TRAINING PROGRAM ON ELECTRICAL SAFETY

FOR OPERATION & MAINTENANCE OFFICERS

AT
M/S HINDUSTAN PETROLEUM CORP LTD
MDI-NIGDI-PUNE (MAHARASTRA)

COVERING

•MAIN INCOMING SUPPLY FROM ELECTRICITY BOARD & OVERVIEW

•HIGH VOLTAGE 2POLE /4 POLE/6 POLE STRUCTURES & ITS FENCING
•HIGH VOLTAGE VACUUM CIRCUIT BREAKERS & INTRUPTERS
•HIGH VOLTAGE TRANSFORMERS & THERIR PROTECTION SYSTEM
•415 VOLTS POWER CONTROL & MOTOR CONTROL CENTRES
•415VOLTS POWER FACTOR CORRECTION PANELS & HARMONICS
•415VOLTS DIESEL GENERATOR SETS & THEIR AUTO MAIN FAILURE
•FLP MOTORS-STARTERS-PUSH BUTTON STATIONS & JUNCTION BOX’S
•POWER & CONTROL CABLES & THEIR FLP TERMINATIONS & GLANDING
•EARTHING SYSTEM-STATIC CHARGE-LIGHTNING -SURGES & CONTROL
• ELECTRICAL ACCIDENTS & CASE STUDIES
• LOCK-OUT/TAG-OUT FOR ALL POWER SOURCES

FACULTY ASSISTANCE
BY
HETCO CONSULTANTS

EXECUTIVE OFFICE: C8/18, MIG FLATS KESHAVPURAM DELHI-110035

 (2)

SL CONTENTS Page From To

01 01 01
FRONT PAGE COVERING
02 02 02
CONTENTS PAGE COVERING
03 03 03
LETTER TO THE SR.DEPOT MANAGER (RAJBANDH)
03 OBJECTIVES OF THE ELECTRICAL AUDIT 04 04
04 04
EXECUTIVE SUMMARYWITH MAIN POINTS AT A GLANCE
05 - 13
DETAILED AUDIT REPORT WITH OBSERVATIONS &
RECOMMENDATIONS FOR CORRECTIVE/RECTIFICATION
ACTION
06 ANNEXURE-1 14 -
TEST REPORT ON ADEQUACY OF EARTHING SYSTEM AS
PER IERULE-61-67(5B), IS: 2309 & IS: 3043
07 ANNEXURE-II - 24
PIPE EARTHING ELECTRODE DESIGN AS PER IS; 3043-1987
ANNEXURE-III - -
PLATE EARTHING ELECTRODE DESIGN AS PER IS: 3043-
1987
08 ANNEXURE-IV 25 -
ELECTRICAL SAFETY AUDIT CHECK LIST AS PER OISD-
STANDARD-137-145 &244
09 STANDARD PROTECTION CO-ORDINATION CHART AS PER - 48
IS : 13947
- 49 50
-
- 51
 (3)

 IT’S A MATTER OF GREAT PLEASURE FOR M/S HETCO CONSULTANTS, NEW DELHI
AND ITS FACULTY MEMBERS TO BE HERE AMONGST YOU THIS MORNING ON THE
OCCASION OF TRAINING PROGRAMME ON ELECTRICAL SAFETY

 THE AIM OF THIS TRAINING PROGRAMME IS TO PROVIDE GOOD

UNDERSTANDING & IDENTIFICATION OF HAZARDS ASSOCIATED WITH THE
ELECTRICAL JOBS

 TO PROVIDE CLEAR UNDERSTANDING OF THE SAFE WAY TO PERFORM THE

ELECTRICAL JOBS

 TO EVOKE CORRECT & PROMPT RESPONSE IN ANY EMERGENCY SITUATION

 TO PROVIDED AWARENESS & SERIOUSNESS TOWARDS THE ELECTRICAL SAFETY IN

PETROLEUM INDUSTRY TO PREVENT RISK OF ELECTRICAL FIRE

 THE CONCEPT AND IDEAS PRESENTED IN THIS TRAINING COURSE ARE

EXPRESSED THROUGH STATEMENTS AND
DIAGRAMS AS WELL

 WE, M/S HETCO CONSULTANTS & ITS FACULTY MEMBERS ARE THANKFUL TO M/S
HINDUSTAN PETROLEUM CORP. LTD, FOR GIVING US THE OPPORTUNITY TO SHARE
OUR EXPERIENCE AND EXPERTISE WITH THE PARTICIPATING ENGINEERS AND
OFFICERS

IN THE END,WE HOPE THAT THE PARTICIPANTS OF THIS TRAINING PROGRAMME
WILL HAVE AN INFLUENTIAL AND REWARDING EXPERIENCE

THANKS
BASANT SEDHA & HARPREET KAUR
M/S HETCO CONSULTANTS NEW –DELHI-35
 1.0: INTRODUCTION ON ELECTRICAL SAFETY IN
1.0PETROLEUM INDUSTRYPREFACE

SAFE WORKING ON ELECTRICAL EQUIPMENT

Electricity in petroleum industry constitutes one of the major source of ignition for fire
Accidents & explosion ,where classified hazardous atmosphere is normally encountered

 In so far 50% of fires losses are due to electrical faults like short circuit-protection not
operated in a stipulated time lag-overloading on wires and cables –Load not balanced
equally on all 3-phases & the Neutral

 Besides equipment damage and property loses, electrical hazards also include injuries
and fatalities to personnel due to electrical shock
 Further the reliability of any electrical service depends ultimately upon the Practical
ability of the Electrical Maintenance Staff and the technical Know How which they
have acquired

Efficiency & the safety in electrical system can not be attained until & Unless the
Operations & Maintenance team is fully conversant with their Electrical System, allied
Protection and know the reason behind Maintenance Instructions

So, there is a huge requirement for such Practical Training Programs for each
Personnel dealing with Electrical works and become accountable for the Operations
and maintenance of the electrical equipment under their Supervision

 We hope that all the Engineers & Officers will Welcome this course and join us in
making this Training Program successful
  2.0:ELECTRICAL HAZARDS & SAFETY RULES
AS PER IE RULE-29-(1-2&3) OF CHAPTER-IV
PAGE-17

 MAJOR ELECTRICAL HAZARDS ASSOCIATED WITH PETROLEUM

INUSTRIES ARE GIVEN AS UNDER:
 Inadequate design of electrical system

 Exposed electrical parts-improper electrical maintenance

 Low or defective insulation of the cables & wires (less than 5 Mega-ohms in HT
And 1-mega-ohm in LT distribution system as per I.E.RULE-48(I-II & III) of page 27 &28

 Improper grounding - Loose wiring & not tightened firmly

 Over loading of wires cables & motors- (No equal load sharing on all 3-phases & Neutral)

 Higher rating of protection relays & fuses- (Not complied with IS:13947)

 RECOMMENDED ELECTRICAL SAFETY RULES SHALL BE FOLLOWED

 Do not renew a blown fuse until you are satisfied as to be the cause and have rectified
the irregularity

 Do not close any switch unless you are familiar with the circuit which it controls & know
the reason for its being open/Switch off
 Do not touch or temper with any electrical gear/conductor unless you have made sure that
it is “DEAD & EARTHED”

 Do not work on or near the live circuit without wearing the hand gloves suitable for working
potential of double the rated voltage & accompanied & companied by a second person to
render “FIRST AID & RESPIRATION”

 Do not disconnect “EARTHING CONNECTIONS” or render ineffective the safety gadgets

installed on mains & apparatus

 Do not open or close switch or fuses slowly do it quickly and positively to prevent risk of spark

