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Work experience report

Submitted under the partial fulfillment of M.Sc. Electrical Power
Engineering program requirement


Employer: Essar Projects (India) Limited.
Work Duration: June 2010 August 2012
Name: Utsav Bhupendrakumar, Gonawala
Mat Nr: 1824450
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Table of Contents
i List of abbreviations 3
1 Introduction of Essar 4
2 Induction at Essar 5
3 Flow chart: My work flow at Essar 6
4 OJT: On Job Training. 7
5 Electrification of Air and Nitrogen generation units 8
6 Electrification of Waste water treatment plant: RO plant. 10
7 Billing and Contracts engineer. 11
8 Summary 12


























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i List of abbreviations

AGU: Air Generation Unit

B&C: Billing and Contracts

BLDC: Brushless Direct Current

EMCC- Emergency Motor Control Center

EOT- Electrically Operated and Traversed

FSNL: Full Speed No Load

GCB- Generator Circuit Breaker

GET- Graduate Engineer Trainee

HOD- Head Of Department.

HT- High Tension

HVAC- Heat Ventilating Air Conditioning

IPBD- Insulated Phase Bus Ducts

LT- Low Tension

MCC- Motor Control Center

MMTPA- Million Metric Tons Per Annum

MV- Medium Voltage

NGU: Nitrogen Generation Unit

OJT- On Job Training

PMCC- Power Motor Control Center

RO- Reverse Osmosis

SFRA- Swipe Frequency Response Analysis

UPS- Uninterrupted Power Supply

WWTP: Waste Water Treatment Plant


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1 Introduction of Essar

Essar is a multinational corporation with annual revenues of US$39 billion and investments in
Steel, Energy, Infrastructure and Services. With operations in more than 25 countries, it
employs over 73,000 people. It has following business verticals:
Essar Steel
Essar Minerals
Essar Oil
Essar Power
Essar Projects
Essar shipping
Aegis (BPO)
Essar Communications
Equinox Reality

Some of Essar projects (delivered and ongoing):

Over 2500 MW of multi-fuel power generation capacity
Almost 10,000 MW of multi-fuel power generation capacity under execution
20 MMTPA capacity refinery with a Nelson Complexity Index of 11.8
10 MMTPA integrated steel plant capacity
26 MMTPA pelletisation capacity
16 MMTPA of beneficiation capacity
2,200 MW of multi-fuel power generation capacity
4,500 MW multi-fuel power generation under execution
6,000 km of multi-use and cross-country pipelines
Marine berths for vessels of 40,000 to 180,000 DWT capacity
Dry and liquid bulk cargo handling berths
Erection and refurbishment of offshore platforms

From the above mentioned projects, I worked for Essar projects business. It had many projects
going on inside India and across India as well. I was the part of highlighted project 20 MMTPA
capacity refinery with a Nelson Complexity Index of 11.8








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2 Induction at Essar
As an electrical engineering graduate I was recruited as Graduate Engineer Trainee (GET) at
Essar. The Induction program was conducted in the month of June 2010. During this program
I was made aware of the Essar business group, its business verticals, its mission statements
and its history. Under this program I was equipped with various training like 5S, Lean
Management, Six Sigma, Global Development Program, Corporate etiquettes and
Document Management. With the help of such training it was an easy transition from an
engineering student to a corporate engineering employ. Some excerpts of the trainings are as
follows:

5S Training:
5S is short for: Sort, Set in Order, Shine, Standardize and Sustain
5S represents 5 disciplines for maintaining a visual workplace (visual controls and information
systems). These are foundational to Kaizen (continuous improvement) and a manufacturing
strategy based "Lean Manufacturing" (waste removing) concepts. 5S is one of the activities
that will help ensure our companys survival.

1. Sort - All unneeded tools, parts and supplies are removed from the area.
2. Set in Order - A place for everything and everything is in its place.
3. Shine - The area is cleaned as the work is performed.
4. Standardize - Cleaning and identification methods are consistently applied.
5. Sustain - 5S is a habit and is continually improved.

Six Sigma
Six sigma is a structured, data driven methodology for eliminating waste from processes,
products and other business activities while having a positive impact on financial performance.
It is mainly about studying a process, dividing it into sub processes and finding out the time for
each process and their interdependences. Finally with all this data, these processes are operated
in most optimum way to be finished in less time producing more output at a cheaper price by
reducing human and machine efforts needed. It also puts effort on reducing any waste and loss
of time.

