angle and the magnitude of the same electrical
quantities

Directional relay

7. Transformer:

Transformer is one of the most important equipment’s in a power transmission and

distribution system. It does stepping up or stepping down the voltage and transfer
power from one A.C. voltage to another A.C. Voltage at the same frequency.
Transformer has Primary & Secondary windings housed in main tank filled with
insulated oil. Oil is used for providing insulation as well as cooling of windings.

 The capacity of Transformer is expressed in Volt-ampere (KVA / MVA)

 The transformation ratio K (constant) = Vs/Vp = Ns/Np
Where Vp, Np denote primary voltage & turns respectively. And Vs, Ns
denotesecondary voltage & turns respectively.
If K > 1, then transformer is called step-up transformer
If K < 1, then transformer is called step-down
transformerFor an ideal transformer, Input VA = Output VA
i.e. Vp x Ip = Vs x Is or Is/Ip = Vp/Vs = 1/K (where Ip & Is are Primary and secondary
current respectively). Hence currents are in the inverse ratio of the (voltage) transformation
ratio.
To calculate current of Primary & Secondary winding of 132 / 33 KV, 50 MVA
Transformer:-
a) Primary Current in amp = Ip = VA / √3 x Vp, where Vp & Ip are primary voltageand
current respectively.
Hence Ip = (50 x 10*6) / (√3 x 132 x 10*3) = 218.69 Amp
b) Secondary Current = Is = VA / √3 x Vs, where Vs & Is are secondary voltageand
current respectively.
Hence Is = (50 x 10*6) / (√3 x 33 x 10*3) = 874.77 Amp

 The three main constructional parts of a transformer are :

1. Primary winding of transformer: which provides magnetic flux when it is

connected to electrical source.

2. Magnetic core of transformer: The magnetic flux produced by the primary winding,
that will pass through this low reluctance path linked with secondary winding and
create a closed magnetic circuit.
3. Secondary Winding: The flux, produced by primary winding, passes through the
core, will link with the secondary winding. This winding also wounds on the same
core and gives the desired output of the transformer.

 Types Of transformer :

Step up & Step down transformer:

 Generally used for stepping up and down the voltage level of power in
transmission & distribution power system network.

1. Three phase transformer &single phase transformer –

 Former is generally used in three phase power system it is cost effective

than later. But when size matter, it is preferable to use a bank of three
single phase transformer as it is easier to transport than one single three
phase transformer unit.

2. Two winding transformer and auto transformer –

 Former is generally is used where ratio between high voltage &low

voltage is greater than 2. It is cost effective to use later where the ratio
Between high voltage and low voltage is less than 2.

3. Outdoor transformer & indoor transformer-

 Transformer that are designed for installing at outdoor are outdoor

transformers & Transformer that are designed for installing at indoor are
indoor transformers.

4. Oil cooled and dry type transformer-

 In oil cooled transformer the cooling medium is transformer oil where as

in dry type transformer is air cooled.

5. Core type, shell type & berry type transformer-

 Core type transformer- it has two vertical legs with two horizontal
section named yoke. Core is rectangular in shape with a common
magnetic circuit. Cylindrical coils (HV&LV) are placed on both the legs.

 Shell type transformer- it has a central limb and two outer limbs. Both
HV, LV coils are placed on the central limb. Double magnetic circuit is
present.
  Berry type transformer- the core looks like spokes of wheels. Tightly
fitted metal sheet tanks are used for housing this type of transformer with
transformer oil filled inside.

 POWER TRANSFORMER –

 Rating – 25 MVA , 132 KV/11 KV

 Cooling type – ONAN (oil natural & air natural )

 Tap change @ step - +5% to -15% @ 1.25%

 Make – ALSTOM

 Standard- IS-2026

Details of items used in power transformer

1. Bushings –

 Description & function :

o An insulated device that allows an electrical conductor to pass safely

through a grounded conducting barrier such as the case of a transformer.
o It is made up of porcelain material.
 HV BUSHING :

 Rating : 145 kv/800A

 Make : ALSTOM

 LV BUSHING :

 Rating : 17.5 kv/2000A

 Make: CJI

2. ON LOAD TAP CHANGER :

 Description & function :

o A mechanism in transformer which allows for variable turn ratios

to be selected in discrete steps.
 Rating : V III 200
 Make : Easun MR

3. BUCHHOLZ RELAY :

 Description & function:

o A type of oil & gas actuated protection relay universally used on

all oil immersed transformers having rating more than 500 KV.
 Rating : GOR-3
 Make : ALVUS

4. RADIATOR:

 Description & function :

o A type of oil and gas actuated protection relay universally used on

all oil immersed transformers having rating more than 500 KV.