 Always use proper fuse puller with Ebonite handle ---Do not use any other tool for pulling out
the fuses incase in case any of them is blown out

 Always ensure that the ‘ON & OFF’ operation of all the main switches & the feeders on the
PMCC or other areas shall be made only when the front cover of the particular feeder is
in locked condition to prevent risk of spark coming out of the same in case of fault

 Do not use wires or the cables with poor insulation (Less than 5-Mega-ohms in case of HT
And 1-Mega-ohm in the case of LT distribution as per IERULE-48(I-II &III) of page 27&28 therein

 Do not touch any electrical circuits when your hands are wet or bleeding from a cut or an
abrasion

 Do not disconnect a plug by pulling the wire or the cable when switch is ON-it may cause
Short-circuit if two wires neutral & phase touches together

 Do not use fire extinguisher on electrical equipment unless it is clearly marked for that
purpose---use dry sand instead

 Do not throw water on live electrical equipment in case fire –use dry sand or CO2
FIRE EXTINGUISHERS suitable for quenching the electrical fires

 Do not attempt to discharge a person in contact with a live part/apparatus which you cannot
switch off immediately insulate your self from earth by standing on rubber mat or dry woo
standing on rubber mat or dry board before attempting to get him/her clear
Do not Touch his body push him/her clear with a piece of dry wood

 Do not test circuits with bare hands-use proper multi meter or the voltmeter
for testing---Using hand lamp with lamp in open is not permitted

 Use proper Fuse/MCB/MPCB/ELCB @ 1.5 times the actual load measured

with tong tester & in any case shall not exceed the cable current rating
 3.0: OVERVIEW OF AN ELECTRICAL SYSTEM AT OIL
INDSUTRIES WITH INCOMING SUPPLY FROM THE
STATE ELECTRICITY BOAD TO PLANT

III 7-DGN

10

11

LEGEND
1-HT POWER FROM EB TO HT-AIR BREAK SWITCH
2-DROP-OUT FUSES ON HT AIR BREAK SWITCH
3-HT VACUUM CIRCUIT BREAKER IN HT ROOM
4-HT TRANSFORMER LIQUID OR DRY TYPE
5-LT AIR CIRCUIT BREAKER ON MAIN PMCC
6-COMMON BUS BAR EB & STAND BY DG
7-STAND BY DG NEUTRAL EARTH
12 8-STAND BY DG SET IN DG ROOM
9-POWER CABLE FROM DG TO CONTROL PANEL
10-DG CONTROL PANEL IN DG ROOM
11-ELECTRICAL/MECHENICAL INTERLOCKING
12- OUTGOING LOAD FEEDERS TO THE LOCATION
 4.0: HIGH VOLTAGE DOUBLE POLE STRUCTURE WITH
LIGHTNING ARRESTORS ON THE TOP OF THE STRUCTURE –
HT JUMPERS-DROP-OUT FUSES & AIR BREAK SWITCH

RED YELLOW BLUE PHASES LA’S

HT DISC TYPE INSULATORS
STEEL STRUCTURE

DANGER
BOARD HT JUMPERS DANGER
BOARD
DROP-OUT FUSES

HT CABLE
RED YELLOW BLUE
AB SWITCH

 HIGH VOLTAGE 4 POLE & 6 POLE COMBINE STRUCTURE

LIGHTNING ARRESTORS

JUMPERS FOR FIXED & MOVING CONTACTS

HT POWER LOOPING
DROP-OUT FUSES

AIR BREAK SWITCH

HT CABLES & PROTECTION PIPE

FENCING
 FIXED & MOVING CONTACTS OF HIGH VOLTAGE AIR BREAK SWITCH

MECH-SURGE INTERRUPTER

HIGH VOLTAGE HIGH VOLTAGE MOVING CONTACT

FIXED CONTACT

HIGH VOLTAGE INSULATOR

BASE CHANEL

 HIGH VOLTAGE DROP-OUT FUSE ASSEMBLY OF AIR BREAK SWITCH

HIGH VOLTAGE
INCOMING TERMINAL DROP-OUT FUSE ASSEMBLY

LATCHING POINT
HT BASE INSULATOR

DROP-OUT FUSE

HIGH VOLTAGE OUT GOING TERMINAL

  3-POLE HIGH VOLTAGE AIR-BREAK SWITCH ASSEMBLY

MOVING CONTACT BLUE PHASE

HT TERMINAL
FIXED
CONTACTS YELLOW PHASE

RED PHASE

BASE ASSEMBLY

 PREVENTIVE MAINTENANCE & TROUBLE SHOOTING ON 2-POLE

4-POLE-6-POLE STRUCTURE & AIR-BREAK SWITCH

 MAINTENANC SCHEDULE
 QUARTERLY
____________________________________________________________
 Check for proper operation of the air-break switch after wearing
hand gloves rated for double the HT working potential & ensure that
no spark should come out during on & off operation of the same
 Checking tightness of all earth & Power connections
 Cleaning of grass or vegetation from the switch yard
 HALF YEARLY
Checking tightness of all incoming & outgoing HT connections after
taking HT Isolation permit & shutdown from high voltage structure
Cleaning of male and female contacts ---apply petroleum jelly on the
same-Checking of earth resistance values by using earth tester 0-10
Ohms range—it should not exceed 2 ohms for individual electrode
-One ohm for the combined grid & one ohm for continuity up to each
equipment to comply with IERULE-61 & IS: 3043-1987 therein
 YEARLY
Check for any crack in all the insulators only after taking complete
shut down-checking of Insulation resistance value of AB switch & the
HT cables by using insulation tester it shall not be less than 5Mega
-Ohms as per Indian electricity rule number-48 (1)(iii) of page 27&28
 5.0 : HIGH VOLTAGE LOAD BREAK SWITCH
SF6 HEXAFLORIDE GAS TYPE

12.0:OFF
LOAD CUT HT LOAD BREAK SWITCH BOARD A SUBSITUTE FOR
SWITCH
HT 2/4/6 POLE STRUCTURE

DIRECT LOAD BREAK SWITCH FOR TRANSFORMER

HT CABLE

 HIGH VOLTAGE LOAD BREK SWITCH IN OPEN VIEW

ALARM SW

HT FUSES

HT CABLE BOX
 Load break switch receives the power from EB & delivers the
same to the transformer through HT VCB or even direct for
converting the HT to LT-415 volts for running plant equipment

 MAINTENANCE & TROUBLE SHOOTING ON

HIGH VOLTAGE LOAD BREAK SWITCH
 MONTHLY:
General cleaning of the load break switch cubical by using blower
only after taking work permit & shut down of EB power
 QUARTERLY:
 Check tightness of all earth and power connections only after work
permit and the shut down of EB power
 Greasing &oiling of all mechanical parts of the load break switch
 HALF YEALY:
 Checking of trip mechanism of the load break switch &indicators
Check tightness of all earth and power connections after work permit
And shut down of EB power
 YEARLY:
 Complete checking of protection relays- Fuse failure switch-Check
terminations-Insulation resistance of HT cables with Meggar1KV-2.5KV
it shall not be less than 5-Mega-ohms if low check for cause-earth
resistance shall be tested with earth tester & not exceed 1-ohm