After a about a months training, I was placed in Essar Projects business vertical, which further
deployed me in a Essar oil refinery expansion project at Jamnagar, Gujarat. This was a refinery
expansion project which would revamp the old refinery and expand its production from 14
MMTPA to 20 MMTPA (Million Metric Tonne Per Annum). After a short visit to the refinery
and its expansion plans, I was given an assignment of assisting testing and commissioning of a
power plant as my OJT (On Job Training).


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3 Flow chart: My work flow at Essar



Figure1: Flow chart for the work done and learnings at Essar.









Induction
June 2010
Learnings: Corporate profile of Essar, Six Sigma, Lean
management, corporate etiquettes and documentation.
OJT
July 2010 - Dec 2010
Learnings: Control scheme of generator protection, MOV, No load
trial runs, FSNL ,GCB and BLDC excitation of generator etc.
AGU and
NGU
Jan 2011 - July 2011
Learnings: Erecetion and testing of various electrical systems,
EOT cranes commissioning, Installing grounding grid etc.
WWTP
July 2011 - Jan 2012
Learnings: Battery charging, Grounding in corrosive areas, inter-
departmental co-operation etc.
B&C
Feb 2012 - Aug 2012
Learnings: SAP for project management, Billing, Contract
preparation, Contract closing, Reconciliation etc
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4 OJT: On Job Training.
After completion of my induction period, I was assigned to assist the testing and
commissioning of a 2x110 MW gas based captive power plant. I was designated as Assistant
Manager, Electrical Department, Essar Projects (India) limited, Jamnagar. I have done following
tasks in the run of this OJT at power plant.

I assisted the testing and commissioning team for testing of GCB (Generator Circuit
Breaker). In this testing, first of all loop checking of all control and protection circuit was
carried out. After positive results the GCB was first manually closed at no load and then
an artificial earth fault is created. Sensing this fault the GCB will open and disconnect the
generator from the output. The closing voltage and current waveforms are studied to
confirm the time for fault clearance.
I was responsible for conducting No load test for all the drives in the power plant like
Auxiliary oil pump, compressor fan drive, lube oil pump, fresh air inlet pump etc. No
load test would be conducted for 4 hours with a reading of current, voltage, temperature
at driving and non-driving end. Also the No load input surge current in measured. From
this I learned that possible reasons for motor driving high currents could be that the rortor
is mechanically jammed and has to be lubricated, the input from cable at termination box
inside the motor is shorted and sometimes when the motor runs in reverse direction then
then the termination order has to be made in reverse order.

This work experience on OJT and then as an Assistant manager taught me that along with the
technical knowledge experience with electrical equipment is equally important when it comes
to trouble shooting.





















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5 Electrification of Air and Nitrogen generation units

After about six months of testing and commissioning at power plant the power plant was fully
functional and then I was given a new assignment. My new assignment was to electrify Air and
Nitrogen generation units of refinery expansion. This also included electrification of an electrical
substation which feeds to these units.

Air generation unit had 4x1.6MW (HT motors-6.6 kV) Induction motors with forced air cooling.
It also had an over-head EOT crane (Electrically operated and traversed) of 12 ton capacity.
Nitrogen generation unit had around 15 drives. The electrical substation feeding these two units
had two 33kV incoming feeders. This would step down to 6.6 kV. MV panels will be charged by
this voltage and would contain vacuum circuit breakers feeding to 1.6 MW drives. Further, this
6.6 kV would step down to 400V with distribution transformer. The distribution transformer will
feed to low voltage induction drives through the panel called PMCC (Power Motor Control
Centers). The lighting system will be electrified using a lighting transformer. I was the only
electrical engineer in charge for all these units and substations.

The works accomplished by me under this assignment are as under:
1. Electrifying a utility substation for refinery.
Erected, tested and commissioned an MV switchgear 19 verticals (6.6kV).
Erected, tested and commissioned a PMCC, MCC and EMCC.
Erected, tested and commissioned a DC UPS (10kVA) and AC UPS (80kVA).
Erected, tested and commissioned two Power transformer (25/31.5MVA), two
distribution transformer (2.5MVA)
Coordinating with vendors for erection and commissioning of firefighting energen
system from Tyco fire, Pressurization system from Almonard, EOT crane from
Konne cranes, HVAC system from bluestar etc.
Executing lighting system, earthing system and lightning protection system.