 Rating : 2400*520*26
 Make : Gururaj
5. MAGNETIC OIL LEVEL GAUGE:

 Description & function :

o Used to indicate the position of the transformer insulating oil level

in conservator of transformer.

 Rating : 150mm
 Make : Atvus

6. WINDING TEMPERATURE INDICATOR :

 Description & function :

o Used to indicate the temperature of winding of transformer.

 Rating : 0 to 150 degree C

 Make : PRECI

7. OIL TEMPERATURE INDICATOR :

 Description & function:

o Used to indicate the temperature of oil in conservator of

transformer.
 Rating : 0 to 150 degree C
 Make : PRECI

8. SILICA GEL BREATHER :

 Description & function:

o Most commonly used way of filtering air from moisture

o Connected with conservator tank by mains of breathing pipe.

 Rating : D2O-7
 Make : YOGYA

9. PRESSURE RELIEF VALVE :

 Description & function:

In the case of sudden & uncontrolled increase in pressure inside

the transformer, the pressure relief device allows the discharge of
insulating fluid in millisecond time facilitating the decrease of
The pressure.
 Rating : T-6
 Make : ATVUS

10. LV (WITH C.T):

 Rating: 1312/1.75A
 Make: A.U.

11.LV NEUTRAL C.T. :

 Rating: 1500/1A, 200/1A

 Make: A.U.

12.TRANSFORMER OIL:

 Description & function :

o Have high dielectric strength, thermal conductivity &

chemical stability.
o Its primary function are to insulate & cool the transformer.

 Rating: N/A
 Make: SAVITA

13.FAN:

 Function :

o For cooling purpose of transformer.

 STATION TRANSFORMER:

 Rating : 315 KVA, 11KV/ .433KV

 Cooling type : ONAN (oil natural &air natural)
 Make: ALSTOM
 Standard : IS-2026

8. Diesel genset:
 Description & function:

o Diesel generator is the combination of diesel engine with

an electric generator to generate electrical energy.
 o Used in places without connection to a power grid or as
emergency supply if grid fails.

 Rating : 500KVA,415V,696A,50 HZ ,3 phase

 Make:

o Diesel engine : Cummins

o Alternator : Stamford
 Ambient temperature : 40 degree C
 Excitation : 48 V , 2.3 A
 Power factor : 0.80
 Rpm : 1500
 Standard : IS-4722

9. Battery charger :

 Description & function:

o A device used to put energy into a secondary cell by forcing

an electric current through it.
 Type : 220 TP 30A float cum boost charger
 Rating : 220V ,30A
 AC input voltage: 415V , 3 phase-4wire system
 Make : HBLNIFE
 Unit : 2

Concept of power factor

 In electrical engineering, the power factor of an AC power system is defined
as the ratio of the real power absorbed by the load to the apparent
power flowing in the circuit, & is a dimensionless number in closed interval of
-1 to 1.
  Mathematically, S2 = P2 + Q2, and the electrical power factor is active power
/ apparent power.

 Lagging & Leading Power Factors

 Causes of Low Power Factor :

1) Inductive load: The current drawn by inductive loads is lagging and results in low pf.
2) Variations in power system loading: When the system is loaded lightly, the voltage
increases and the current drawn by the machines also increases. This results in low power
factor.
3) Harmonic Currents: The presence of harmonic currents in the system also reduces the
power factor. In some cases, due to improper wiring or electrical accidents, a condition
known as 3-ϕ power imbalance occurs. This results in low power factor too.
  Disadvantages and Effects of Low Power Factor:

1) Large Line Losses (Copper Losses): the larger the current, the greater the line
losses.
2) Large kVA rating and Size of Electrical Equipment: Power factor is inversely
proportional to the kVA i.e.
CosФ = kW / kVA
Therefore, The Lower the Power factor, the larger the kVA rating of Machines also, the larger the
kVA rating of Machines, The larger the Size of Machines and The Larger the size of Machines, The
Larger the Cost of machines.
3) Greater Conductor Size and Cost: In case of low power factor, current will be
increased, thus, to transmit this high current, we need the larger size of conductor.
Also, the cost of a large size of conductor will be increased.
4) Poor Voltage Regulation and Large Voltage Drop: In case of Low Power Factor
(lagging Power factor) there would be large voltage drop which causes low voltage
regulation.
5) Low Efficiency: In case of low Power Factor, there would be large voltage drop and
large line losses and this will cause the system or equipment efficiency too low.
6) Penalty from Electric Power Supply Company on Low Power factor: Electrical
Power supply Company imposes a penalty of power factor below 0.95 lagging in
Electric power bill. So you must improve Pf above 0.95.