 TROUBLE SHOOTING ON H T LOAD BREAK SWITCH

 NATURE OF PROBLEM
 LBS- switch though-On---but “ FUSE FAILURE ALRM” persists
 POSSIBLE CAUSE & REMEDY
Fuse failure switch remain close –put the same in normally open
 NATURE OF PROBLEM
 LBS-As soon as switched on---giving trip alarm but LBS still On
 POSSIBLE CAUSE & REMEDY
 Trip alarm relay may be faulty giving false alarm—check & rectify
 NATURE OF PROBLEM
 LBS stops blowing one fuse & no power in all three phases
 POSSIBLE CAUSE & REMEDY
 Isolate the particular phase –check insulation resistance of the
cable by using insulation tester 1000-2500v- if shows more than
5-mega-ohm cable is-ok-further check the insulation resistance of
The load break switch if shows ‘0’ value then the problem is in LBS
rectify the same by giving proper insulation cushion to the same
 6.0: FENCINIG AROUND HIGH VOLTAGE SWITCH
YARD AS PER IERULE 68(b) OF PAGE-47

BONDING

WELDED MESH WITH PROPER EARTH CONTINUITY ALL ROUND

PVC INSULATED MATS GAP

EARTHING STRIP 25x3mm

PVC COATED TYPE FENCING

Fencing though looking a very simple item but it plays a great role for
preventing an unauthorized entry to the high voltage switch yard or to
the transformer yard
 As per Indian electricity rule number-68(b) of page 47 the fencing shall
be 1.8 meter height & shall be earthed
 MAINTENANCE & TROUBLE SHOOTING ON THE FENCING
 DURING PROJECT TIME
 During installation of new fencing it shall be ensured that the fencing
around the High voltage switch yard shall be provided with continuous
thick welded mesh but definitely not with broken contact type/PVC coated
As shown in figure -2 above
 Ensure that the earth connections to the fencing shall be provided by
using GI strip of at least 25x3mm & the flexible bonding shall be provided
on the main opening doors by using flexible green earth wire of at least
10 sq mm size with 2-lugs at both ends of said earth wire therein
 YEARLY
 Earth continuity test on the fencing shall be carried out by using earth
tester 0-10-ohms range only-- but definitely not the multi meter in any
case & the earth resistance value shall not exceed “one ohm”
 Bottom portion of the fencing left open shall be covered by four side
masonry wall provided around the same to prevent entry of Cats & Dogs
 Area inside & outside the fencing shall be kept clean all the time.
growth of Dry grass or vegetation shall be prevented by providing PCC
flooring in slope And then providing the crushed stones of at least 40 mm
size as per IS:2517 & 2518 to maintain discontinuity & to prevent crawling
of snakes therein
 Ensure that the gate of the fencing shall be opened “ OUTWARD” only to
ensure easy opening in case of emergency to comply with IERULE-29
 Ensure that the key of the main entrance door shall be kept in the key
board and the key number shall also be painted near the door lock of the
same also
 Ensure that the “DANGER BOARD “ in HINDI or ENGLISH and the local
language of the district with a sign of skull and bones of the rated voltage
Shall be affixed on the fencing to comply with IERULE-35 of page-20
 TROUBLE SHOOTING ON THE FENCING AROUND HT SWITCH YARD
_______________________________________________________________
 NATURE OF PROBLEM
The main entrance door not opening and closing properly locking not
possible
 POSSIBLE CAUSE & REMEDY
 May be jammed -Oil or greasing the opening and closing mechanism of
the same & make it free for easy opening/closing & locking of the same
therein
7.0: HIGH VOLTAGE CIRCUIT BREAKER WITH ALARM & TRIPPING
ARRANGEMENT THROUGH : EARTH FAULT-OVER CURRENT- HIGH
OILTEMPERATURE- HIGH WINDINGTEMPERATURE & THE –
BUCHHOLZ RELAY OF THE TRANSFORMER
  HIGH VOLTAGE VACUUM CIRCUIT BREAKER is used for
receiving the power from state electricity board & then to the
transformer for converting the HT power to the LT power to 415V
for running the plant equipment & the lighting

INDICATION LAMPS

MULTI FUNCTIONAL METER

FAULT ANNUNCIATOR

AMMETER & SELECTOR SWITCH

INSPECTION COVER

MAIN VCB (VACUUM CIRCUIT BREAKER TROLLY

 HIGH VOLTAGE VACUUM CIRCUIT BREAKER WITH
iiiiiii

BOTTLES –INSULATORS-FIXED & MOVING CONTACTS

INSULATORS

VCB VACUUM BOTTLES

 HOW THE VACUUM BOTTLES WORKS

 PREVENTIVE MAINTENANCE & TROUBLE SHOOTING ON
THE HIGH VOLTAGE VACUUM CIRCUIT BREAKER

 MONTHLY
 General cleaning of the VCB panel by using blower only after
taking work permit & shut down of main EB power
 Checking all indications for proper functioning & not blown
 QUARTERLY
Checking of all protection coordination by simulating the same
Checking for alarm and trip sequences through transformer
protection by simulating the OTI-WTI-BUCHHOLZ ALARM & TRIP
 HALF YEARLY
Checking of alarm and trip sequences of the HTVCB through the
high Oil temperature-high winding temperature & BUCHHOLZ
Relay of the transformer
 Check tightness of all earth and power connections of the VCB
 YEARLY
 Checking of insulation resistance of HT CABLES & the VCB by
using insulation tester of 1KV-2.5KV & the insulation resistance

shall not be less than 5Mega-ohms in the case of HT & 1-Mega-ohm

in the case of LT as per IE RULE-48 (i)(ii)(iii) of page-28 therein
 TROUBLE SHOOTING ON HIGH VOLTAGE VCB
 NATURE OF PROBLEM
 HT VCB is not racking in and out properly even after unlocking
the mechanism for racking in & racking out
 POSSIBLE CAUSE & REMEDY
 Rack in & rack out rail may be misaligned-check &clear the same
to ensure proper rack in & rack out of the same therein
 NATURE OF PROBLEM
 HT VCB is not operating electrically through its “T-N-C” switch
 POSSIBLE CAUSE & REMEDY
 Control supply is not available –check and shall be made available
for proper operation of the TNC-(TRIP-NEUTRAL –CLOSE) Switch
 NATURE OF PROBLEM
HT VCB is not tripping in case of earth fault-over current
 POSSIBLE CAUSE & REMEDY
 Control supply for alarm and tripping not available provide the
Same to ensure quick tripping of the same therein
 8.0: HIGH VOLTAGE AUTOMATIC VOLTAGE REGULATOR
FOR IMPROVING THE MAIN INCOMING SUPPLY

TEMPERATURE SENSOR

AUTO CUT OFF BOX HT INCOMER & OUT GOING

CABLE BOX

TEMPERATURE CONTROLLER

Cooling radiator

EARTH ING BOSS

The HT voltage stabilizer is connected in the main incoming HT power after the
double pole structure & its outgoing HT power is given to the HT side of
Transformer so as to get stabilized power in the LT side of the transformer
  415V-LOW VOLTAGE SERVO STABILIZER FOR
IMPROVING THE VOLTAGE ON LT SIDE

METERING & INDICATION

COOLING RADIATORS

EARTHING
WHEELS

PREVENTIVE MAINTENANCE & TROUBLE SHOOTING ON THE HT & LT

VOLTAGE SERVO STABILIZERS
 HALF YEARLY
 Checking tightness of incoming & outgoing cable terminations
 check for correct output Voltage from the Stabilizer
 check setting of the rollers and the brushes moving on the voltage
regulating coils
 check for any overheating in the cable terminations—rectify if any
 YEARLY
Check insulation resistance of the winding and the coils by using
Insulation tester of 1.1KV-2.5KV—insulation resistance shall not be less
than 5 mega-ohms in HT & 1-mega-ohm in LT as per IERULE-48(i-ii-iii) of
page-27 & 28 therein
 TROUBLE SHOOTING FOR HT & LT SERVO STABILIZER
 NATURE OF PROBLEM
 Voltage stabilizer is on but not giving out put voltage
 POSSIBLE CAUSE & REMEDY
 Open circuit in output coils or the wiring rectify the same through OEM
 9.0: HIGH VOLTAGE TRANSFORMER WITH ITS MAIN
PARTS & THE SAFETY DEVICES