2. Erection, testing and commissioning of air and nitrogen generation utility units.
Electrification of 4 HT motors (1.6 MW) and 150 LT motors.
Execution of earthing and lighting system.
Completed sixty kms of cable laying and respective glanding and terminations.

I also did various necessary on-site tests to be performed on a transformer before it could be
commissioned. These tests are mentioned below:

Insulation resistant measurement test
-Input side
-Output side
Winding resistance measurement test
-Input side
-Output side
Magnetic current test
Magnetic balance test:

-R Phase open:
1V-1W= 1U-1V+ 1U-1W

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-Y Phase open:
1U-1W= 1U-1V+ 1W-1V
-B Phase open:
1U-1V = 1U-1W + 1V-1W

Vector group test:

1.1U-2N=1U-1N+1N-2N

2.1W-2V=1V-2W

3. 1V-2V<1V-2W

4.1W-2W<1W-2V

Where, 1U, IV and 1W are the three phase windings of primary side of
transformer.
And 2U, 2V and 2W are the three phase windings of the secondary side of
transformer.

Turns ratio test
Tan test for bushing
Short circuit test
SFRA test

First I have observed all these tests and then I have also performed them on the transformers of
my substations. With this I gained a lot of valuable experience of testing transformers.

One important fact that I would like to point here is that, once there was a load test by third party
scheduled for EOT crane. Somehow the crane would not work and the testing company was
furious as their time was being wasted. We didnt have the EOT manufacturers Konne cranes
engineers with us at that time. I took a call to see for the problem by myself and try to correct it. I
had to climb up to the control panel of the EOT crane on the top. I checked the control circuit of
the EOT and tried to compare it with the diagram step by step. After around 30 minutes I found
that there was a problem with the limit switch and a contactor. I made the necessary changes,
then the crane started working and cleared the test. For this, I was commended by HOD of my
department and by the HOD of the client as well.

This assignment lasted for around 6 months. As it was my first assignment, I made some
mistakes but then even I learned from them. It taught me that how important it is to do insulation
test of cables after laying and before backfilling the trench. I learned about minimum clearances
required between bus-bars, inside the panels. This was the first time that I worked with IPBD and
understood the reason for installing them which is its maintenance free life. I learned about the
importance of earthing system for a sub-station. The resistance of all the earth pits in parallel
should be less than 10 under any condition. If not then various measures like adding salt and
water to soil, increase the amount of fine sand and removing big gravels and putting more earth-
pits in parallel have to be implemented.




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6 Electrification of Waste water treatment plant: RO plant.

Around July 2011, I finished my previous assignment and I was given my next assignment. At
this time almost all the units of refinery were commissioned but waste water treatment plant. I
was assigned for the electrification of this plant and its respective substation. Particularly, as this
task was last for the refinery there was a huge pressure on me to finish it very fast. The plant had
around 100 LT motors and the substation design was almost same as the previous one.

The works accomplished by me under this assignment are as under:
1. Electrifying a utility substation for electrifying waste water treatment plant.
Erected, tested and commissioned a PMCC, MCC and EMCC.
Erected, tested and commissioned a DC UPS (6 kVA), AC UPS (20 kVA).
Executing lighting system, earthing system and lightning protection system.

2. Erection, testing and commissioning of air and nitrogen generation utility units.
Electrification of 4 HT motors (1.6 MW) and 150 LT motors.
Execution of earthing and lighting system.
Completed sixty kms of cable laying and respective glanding and terminations.

Amongst many things that I learned under this assignment one is first time battery bank charging.
Normally all electrical substations have a UPS and a back-up battery system. This battery backup
will supply power through inverter in case of mains power failure. It will not supply power to
whole substation and plant but only to most important loads. Emergency lightings, computer
supplies, lube oil pumps etc. After electrolyte is being filled in battery bank, battery bank has to
be 2 times completely charged and discharged. For this initial charging purpose, 5 times faster
charging has to be performed. To do that inverter was setup as constant current source that will
supply 5 times the rated charging current of battery bank. For discharging purpose, it is very
difficult and uneconomical to find a big load bank, therefore we used a water barrel with added
salt in it. This would act as water filled resistor load. Normally even with five times faster
charging, it would need 2 complete days to charge the whole battery bank completely. Care has
to be taken during this period that temperature of the electrolyte doesnt go beyond 50 C. Hence
every hour the temperature would be noted for safety reasons.