There are three main ways to improve power factor:

 Capacitor Banks
 Synchronous Condensers
 Phase Advancers

 Capacitor Banks: Improving power factor means reducing the phase

difference between voltage and current. Since the majority of loads are of
inductive nature, they require some amount of reactive power for them to
function. A capacitor or bank of capacitors installed parallel to the load
provides this reactive power. They act as a source of local reactive power,
and thus less reactive power flows through the line. Capacitor banks
reduce the phase difference between the voltage and current

 Synchronous Condensers: Synchronous condensers are 3 phase

synchronous motors with no load attached to their shaft. The synchronous
motor has the characteristics of operating under any power factor leading,
lagging, or unity depending upon the excitation. For inductive loads, a
synchronous condenser is connected towards the load side and is overexcited.
 Phase Advancers: This is an AC exciter mainly used to improve the PF of
an induction motor. They are mounted on the shaft of the motor and are
connected to the rotor circuit of the motor. It improves the power factor by
providing the exciting ampere turns to produce the required flux at the given
slip frequency. Further, if ampere-turns increase, it can be made to operate at
the leading power factor.
 Method adapted in SED:
 By use of APFC (Capacitor Bank)

 Automatic power factor correction panel in 132KV substation:

 Type: cubicle

 Steps: 6(9000+500+400+200+100)

 Rating: 3000 KVAR

 Rated system voltage, line current: 12.65 KV, 136.92A

 Connection of capacitor bank: Star
  DETAILS OF COMPONENTS USED IN APFC PANEL:

NAME OF THE RATINGS MAKE QTY

COMPONENT

VCB 11KV ABB 1

VCB E/FO/L/RELAY AVANA 1

PROCTECTION
RELAY

APFC RELAY BR5008, POWER EPCOS 1

FACTOR
EPCOS
Vacuum contactor 12kV, 400A 5
EPCOS
Reactor 6% CU wound reactor 5
EPCOS
RC surge capacitor 3 phase, c: 0.1 6
MFD/phase,3.3/6.6/11kv

Capacitor 225kVAR ELETRONICON 8

ELETRONICON
250kVAR 2
ELETRONICON
200kVAR 3
ELETRONICON
100kVAR 1
 DETAILS OF INSTALLATIONS USED IN SED:

NAME NAME OF HANGAR TRANSFORMERS APFC NO OF HT

OF S/S PANEL BREAKER
NAME KVA (KVAR)

S/S-01 HANGAR -101 D-5192 2000 600 08

(compressor, blade, turbine D-5192
shop) 2000 600
D-5192
1000 N/A
D-5192
315 N/A
S/S-02 HANGAR -102 (GEAR &,
CNC shop) D-5201 2000 600 06