CONSERVATOR
OIL LEVEL GAUGE

BUCHHOLZ
LT CABLE BOX

HT CABLE BOX
COOLING
RADIATOR
MARSHALLING BOX

 The transformer is a simple static device without any moving parts which
is used for stepping up or stepping down alternating current or voltages
It works on the principle of electro-magnetic induction
 The main parts of the transformer are:-
 Transformer oil tank
 Cooling radiators
 HT cable box
 LT Cable box
 Conservator
 Buchholz relay
 Explosion vent
 TYPES OF THE TRANSFORMER:
Mainly there are two types of transformer
 CORE TYPE:
 in a core type transformer the HT and LT windings are placed on the
each leg
 SHELL TYPE:
 In shell type transformer both the primary and secondary windings
are placed on a common central core ,which has a cross-sectional area
double that of the core type transformer
 WNDING OF THE HT TRANSFORMER IN OPEN
CONDITION WITHOUT OIL TANK

HT & LT TERMINALS

THREE PHASE HT TRANSFORMER WINDING USING HIGH GRADE

DMC/SMC & HIGH GRADE SUPPER ENEMALLED COPPER STRIPS
COVERED WITH DOUBLE COTTON TAPE & HIGH GRADE VARNISH
OF DOCTOR BAKE/INSULVAR
 ON LOAD TAP CHANGER TYPE HT TRANSFORMER
WITH OUTDOOR CONNECTIONS

HT TERMINALS

CONSERVATOR

 The OLTC (ON-LOAD TAP CHANGER ) type transformer is that where the
HT voltage is controlled with the help of “On load tap changer” which
changes the HT voltage tap of the transformer automatically on –load
with the help of a motor & the limit switches & improves overall voltage in
LT side of the transformer

Frequent running of the “on-load tap changer “for improving the voltage
may cause serious voltage hazards and damage to the transformer
Hence the care shall be taken that there shall not be any fluctuation in
voltage from EB side ---If found then the transformer shall be put on
manual mode to prevent further risk of damage to the same therein
 HIGH VOLTAGE OUT DOOR TRANSFORMER WITH
CUT VIEW OF WINDING PLACEMENT

CONSERVATOR

HT BUSHINGS

WINDING ARRANGEMENT

TRANSFORMER TANK
 TYPICAL CONSTRUCTION OF THE OIL FILLED
TRANSFORMER

 In the above shown typical construction of the transformer each part

plays a great role .The brief detail of each part is given as under:
 TRANSFORMER OIL TANK:
 Primary & secondary windings are placed in the tank covered with
transformer oil
 COOLING RADIATORS:
 are provided for the proper cooling of the whole transformer by circulation
of oil
 CURRENT TRANSFORMER:
 is placed inside the LT cable box for the measurement of the winding
current/temperature
 CONSERVATOR:
 it is also known as make up tank for level of oil due to variation in temp
 SILICAGEL DEHYDRATING BREATHER :
It contains silica gel which absorbs the moisture and prevents the entry
of moisture to the transformer
 DIAL THERMOMETER:
 It shows the temperature inside the transformer
  WORKING PRINCIPLE OF THE HIGH VOLTAGE
TRANSFORMER

TRANSFORMER
PRIMARY &
SECONDARY
WINDINGS

 it operates on the principal of electromagnetic induction

 Basically a transformer consist of closed magnetic core made of thin silicon
iron or steel alloy sheets with one or more coils of insulated wire placed on
its limbs. The winding which is connected to the main HT power is called
PRIMERY WINDING and that to which the load is connected is called the
SECONDARY WINDING
 DEHYDRATING SILICAGEL BREATHER OF THE
HIGH VOLTAGE TRANSFORMER

SILICAGEL BREATHER

TRANSFORMER OIL TO BE FILLED IN THIS OIL CUP

 DEHYDRATING SILICAGEL BREATHER FITTED ON
THE CONSERVATOR

OIL TOP UP AREA

SILICAGEL BREATHER

CONSERVATOR
TRANSFORMER OIL
TO BE PROVIDED IN
THIS BOTTOM OIL CUP

 SILICAGEL BREATHER FOR PREVENTING MOISTURE ENTRY

  BUCHHOLZ RELAY OF THE HIGH VOLTAGE
TRANSFORMER

AIR RELEASE VALVE

INSPECTION WINDOW
FROM TO CONS
TRANSFORMER TANK ERVATOR

CABLE ENTRY

 Any internal fault in the transformer is almost invariably accompanied by

evolution of gas. Any intense heat produced inside the tank, decomposes
the oil and liberates gas. The rate of gas formation is in proportion to the
amount of heat produced

 The Buchholz relay functions by making use of the gas liberated inside the
the transformer due to an internal fault to actuate an “ALARM OR TRIP”
the HT circuit breaker and thus saves an expensive transformer from the
serious damage therein

 BUCHHOLZ relay also detects accumulation of air on account of low oil level

An inspection window shows the amount of gas which has accumulated

BUCHHOLZ relay to give alarm and tripping shall be provided on all the
transformers of rating 1000KVA & above to comply with IERULE -64(A)(2)(c)
of page-44 therein
PROTECTION SEQUENCES OF BUCHHOLZ RELAY WITH
FLOATERS IN THE HIGH VOLTAGE TRANSFORMER

CONNECTION ARRANGEMENT OF BUCHHOLZ RELAY

TRANSFORMER 3 PHASE WINDING

 FIXING OF BUCHHOLZ RELAY - ALARM & TRIP
WIRING IN HT TRANSFORMER

The BUCHHOLZ relay comprises a cast iron housing inserted in the pipe
Connecting the transformer tank with the conservator tank. It consist of
two bucket mechanism each connected to a tilting head on which a mercury
switch is mounted .

The upper assembly traps small gas bubbles generated by an incipient fault
and if sufficient gas collected , it closes a contact and sounds a hooter in the
control room or the MCC room

The lower assembly which is directly in the path of the connecting pipe
operates when there is a serious internal fault like: SHORT CIRCUIT between
phases- coils or turn or EARTH FAULT. This liberates a considerable amount
of gas, and the displaced oil tilts the mercury switch which in turns trip the
The HT Circuit breaker & SAVE GUARD THE EXPENSIVE TRANSFORMER
THEREIN
 EXPLOSION VENT OF THE HIGH VOLTAGE
TRANSFORMER FITTED WITH THIN DIAPHRAM IS
THE LAST SAFETY IF NO OTHER SAFETY WORKS

CRACKED DIAPHRAM SHOWING RELEASE OF

INTERNAL PRESSURE FROM THE TRANSFORMER

Explosion vent is the last mechanical safety fitted on the transformer

tank with DIAPHRAM of thin BAKALITE or Tin foil of size 0.5 to1mm to
release the excess internal pressure developed inside the tanks under
major fault condition like short circuit in winding if other safeties like high
oil/Winding temperature of the transformer & BUCHHOLZ relays fails to
trip the main--- the said explosion vent thus prevents the transformer tank
from BULJING