The most important thing that I learned from this assignment was to work under pressure. It was
very much necessary to co-ordinate with civil, chemical and mechanical department so that I can
do get my work done at a faster rate. Because of this assignment I learned the importance of
interdisciplinary co-operation. It was really interesting to see that there were some motors which
cant be stopped even if there is an under voltage fault as it would affect the operation very
badly. So these motors were given a logic which would allow them to work even with low input
voltage to some extent. The liquids in the plants were of very corrosive nature so to [prevent
earthing strips from getting corroded was a challenge here. As a reason, we used Bitumen paint
on the earthing strips wherever there was a welded joint.




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7 Billing and Contracts engineer.

When the project was nearing its end, it was really important to clear the pending bills of the
work done by contractors so that Essar could close their work orders and show officially to
government that the expansion work is over on time. Meeting the dead line was important as
otherwise it would have cost the companies extra penalties from banks which provided loans for
the project. After I finished my last assignment, I was assigned as in-charge for clearing electrical
bills, doing reconciliations for all the vendors and then for the whole electrical project. It was
really a challenging job for me. But with my field experience I was very quick in finding the
wrong and extra claims by contractors in bills. For this reason, I was made in-charge for bills and
reconciliation of all department bills.

There was one incident with a bill for fire retardant paint. While I was checking the bill, I found
some extra and wrong claims. Through SAP I got data of total surface area painted, them from
the data sheet I calculated the required paint for that. After these calculations, I could reduce the
bill amount by 70 million INR (approx. 1 million Euro). For this work I was rewarded by the
HOD of the respective department for saving companies money.
With this work of reconciliations, I learned professional used of SAP and also learned about the
commercial side of the project business. With this assignment, I have now an estimate of the
price and installation cost and time of all the electrical systems and hence it helps me plan my
work in more economical and optimum way.





























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8 Summary

With a very good and exhaustive orientation followed by induction program with a couple of
trainings I made a kick start of my engineering career with a multinational company called Essar.
In accordance with my capabilities which would have been targeted during the induction, I was
selected as an execution engineer for Essar Projects (India) limited, Jamnagar.

The management at Essar, Jamnagar decided to turn our probation period to on the job training
and with that I was titled as Assistant Manager, Electrical department, Essar Projects (India)
Limited, Jamnagar. As my first task on job training, I was assigned to assist the testing and
commissioning of all electrical systems of the captive power plant for the refinery expansion
project. In my works at power plant I learned the testing methods for all electrical systems at
power plant. I also learned the order of commissioning for different systems in a power plant.
With an opportunity to test motors, I did no load trials of all electrical drives at power plant.

First individual assignment was to electrify Air and Nitrogen generation facility and it feeding
electrical substation. Starting right from drilling earth pits in ground making grounding grid to
lighting system, panel erection with installation, cable laying, terminations of cable, transformer
installations and lightning protection was performed under my supervision. Along with this I also
did erection, testing and commissioning of 12 ton overhead EOT crane in air generation facility.
Also had a first experience with erection and commissioning of a large induction motor of 1.6
MW.

After the commissioning of these units, I was assigned with the electrification of waste water
treatment plant and its feeding substation. Most of the work was same as in previous assignment
but had to be completed in a very short time. Due to lack of time I had to work in tight co-
ordination with other departments such as civil, mechanical, chemical etc. This taught me the
importance of inter departmental harmony. The challenge here was to do grounding grid but with
proper corrosion protection.

Finally after having enough of technical experience of project business I was lucky enough to see
the commercial side of this business, I was placed in Billing and Contracts department. The most
important thing that I learned here was the reconciliation. This is very important for a project
engineer and a manager.

Over all with this work experience of two years and two months, I had abundance of hands on
experience of most of the electrical equipment. This helped me realize what I have studied in my
Bachelors of Electrical Engineering for 4 years. Apart from a practical experience I also acquired
managerial skills. I had to manage a team of 50 people including technicians, mechanics, labors
etc. along with resource management for Hydra, Cranes and trucks for shifting materials. Over
all I learned the importance of preplanning the tasks, anticipating the machine and man power
along with time required for any task. This made me a better manager.