D-5190 1000 N/A

N/A
D-5321 1000
N/A
D-5258 0315
S/S-03 HANGAR -103
(ELECTROPLATING D-5197 2000 600 07
SHOP)
D-5198 2000 600

D-5196 2000 600

D-5260 315 N/A

S/S-04 HANGAR -103(HEAT
TREATMENT Shop) D-5196 2000 600 07

D-5200 2000 600

D-5199 2000 600

D-5193 2000 600

S/S-05 HANGAR -104(FUEL &
SMALL PART D-5587 2000 600 06
ASSEMBLY RIG ROOM)
D-5590 2000 600

D-5535 2000 600

S/S-06 HANGAR -105
(WELDING SHOP) D-5693 2000 600 06
 D-5612 1000 300

D-5636 315 N/A

S/S-07 HANGAR -105 (SHEET
METAL shop) D-5592 2000 600 06

D-5594 2000 600

D-5620 1000 300

S/S-08 COMPRESSOR,AC
PLANT D- 2000 600 09

D- 2000 600
s/s 09 Overhaul shop
D-7946 2000 600 07

D-7947 2000 600

D-7548 2000 600

D-7445 315 N/A

132 KV SWITCHYARD COMPRISING OF:

 25 MVA ,132/11 KV transformer with OLT C/RTCC

 132 KV , 25KA , 400 A SF6 circuit breaker
 132 KV ,800 A double breaker isolator
 132KV/110V potential transformer
 132KV current transformer
 120 KV lighting arrester
 Earth mast
 ACSR conductor ,tension isolator
 Earthing & lighting protection for yard and control room
 11KV , 1600A copper bus duct
 315 KVA transformer
 Station battery
 Earth electrodes
 Earth conductors
 25 MVA, 132/11KV transmission remote tap changer control panel

 132 KV line control & relay panel

 HT panel

 Apex metering panel

 25 MVA,132/11kv transmission remote tap changer control panel:

 Tap position indicator

 Voltmeter
 Sequence selector switch
 Tap changer supply switch
 OLTC control selector
 Automatic voltage regulating relay

 132 KV line control & relay panel :

 Trivector meter

 Type : E3M051, 3 phase, 4 wire

(MWh, MVArh , MVAh, MVA)

 Relay (LBB, high speed, no volt, DC supervision)

 Breaker control switch
 MiCOM P-127 (O/C & E/F protection relay )

 25MVA, 132/11KV transformer control & relay panel :

 Breaker control switch

 Relay
 Diff. protn. (MiCOM P-632),standby earth fault ,DC suppression ,high
speed tripping , BKR (52-2) TC -1 suppression ,BKR (52-2) TC-2
suppression, auxiliary

 HT PANEL:

 HT panel comprises of:

 Relay (MiCOM, trip, auxiliary )
 Vacuum circuit breaker
 Multi-function meter
 Current transformer
 Potential transformer
 Panel Panel no. Rating MAKE standard
Incomer(from 1,16 11kv,1600A, 3 ALSTOM IS-2705
transformer ) phase ,50Hz
Incomer(from 2,9,15 11kv,800A, 3 phase - -
,50Hz
CPP)
Bus coupler 11 11kv,1600A, 3 - -
phase ,50Hz
Bus trunk 12 - - -
SED 3,7-10,13- 11kv,1200A, 3 - -
phase ,50Hz
Substations 15,17,20
feeder
Spare feeder 4,21,22,23 11kv,1200A, 3 - -
phase ,50Hz
ED feeder 5,6,18 11kv,1200A, 3 - -
phase ,50Hz
Station 24 11kv,1200A, 3 - -
phase ,50Hz
transformer
feeder

11KV SUBSTATION DETAILS:

Incoming system voltage: 11KV, 3 phase, 3 wire, earthed system

System fault level : 350 MVA
Operating voltage for power: 415V, 3 phase, 4 wire, 50 kA
Operating voltage for lighting: 230 V, single phase, AC
Design ambient temperature: 45 degree Celsius

11KV SUBSTATION COMPRISING OF :

 11KV & 6.6KV panels

 HT ,LT, auxiliary cables
 Power transformer
 Lighting transformer
 LT bus duct
 Main LT panels
 Lighting panels
 APFC panels
 Distributions board

 HT PANEL:
 VCB for incomer and ring feeder
 2000kVA transformer
 1000kVA transformer
  315 kVA transformer for lighting purpose

 Micom P122, P127 relay

 LT PANEL :

 Air circuit breaker (ACB)

 Molded case circuit breaker (MCCB)
 Micom P122 relay

 SUBSTATION AUXILIARIES:

 Sub switch boards

 Distribution boards
 Rush button station
 Earthing system

 AUXILIARY EQUIPMENTS USED IN 132KV SUBSTATION:

1) Diesel generator set

2) Lighting transformer
3) Lighting
4) Battery charger
5) DC Panel

 A flat , often vertical, area where control instrumentation for DC

supply is mounted.
 Make : Vintech
 DC panel comprises of :

Instrument Type Rating Used for

MCCB TP 630A Incomer

MCCP TP 63A CRP, DCDB, Tr.