 IF THE DIAPHRAM FOUND CRACKED AS SHOWN ABOVE IS THE CLEAR

INDICATION THAT NO OTHER SAFETY OPERATED OTHER THAN THIS &
THE SAME SHALL BE REPLACED AT ONCE TO PREVENT ENTRY OF
MOISTURE TO THE TRANSFORMER THEREIN
 TRANSFORMER OIL AS PER IS: 335-1993-IS: 12463 –
ITS TESTING AS PER IS: 1866:2000

The Mineral oil shall comply with IS:335-1993, and shall be tested as
per the chart given below

APPLICATION OF TEST ON TRANSFORMER

OIL AS PER IS: 1866-1983 (AT 2.5 MM GAP OF
TEST ELECTRODES)

SL TEST TEST TEST PERIODICITY PERMISSIB ACTION

DETAILS METHOD VENUE OF TEST LE LIMIT OUT
SIDE
LIMIT

1. Di-electric IS:6792 Lab  After 40KV

strength Filling
(Break
down  Prior
voltage in  To
(KV)  Energizin
g

 After
Monsoon
 TEST TEST TEST PERIOD PERMIS ACTION OUT
DETAILS METHOD VENU ICITY SIBLE SIDE LIMIT
SL E OF LIMIT
TEST

2. Water IS:225-83 Lab -do 34PPM

Content

3. Neutralisa IS:1448- Lab -do 0.5Mg

tion value 67 KOH /gm
(Total Max
acidity)

4. Sediment IS:1866- Lab -do No

and / or 83 sediment
precipitab Appendix
le -A

5. Flash IS:1448- Lab 2Years Decrease

point 70 in the
flash
point-
150C of
the initial
value
1250C

 Every time a transformer is subjected to an external short circuit.

 Presence of moisture in the insulation ,even in very small quantities has
surprisingly great effect in causing decomposition and deterioration of the
insulation----Hence to ensure high state of dryness and purity of the TR-oil
IT IS HIGHLY RECOMMENDED FOR PROVIDING THE RAIN PROTECTIVE
SHED ABOVE THE TRANSFORMER TO ENSURE THE DRYNESS & PURITY
OF THE TRANSFORMER OIL THEREIN
 MAINTENANCE SCHEDULE & TROUBLE SHOOTING
ON THE HIGH VOLTAGE TRANSFORMER

SL Inspection Item to be Inspection ACTION

Frequency inspected Note

1 Daily  Ambient  Check Reduce

Temperature Temp rise load &
is within Analysis
Limit, if reason
high

2 Daily  Oil level in  Check Top up oil

the against When
conservator level required
marking
should be
between
½ to 3/4
but
definitely
not full,
otherwise
oil will
come out
due to
expansion
 SL Inspection Item to be Inspection ACTION
Frequency inspected Note

3 Monthly  Silica gel-  Check  Change if

Breather color of required
the active
agent
should be
Blue
4 Yearly  Bushing  Check for  Replace crack
 HT-LT CON any crack insulator
 Earth CON
 VALVECOND in  Tight all
Gasket bushing power &
 Relay, Alarm  Check for earth
Trip & their any loose connections
Functioning
earth
5. Yearly  Painting of  Painting  Universal rust
the should be converter to be
transformers done after used before
if found treatment painting
defective and use
rust
converter
or the
primer

 TROUBLE SHOOTING IN THE OIL FILLED HIGH VOLTAGE TRANSFORMER

 NATURE OF FAULT:
Current flowing through the neutral & flickering in lights & Power-many lamps
fused
 POSSIBLE CAUSE & REMEDY:
 Neutral of the transformer may be loose, tightened firmly and the neutral strip
of the transformer shall be well insulated by using black color sleeve
or the PVC tape right from the earth pit to the neutral point of the transformer
to prevent further flickering in lights & power therein
 NATURE OF FAULT:
HT VCB is not tripping on high oil temperature-high winding temperature
and BUCHHOLZ of the transformer
 POSSIBLE CAUSE & REMEDY:
 Control supply fails or disconnected completely-check & restore the same
 10.0: DRY TYPE HIGH VOLTAGE TRANSFORMER ENCLOSED
IN A WELL VENTILATED ENCLOSURE /ROOM

Dry Type Transformer

LOOVERS

HT WINDING

EARTH

LOOVERS FOR VENTILATION

DRY TYPE TRANSFORMER

 DRY TYPE TRANSFORMER WITH 3-PHASE HIGH
GRADE WINDING IN OPEN VIEW

3PHASE & NEUTRAL-415V

3 PHASE HT CONNECTONS

HIGH GRADE HT & LT WINDING

EARTH

OPEN TYPE HT WONDING

 DRY TYPE TRANSFORMER CUBICAL WITH PROPER
COOLING ARRANGEMENT & OPEN VIEW OF WINDING

LOOVERS

3 phase transformer winding

DRY TYPE TRANSFORMERS IN OPEN & CUBICAL TYPES : are cooled

by the natural circulation of air through the winding instead of using
oil as cooling medium
 PREVENTIVE MAINTENANCE & TROUBLE SHOOTING ON DRY-TYPE TXF
 QUARTERLY: General cleaning from the coil winding with air blower after
Work permit & shut down
 checking of proper ventilation and cleaning of all louvers
 checking of ventilation system in the room and their thermostat setting
HALF YEARLY: General cleaning from the coil winding with blower after
work permit & shut down
 Checking tightness of earth & power connections and no sign of heating
 check auto temperature cut in cut out sensing device & function properly
YEARLY: Check Insulation resistance of HT winding of the transformer-LT
winding of the transformer-HT & LT cables of the transformer by using insulation
tester from 1.1KV-2.5KV range & the insulation resistance values shall not be less
than -5mega-ohms in HT & 1-mega-ohm in LT as per IERULE-48
Check automatic tripping of the transformer by raising the temperature
 check earth fault -over current & other relays- like winding temperature for
proper alarm & tripping sequences
  11.0: 415 V-POWER AND MOTOR CONTROL CENTRE
WITH PROTECTION SYSTEM AS PER IS: 13947

BUS BAR CHAMBER

EARTHING

PVC INSULATED MAT FLOORING

 MOTOR CONTROL CENTRE WITH OPEN BUS BAR

& FEEDERS CONNECTION THROUGH MCCB’s

EARTH
 415 V-MAIN ACB (AIR CIRCUIT BREAKER) FOR EB /DG INCOMER
 The Main air circuit breaker is provided for receiving 415V main power
from the LT side of the transformer for running the plant equipment & the lighting
The main parts of the ACB are given so as to ensure proper operation of the
same therein
 LIST OF PARTS OF THE MAIN LT AIR CIRCUIT BREAKER
415V-MANUAL CHARGING AIR CIRCUIT BREAKER & TRIP MECHANISM
 The manual charging ACB (AIR CIRCUIT BREAKER) is used for receiving
The power from the LT Side of the transformer as main incomer on MCC
Panel for running the plant equipment

CHARGING HANDLE
ON-OFF

DASH BOARD FOR

PROTECTION

BREAKER RACK OUT HANDLE

TRIP MECHANISM
MICRO SWITCH

SPRING LOADER
 415 V-MAGNETIC CONTACTOR & ITS OVERLOAD RELAY

The magnetic contactor

is used for giving
3-phase power to the
Motor through the
fixed and moving contacts
Either in DOL Or Star-Delta mode

The overload relay is intended to protect the motor against

Over loads The overload relay make use of the current through the
Motor circuit to lift off a contact in the no volt coil thus trips the motor
tripping the motor
  HRC FUSES FOR THE PROTECTION OF LIGHTING & POWER CIRCUIT
 HRC fuses are provided as a back up protection for the lighting & power circuit to
give protection against over current and short circuit. Any fuse provided for the motor
circuit must be of such a rating that it will not blow off at initial rush of current
If the fuse is of so high a value it will be totally be ineffective for giving any protection
against overloading of the motor .Fuses shall be provided @ 1.5times the actual load
in lighting 4-5 times of KW rating of each motor to comply with IS:13947 therein

FUSE PULLAR IS MUST

FOR REMOVING ALL THE FUSES SHOWN

INDICATION LAMPS FOR ELECTRICAL OPERATION

Proper sequence of indication lamps shall be as s under
RED-YELLOW-BLUE-----For main incoming supply-RED-Motor-ON-
GREEN- Motor OFF- AMBER-Motor Trips
 WIRING DIAGRAM FOR STAR DELTA STARTER
USED FOR RUNNING HIGHER RATING OF MOTORS

WITH EARTH FAULT

& OVERCURRENT

Star-Delta starters are used for reducing the high starting torque of the of the
higher rating induction motors beyond 7.5KW .
Maintenance required on these starters every 6 months is just cleaning of
the contacts proper setting of the overload relay & the timer
 Trouble shooting required only when not changing from star to delta mode
Is to check the change over timer it may be stuck or defective repair or
replace----CONTACT CLEANING MUST WITH CARBON TETRA CHLORIDE
 WIRING DIAGRAM FOR DIRECT- ON-LINE STATER
FOR RUNNING THE MOTORS BELOW 7.5KW

 CONTROL WIRING DIAGRAM OF DIRECT-ON –LINE STARTER

INSIDE DOL STARTER

  POWER & CONTROL WIRING DIAGRAM FOR
DIRECT ON LINE STARTER

230 V CONTROL SUPPLY

MAIN SWITCH

OVER LOAD OVER LOAD RELAY

RELAY

MAIN CONTACTOR
START
MAIN CONTACTOR BUTTON

NO VOLT COIL

FLP MOTOR

___________________________________________________
The over load setting shall be set @ of 80% of the full load current written
on the name plate of each motor in the case of DOL(DIRECT-ON-LINE)
60% of the full load current written on the name plate of each motor in the
case of Star-Delta
(OR)
1.5 times the actual current drawn by each motor in peak load condition
And which ever is less

 The main back up fuses shall be provided @ 4-5times of the rated kilowatt
Written on the name plate of each motor – for this refer the standard load
chart given to comply with IS: 13947 therein

 The main fuses/MCBs/ELCBs/MPCB shall be provided @ 1.5 times the

actual load measured with tong tester in the lighting circuits & in no case
the fuse rating shall not exceed the full load current rating of the main
lighting cable to prevent overheating of the cables or burning of lamps
therein
 EARTH LEAKAGE CIRCUIT BREAKER-EARTH
LEAKAGE RELAY & RESIDUAL CURRENTCIRCUIT

 There are mainly two types of above mentioned ELCBs-ELRs-RCCBs breakers VIZ:
 VOLTAGE OPERATED
 CURRENTLEAKAGE OPERATED
In the voltage operated, supply is arranged to cut-off when the potential
difference between the metal body of the equipment rises to 40 volts or
more above earth
In the current leakage operated arrangement the equipment is installed
On an insulated pedestal and connected to the earth through a series trip
relay which is specially designed to carry full load current and trips off as
Soon as the leakage current exceeds the pre-set limit to protect the system
therein

 ELCBs /ELRs/RCCBs WILL CONTINUE TO TRIP IF THERE IS NO PROPER

SEGREGATION OF TRANSFORMER NEUTRAL FROM THAT OF THE BODY
EARTH----SO IT IS HIGHLY RECOMMENDED FOR PROVIDING OF INSULATED
CABLE RIGHT FROM THE NEUTRAL EARTH PITS TO THE NEUTRAL POINT
OF THE TRANSFORMER & IN THE AREA WHEREELCBs ARE TO BE
INSTALLED
  STANDARAD PROTECTION CO-ORDINATION CHART AS PER
IS: 13947 – FOR PROVIDING/SETTING OF HRC FUSES &
OVERLOAD RELAYS FOR THE SAFETY OF THE ELECT- SYSTEM

SL MOTOR MOTOR CURRENT IN Main MAIN Control Overload

RATING IN (AMPS) Switch FUSES fuse size relay size
KW HP LINE PHASE fuse SIZE IN in in (AMPS)
CURRENT CURRENT unit size (AMPS) (AMPS)
in
(AMPS)
1. 0.37 0.50 1.1A - 32A 4A 2A 0.65-1.1A
DOL
2. 0.55 0.75 1.5A - 32A 4A 2A 1.3-1.9A
DOL
3. 0.75 1.0 2A - 32A 4A 2A 1.8-2.7A

4. 1.1 1.5 2.5A - 32A 6A 2A 1.8-2.7A

DOL

5. 1.5 2 3.4A - 32A 10A 2A 2.5-4A

DOL
6. 2.2 3 4.5A - 32A 10A 2A 4-6.3A
DOL
7. 3.0 4 6.2A - 32A 16A 2A 5.5-8.5A
DOL
8. 3.7 5 7.8A - 32A 16A 2A 5.5-8.5A
DOL
9. 5.5 7.5 11A - 32A 20A 2A 8-12A
DOL
10. 7.5 10 14A - 32A 32A 2A 9-15A
DOL
11. 7.5 10 14A 8.1A 32A 20A 2A 8-12A
Star
Delta
12. 9.3 12.5 19A 10.4A 63A 32A 2A 17.5-22A
DOL

13. 9.3 12.5 18A 10.4A 32A 25A 2A 8-12A

Star
delta
14. 11 15 21A 10.4A 63A 50A 2A 17.5-22A
DOL

15. 11 15 21A 12.1A 32A 25A 2A 10-16A

Star
Delta
16. 15 20 28A 16.1A 63A 63A 2A 25-32A
DOL

17. 15 20 28A 16.1A 32A 32A 2A 14.5-18A

Star
Delta
18. 18.5 25 35A 20.2A 125A 80A 2A 30-40A
DOL

19. 18.5 25 35A 20.2A 63A 50A 2A 17.5-22A

Star
Delta
20. 22 30 40A 23A 125A 80A 2A 30-43A
DOL
21. 22 30 40A 23A 63A 50A 2A 21-25A
Star
Delta
22. 30 40 55A 30.6A 125A 100A 2A 54-65A
DOL
23. 30 40 53A 30.6A 125A 63A 2A 30-40A
Star
Delta
24. 37 50 66A 37.5A 125A 100A 2A-4A 64-82A
DOL
25. 37 50 66A 37.5A 125A 80A 2A-4A 30-40A
Star
Delta
26. 45 60 75A 45A 250A 160A 2A-4A 64-82A
DOL
27. 45 60 75A 45A 125A 100A 2A-4A 42-55A
Star
Delta
28. 50 66 88A 47A 250A 160A 2A-4A 78-
DOL 97A