MARSH. Box, HT
Panel, Auxiliary
Panel, Apex Meter,
Substations –
1,2,5,6
 6) LSB PANEL:

 Make : Vintech
 LSB panel comprise of:

Instrument Type Rating Used for

MCCB TP 100A Incomer from

Auxiliary panel
Incomer from AMF
panel
MCCB TPN 32A Ext LDB, LDB
Apex meter , street
light

7) ACDB PANEL:

 Make : Vintech
 ACDB panel comprises of :

Instrument Type Rating Used for

MCCB TP 100A Incomer

MCB TP 32A Various

Applications

8) AUXILIARY PANEL:

 Auxiliary panel comprises of :

Instrument Type Rating Used for

MCCB TPN 250A Battery Charger,
PBDC(AC)
MCCB TPN 200A Capacitor bank
MCCB TP 100A LSB , Gas store
MCCB TPN 32A ACDB
ACB (Air TPN 800A Incomer
Circuit Breaker)
 9) AMF PANEL :

 Make : VINTECH

10) FAULT LOCATING SYSTEM:

 Make: MEGGER

o Emergency preparedness at 123kV substation:

i. Firefighting system
ii. Oil pit oil drain system

METHOD TO VERIFY THE CORRECT OPERATION OF THE PROTECTION SYSTEM:

1. Primary injection Testing: In this method a pulse of current is applied to the

primary side of CT. This test is done to check the proper functioning of the relays
circuit breakers installed in the circuit & the CT /VT ratio, polarity & phasing.
2. Secondary injection testing: In this method a pulse of current is applied to the
secondary side of CT. this test is done to check the proper functioning of the relays,
Circuit breakers installed in circuit.

 TARIFF PLAN BY WHICH HAL IS PAYING ELECTRICITY BILL:

 Tariff: large industry

 Contract demand : 15445 KVA
 Meter side : HT
 Energy charges for factory consumption: @ RS 5.80/KWH
 Energy charges for colony consumption : @ RS 4.80/KWH
 Demand charges : @RS 250/KVA
 Electricity duty : 9%
 SOLAR POWER PLANT

Solar energy is the radiation from the Sun capable of producing heat, causing
chemical reactions, or generating electricity. The total amount of solar energy
received on Earth is vastly more than the world's current and anticipated energy
requirements. If suitably harnessed, solar energy has the potential to satisfy all
future energy needs.

Solar energy is commonly used for solar water heaters and house heating. The
heat from solar ponds enables the production of chemicals, food, textiles, warm
greenhouses, swimming pools, and livestock buildings. Cooking and providing a
power source for electronic devices can also be achieved by using solar energy.

The most common devices used to collect solar energy and convert it to thermal
energy are flat-plate collectors. Another method of thermal energy conversion is
found in solar ponds, which are bodies of salt water designed to collect and store
solar energy. Solar radiation may also be converted directly into electricity by
solar cells, or photovoltaic cells, or harnessed to cook food in specially designed
solar ovens, which typically concentrate sunlight from over a wide area to a
central point.

1st Generation Solar Panels

These are the traditional types of solar panels made of monocrystalline silicon or
Polysilicon and are most commonly used in conventional surroundings.

Monocrystalline Solar Panels (Mono-SI)

This type of solar panels (made of monocrystalline silicon) is the purest one. You can
easily recognise them from the uniform dark look and the rounded edges. The silicon’s
high Purity causes this type of solar panel has one of the highest efficiency rates, with the
newest Ones reaching above 20%.

Monocrystalline panels have a high power output, occupy less space, and last the
longest. Of course, that also means they are the most expensive of the bunch. Another
advantage to consider is that they tend to be slightly less affected by high temperatures
compared to polycrystalline panels.

Monocrystalline panels
Polycrystalline Solar Panels (Poly-SI)

You can quickly distinguish these panels because this type of solar panels has squares, its
angles are not cut, and it has a blue, speckled look. They are made by melting raw silicon,
which is a faster and cheaper process than that used for monocrystalline panels.

This leads to a lower final price but also lower efficiency (around 15%), lower space
efficiency, and a shorter lifespan since they are affected by hot temperatures to a greater
degree. However, the differences between mono- and polycrystalline types of solar panels
are not so significant and the choice will strongly depend on your specific situation. The first
option offers a slightly higher space efficiency at a slightly higher price but power outputs
are basically the same.

Polycrystalline Solar Panels

2nd Generation Solar Panels

These cells are different types of thin film solar cells and are mainly used for
photovoltaic power stations, integrated in buildings or smaller solar systems .