29. 50 66 88A 47A 125A 125A 2A-4A 42-

Star 55A
Delta
30. 55 75 100A 58A 250A 200A 2A-4A 90-
DOL 110A
31. 55 75 100A 58A 125A 100A 2A-4A 54-
Star 65A
Delta
32. 75 100 135A 78A 250A 250A 2A-4A 110-
DOL 140A
33. 75 100 135A 78A 250A 160A 2A-4A 64-
Star 82A
delta
34. 90 125 165A 95A 250A 250A 2A-4A 140-
DOL 190A
35. 90 125 165A 95A 250A 160A 2A-4A 90-
Star 110A
Delta
36. 110 150 200A 115A 400A 400A 2A-4A 175-
DOL 280A
37. 110 150 200A 115A 250A 200A 2A-4A 90-
Star 120A
Delta
38. 132 180 230A 139A 400A 400A 2A-4A 175-
DOL 280A
39. 132 180 240A 139A 250A 250A 2A-4A 110-
Star 140A
Delta
40. 160 215 271A 156A 400A 400A 2A-4A 200-
DOL 310A

 FROM THE ABOVE GIVEN PROTECTION CHART IT IS CLEAR THAT IT IS

ALWAYS BETTER TO CONNECT THE MOTORS BEYOND 7.5KW IN THE
STAR-DELTA MODE TO ENSURE REDUCTION IN POWER-SIZE OF THE
MAIN FUSES – SIZE OF THE OVERLOAD RELAYS &FINALLY REDUCTION
IN POWER COST THEREIN
41. 160 215 271A 156A 400A 315A 2A-4A 140-
Star 190A
Delta
42. 200 270 350A 196A 400A 400A 2A-4A 315-
DOL 500A

43. 200 270 340A 196A 400A 315A 2A-4A 175-

Star 280A
Delta
44. 250 335 437A 243A 630A 500A 2A-4A 315-
DOL 280A

45. 250 335 437A 243A 630A 400A 2A-4A 175-

Star 280A
Delta
46. 315 422 530A 328A 630A 630A 2A-4A 430-
DOL 700A
47. 315 422 530A 328A 630A 560A 2A-4A 250-
Star 400A
delta
48. 355 475 600A 360A 630A 630A 2-4A 430-
DOL 700A

49. 355 475 600A 360A 630A 630A 2-4A 250-

Star 400A
delta
50. 400 536 673A 404A 800A 750A 2-4A 430-
DOL 700A

51. 400 536 673A 404A 800A 750A 2-4A 315-

Star 500A
delta
52. 450 600 756A 438A 800A 800A 2-4A 430-
DOL 700A
53 450
star 600 756A 438A 800A 800A 2-4A 430-
delta 700A
 SAMPLE FORMAT FOR RELAY TESTING
SAMPLE FORMAT FOR INSULATION RESISTANCE TEST

IN CASE OF LT & 5-MEGA-OHMS IN CASE OF

  12.0:POWER FACTOR CORRECTION PANEL FOR
IMPROVING THE POWER FACTOR TO THE RESONABLE
FIGURE OF 0.99

VENTILATION FAN

VOLTMETER & AMMETER

POWER FACTOR
CORRECTION
RELAY
MAIN MCCB

ON-OFF CONTROL

CAPACITOR CABIN

POWER FACTOR RELAY

WITH SETTING BLOCK

EARTHING

 POWER FACTOR: is the ratio of true power to apparent power. Hence

TRUE POWER IN (KW)=APPARENT POWER IN (KVA)x POWER FACTOR
POWER FACTOR=REAL POWER/APPARENT POWER =KW/KVA
 POWER FACTOR PANEL WITH PROPER WIRING &
CAPACTORS CONNECTIONS

MAIN MCBs& CONTACTOR

CAPACITORS

The power factor shall always be maintained to 1.00 if not at least maintain
in the reasonable figure of 0.99

if power factor is unity 1- The Real power(KW) will become equal to Apparent
power (KVA) and at unity power factor the current for any given load is the
lowest & therefore the mains as well as the plant used to the best advantage

 if the power factor is low the mains and the generator capacity are
inefficiently utilized-the voltage regulation will be poor –system losses
And energy consumption will be high as the rating of electrical equipment
is based on KVA and not on KW demand
POWER FACTOR CAPACITOR BANK WTH 5
NUMBERS OF CAPACITORS OF SAME RATING

3-PHASE POWER

CAPACITOR BANK
 POWER FACTOR V/S KVA CHART FOR WELL
UNDERSTANDING ABOUT POWER FACTOR-VS-LOAD
SELECTION OF CAPACITORS AS PER THE REKONER
CHART FOR INITIAL POWER FACTOR V/S TARGET P.F
 13.0: VFD PANELS WITH AC DRIVES & SOFT
STARTERS

VFD & SOFT STERTER panels are provided as per IEEE 519B for driving the
pumps at full load with speed cycled during automation ensuring that total
harmonic voltage distortion remain less than 5%-

 MAINTENANCE & TROUBLE SHOOTING ON VFD/SOFT STARTER PANELS

 Check whether converting fixed frequency of 3-phases into adjustable frequency
for controlling the speed of motor
Check whether motor voltage is varied with frequency to maintained desired
motor current suitable for the driven load
Check whether VFD run the motor at full rated power
Check whether VFD maintains the power factor to unity & not spoiling
 Check whether VFD minimizes the power line harmonics at full load
 Check whether VFD is able to provide full rated output current of 110%
continuously & 120% rated torque for up to 0.5Second while starting
Check whether VFD is protected from power line transients by providing choke
in incoming
 Check VFD is providing full motor torque at any selected frequency 20HZ
to base speed while providing a variable torque at reduced speed
 TROUBLE SHOOTING ON VFD/SOFT STARTERS

 TROUBLE SHOOTING ON VFD & SOFT STARTERS

 NATURE OF PROBLEM
 Over current always trips takes more time to reset and restart
 POSSIBLE CAUSE & REMEDY
Overload relay setting low –Check & set @ 80% of the full load current
 NATURE OF PROBLEM
 Overloading Signal persists but motor not tripping
 POSSIBLE CAUSE & REMEDY
 False signal –check actual load on the motor if ok-rectify the false signal
 NATURE OF PROBLEM
 Command loss trip alarm comes
 POSSIBLE CAUSE & REMEDY
 Wrong operation-check for correct operation
 NATURE OF PROBLEM
 CPU watch dog trip
 POSSIBLE CAUSE & REMEDY
 Low setting –check and adjust for proper setting
  14.0: DIESEL GENERATOR SET WITHOUT CANOPY
WITH LOCAL CONTROL PANEL

RADIATOR

ALTERNATOR

ENGINE

EARTHING

 CANOPY TYPE DIESEL GENERATOR SETDS WITH INBUILT PANEL

In canopy type DG sets Diesel shall not

Be stored in the inbuilt tanks as may catch fire due to
The short in battery terminals or in alternator
Batteries shall be placed outside
On a angled frame with wooden base
SILENCERS

CANOPY

ENGINE & PANEL

INSPECTION DOORS

D.G Sets are provided as a standby source of power for the plants to cater
power in case the state electricity board supply fails
 DG Sets start either automatically through AMF panel or manually through
push button stations or the key
  CONTROL PANELS FOR DIESEL GENERATOR SETS
RUNNING IN AUTO-MAIN-FAILURE MODE OR MANUAL MODE

METERING

MAIN ACB

ON-OFF OPERATION

PROTECTION
 COMMON CONTROL PANEL FOR ONE EB INCOMER &ONE BUS
COUPLER & 3 NUMBERS OF DG SETS OF DIFFERENT
CAPACITIES

DG-1 DG-2 DG-3 BUS

EB INCOMER COUPLER

WHERE MORE THAN 2 DG PROVIDED IN AUTO

WITH 4-POLE SWITCHES “ NO-MECH-INTERLOCKING” REQD

 AMF (AUTO MAIN FAILURE PANEL)