Thin-Film Solar Cells (TFSC)

If you are looking for a less expensive option, you might want to look into thin-film. Thin-
film solar panels are manufactured by placing one or more films of photovoltaic material
(such as silicon, cadmium or copper) onto a substrate. These types of solar panels are
the easiest to produce and economies of scale make them cheaper than the alternatives due
to less material being needed for its production.

They are also flexible—which opens a lot of opportunities for alternative applications—
and is less affected by high temperatures. The main issue is that they take up a lot of space,
generally making them unsuitable for residential installations. Moreover, they carry
the shortest warranties because their lifespan is shorter than the mono- and polycrystalline
types of solar panels. However, they can be a good option to choose among the different
types of solar panels where a lot of space is available.

Thin-Film Solar Cells (TFSC)

Amorphous Silicon Solar Cell (A-Si)

Have you ever used a solar powered pocket calculator? Yes? Then you have definitely seen
these types of solar panels before. The amorphous silicon solar cell is among the different
types of solar panels, the one that is used mainly in such pocket calculators. This type of
solar panel uses a triple layered technology, which is the best of the thin film variety.

Just to give a brief impression of what “thin” means, in this case, we’re talking about a
thickness of 1 micrometre (one millionth of a metre). With only 7% efficiency rate, these
cells are less effective than crystalline silicon ones—that have an efficiency rate of circa
18%—but the advantage is the fact that the A-Si-Cells are relatively low in cost.

3rd Generation Solar Panels

3rd generation solar panels include a variety of thin film technologies but most of them are
still in the research or development phase. Some of them generate electricity by using
organic materials, others use inorganic substances (CdTe for instance).

Bio hybrid Solar Cell

The Bio hybrid solar cell is one of the types of solar panels that is still in the research phase.
It has been discovered by an expert team at Vanderbilt University. The idea behind the new
technology is to take advantage of the photosystem 1 and thus emulate the natural process
of photosynthesis. In case you want to learn more about how the bio hybrid solar cell works
in detail, read more about it in the American Journal of Optics and Photonics. It explains
more detailed how these cells work. Many of the materials being used in this cell are similar
to the traditional methods, but only by combining the multiple layers of photosystem 1, the
conversion from chemical to electrical energy becomes much more effective (up to 1000
times more efficient than 1st generation types of solar panels).

Cadmium Telluride Solar Cell (CdTe)

Among the collection of different types of solar panels, this photovoltaic technique
uses Cadmium Telluride, which enables the production of solar cells at relatively low cost
and thus a shorter payback time (less than a year). Of all solar energy technologies, this is
the one requiring the least amount of water for production. Keeping the short energy payback
time in mind, CdTe solar cells will keep your carbon footprint as low as possible. The only
disadvantage of using Cadmium Telluride is its characteristic of being toxic, if ingested or
inhaled. In Europe especially, this is one of the greatest barriers to overcome, as many people
are very concerned about using the technology behind this type of solar panel.
 Concentrated PV Cell (CVP and HCVP)

Concentrated PV cells generate electrical energy just as conventional photovoltaic systems

do. Those multi-junction types of solar panels have an efficiency rate up to 41%, which,
among all photovoltaic systems, is the highest so far.

The name of such CVP cells is related to what makes them so efficient, compared to other
types of solar panels: curved mirror surfaces, lenses and sometimes even cooling
systems are used to bundle the sun rays and thus increase their efficiency.

By this means, CVP cells have become one of the most efficient solar panels, with a high
performance and efficiency rate of up to 41%. What remains is the fact, that such CVP solar
panels can only be as efficient if they face the sun in a perfect angle. In order to reach such
high efficiency rates, a solar tracker inside the solar panel is responsible for following the
sun.

Type of panel used in HAL setup

 Polycrystalline Solar Panels (Poly-SI)

Why are Polycrystalline Solar Cells so Popular?

Polycrystalline (sometimes also called multi crystalline) solar panels are the most common
because they are often the least expensive. They are the middle choice in the marketplace ...
almost as good as single cell monocrystalline silicon panels but generally with a better
efficiency than thin film solar panels.

Polycrystalline cells can be recognized by a visible grain, a “metal flake effect”. The solar
cells are generally square in shape, and may have a surface that looks somewhat like a
mosaic. That’s because of all the different crystals that make up the module.
 Benefits of Polycrystalline Solar Panels
1. Lower per Panel Costs are much simpler to produce, and cost far less
to manufacture. This makes them much less expensive for buyers,
especially those with small to medium sized roofs.
2. Durability and Longevity The durability and longevity are comparable
to their monocrystalline cousins – namely at least 25 years.
Polycrystalline solar panel modules could put solar power into the hands
of people who could not afford the polycrystalline cells.

3. Environmental Enhancements Besides being able to produce energy

from the sun and thus help reduce greenhouse gases and related
environmental problems of extracting fossil fuels (e.g., the BP oil spill,
coal mining accidents, geo-political resource wars, etc.), some
polycrystalline solar panel manufacturers (e.g., Mitsubishi) go the extra
mile by inventing new technologies that eliminate expensive soldering
(which also contains lead) making these panels even more
environmentally friendly.

4. Lower Electric Bills any solar system can and probably will result in a
lower electricity bill. Even though the amount of electricity produced
from a polycrystalline solar panel is less than from a monocrystalline
panel – so are the costs … so you have to fine tune your analysis to see
which one has the better payback over the time frame of your analysis
(e.g., 20 years in Europe – which is usually the time period of the Feed in
Tariffs).

Efficiency:
Generally speaking, polycrystalline panels have an efficiency that is about 70% to 80% of a
comparable monocrystalline solar panel. The most efficient polycrystalline panels are built
by Mitsubishi Electric Corporation. In February 2010, Mitsubishi set two world records for
photoelectric conversion efficiency in polycrystalline silicon photovoltaic (PV) cells, which
was achieved by reducing resistive loss in the cells. The conversion efficiency rates have
been confirmed by the National Institute of Advanced Industrial Science and Technology
(AIST), in Japan.

Another one of the world records, which Mitsubishi Electric has now renewed for the third
consecutive year, is a 19.3-percent efficiency rating for photoelectric conversion of a
practically-sized polycrystalline silicon PV cell of 100 squared centimetres or larger, with
the PV cell measuring approximately 15cm x 15cm x 200 micrometres. The rating is 0.2
points higher than the company's previous record of 19.1 percent.
The second world record, achieved with the same technologies in an ultra-thin
polycrystalline silicon PV cell measuring approximately 15cm x 15cm x 100 micrometres, is
an efficiency rating of 18.1 percent, a 0.7-point improvement over the company's previous
record of 17.4 percent.

Currently the solar industry is investing lots of money in research and development to find
ways to increase manufacturing costs and boost overall efficiency of the solar modules. As
you can see from the work done by Mitsubishi, these improvements are primarily
incremental in nature and are more on the manufacturing side than on the efficiency side.

Current Market Overview

The current market for solar PV is dominated by crystalline silicon (c-Si) solar panels
(around 80%), and c-Si solar technology is expected to continue to dominate in the
residential and commercial rooftop markets due to higher efficiency and rapidly reducing
costs.

There has been a 40% price reduction since the middle of 2009, largely as a result of the
improved supply of polysilicon, which is the basis of c-Si-based panels. When supply was
constrained by limited production of polysilicon, the price reached over $300/kg. Now, the
cost has fallen to below $100/kg and supplies are readily available for mass production —
driving a continuing decline in panel prices.

Lower cost c-Si panels support a key goal for solar known as grid parity, where it costs the
same to generate power on their rooftops as it does to buy it from the grid. This point has
already been reached during the peak demand period. According to the European
Photovoltaic Technology Platform group, solar PV is expected to reach grid parity in most
of Europe over the next 10 years.

In HAL off - Grid solar system is used for saving & backup purpose. An off-grid solar
power plant is a battery-based solar power system. In this type of solar system, there are
solar panels, solar inverter, and solar battery. This system will run your home appliances
or connected load (as per solar inverter capacity) by using solar power. The unconsumed
or surplus power will be stored in the solar battery bank. An off-grid solar power system is
recommended where power cuts are the major problem. In HAL solar power plant the
power generated is 6MW and is transferred to 132/11 KV substation through underground
cables to the feeder.
 CONCLUSION

Electric power plays a vital role to run any industry. We studied about the power supply &
distribution in Sukhoi Engine Division, Hindustan Aeronautics Limited, Koraput. During the
Study we visit the 132 KV & 11 KV substations in SED and study about various equipment’s
Such as power transformer, isolator, protective relay , instrument transformer, APFC panel,
circuit breakers etc. We also studied about tariff plan by which HAL is paying electricity bill,
emergency preparedness, method to verify the correct operation of the protection system. In
protection system , study of coordination of protective relay is beyond of our scope.