S ENGINE START
OUTGOING &UPERVISION RELAYS
LOAD BUS

EB DG
 MAINTENANCE & TROUBLE SHOOTING ON DIESEL
GENERATOR SETS & THEIR CONTROL PANELS

 MONTHLY:
 Cleaning of DG panel & alternator unit with air blower
 QUATERLY
Check tightness of all earth and power connection and no overheating
 HALF YEARLY :
Check the moving & fixed contacts of 4 pole change-over switch
provided between EB & DG Power and their change –over operation
 YEARLY :
 Insulation resistance of power cables with Earth tester 0-10 ohms range
& the Insulation tester 1.1KV-2.5KV range the earth resistance values
shall not exceed 2-ohms for individual electrode-1-ohm for grid & 1-ohm
for continuity up to equipment And insulation resistance shall not be less
Than 1-mega-ohm
Check alarm and tripping arrangement of DG sets as under
 LOW LUBE OIL PRESSURE
 HIGH WATER PRESSURE
 LOW FUEL OIL LEVEL
 EARTH FAULT
 OVER CURRENT
 UNDER VOLTAGE
 REVERSE POWER
Check discoloring & overheating of cables rectify if any
 check auto change over sequences

 TROUBLE SHOOTING ON DG SETS & CONTROL PANELS

 NATURE OF PROBLEM
 DG running but not showing any out put voltage
 POSSIBLE CAUSE & REMEDY
 Rotating diodes faulty-replace the same
 NATURE OF PROBLEM
DG not tripping through earth fault- over current –Low lube oil pressure
high water temperature-Low fuel oil safety
 POSSIBLE CAUSE & REMEDY
Relays may be by-passed or control fuse blown---rectify the same
 15.0: FLP MOTORS AS PER IS:325-IS:2148/IEC-
60079-1:2007 WITH FOOT MOUNTING

FLP MOTOR is a device which convert electrical energy to the mechanical

Energy It works on the principle of electromagnetic lines of force

TERMINAL BOX

STATOR

SOLID BAR
ROTOR
 DEGREE OF PROTECTION

Enclosu First digit Second digit Protection against water

re as Protection protection against foreign
per IS: against bodies & dust
4691 accidental
contact
IP-11  Against Against foreign bodies Prevents damage from dripping (vertical
contact grater than 50 mm DIA falling drops) water
of the
entire
hand
IP-13  Against  Against foreign Prevents damage falling water at any
contact bodies grater than angle up to 600 from the vertical
of 50mm dia
entire
hand
IP-21  Against  Against Foreign Prevents damage from dripping water
contact bodies greater than
with 12mm dia
Fingers
IP-22  Against  Against Foreign Prevent damage from water falling at any
contact bodies greater than angle up to 150 from the vertical
with 12mm dia
Fingers
IP-23  Against  Against foreign Prevents damage from water falling at
contact bodies greater than any angle up to 600 from the vertical
with 12mm DIA
Fingers

IP-44  Against  Against foreign Prevents damage from water splashed

contact bodies greater than against the machine from any direction
of tools 1mm DIA
and
similar
objects
thicker
than
1mm

IP-54  Against  Against ingress of Prevents damage from water splashed

contact Dust against the machine from any direction
of all
foreign
bodies

IP-55-65 &  Against  Against ingress of Prevents damage from water jets coming
above contact dist from any direction
of all
types of
foreign
bodies

Note: Apart from above protection

Recommended for canopy on each Motor or JB
installed outside in Depot/Installation/Terminal
specially outside the sheds
 16.0: FLP STATERS & THEIR FUNCTION AS PER
IS:2148/IEC-60079-1:2007

FLP starters/FLP push button stations/FLP Junction boxes/ & like are those
enclosures which can withstand the external explosion of gas or vapor when
parts are fully intact & should not ignite the surrounding area by weak points
like Unused holes-improper glands with armor coming out & damage

ON-OFF PUSH BUTTONS

 FLP ON & OFF EMERGENCY STARTER WITH
INBUILT MAGNETIC CONTACTOR & OVER LOAD

ALL FIXING BOLTS SHALL BE TIGHTENED FIRMLY

THESE HOLES SHALL BE PLUGGED WITH CIMFR

APPROVED -DUMMY PLUGS

FLP STARTER WITH PROPER CIMFR APPROVED

FLP GLANDS-ALL BOLTS INTACT & DUMMY PLUGS
 FLP ON-OFF SWITCHES & THEIR FUNCTION AS PER
IS:2148/IEC-60079-1:2007

ON & OFF OPERATING KNOB

ALL BOLTS SHALL BE

INTACT & TIGHTENED FIRMLY

THESE HOLES SHALL BE PLUGGED WITH CIMFR APPROVED

DUMMY PLUGS

FLP STARTER WITH AMMETER & ON-OFF PUSH BUTTONS

AMMETER

INDICATIONS
& ON-OFF PUSH
BUTTONS

MAIN SWITCH
 FLP STARTERS WITH WINDOW ANNUNCIATION

INDICATIONS

WINDOW DISPLAY

OPERATING SWITCHES

These holes shall be plugged

THREADED TYPE FLP JUNCTION BOXES

OPENING WITH ROD

THREADED JOINTS SHALL ALWAYS BE PROVIDED WITH

PETROLEUM JELLY OR WHITE GREASE

THESE HOLES SHALL BE PLUGGED WITH CIMFR APPROVED PLUGS

 17.0: FLP CABLE GLANDS AS PER IS:2148/IEC-60079-1:2007
AS PER THE OUTER DIAMETER OF THE EACH CABLE

Each FLP cable gland shall be embossed with CIMFR

( CENTRALINSTITUDE OF MINING & FUEL) Number with test CF

Half threaded cable glands fixing is not permitted

 Cable glands shall be provided strictly as per the outer DIA
of the cable-TOP GLAND ENTRY IS NOT PERMITTED IF IT IS
THERE IN OLD ENCLOSURES IT SHALL BE SEALED WITH TG-05/SILC

 CUT VIEW OF FLPCABLE GLAND

 CIMFR (CENTRAL INSTITUTE OF MINING & FUEL
RESEARCH DHANBAD) APPROVED GLANDS & DUMMY
PLUGS OF VARIOUS DESIGNS

 From the above given design of dummy plugs, it is preferable for providing
only Hexagonal stainless steel plugs as other plugs remain loose & go inside
the FLP enclosure in absence of the stopper

 Proving of locally fabricated plugs are not permitted as the Flame proof
features Purely depends on its parts

 Half threaded plugs provided in the FLP enclosures not permitted

 PROPER CABLE GLANDING PROCEDURE

CHECK NUT TO TIGHTENED

INSIDE THE FLP ENCLOSURE

4 –CORE CABLE

PVC HOODS/BOOTS FOR COVERING THE FLP VABLE GLANDS

THESE PVC HOODS/BOOTS PROVIDED

FOR COVERING THE FLP CABLE GLANDS
SHALL NOT BE PROVIDED AS IT IS NOT
PERMISSIBLE FOR BRINGINGINTO USE
SUCH MATERIAL WHICH MAYPRODUCE
NOXIOUS GASES OR EXPLOSIVE GASES
ON EXCESSIVE HEATING & THUS TO
COMPLY WITH IERULE-39(2) OF PAGE-22
 PVC HOOD FOR COVERING FLP CABLE GLAND

THIS TYPE OF COVERING WITH NON FLP

PVC MATERIAL IS NOT PERMITTED AS
PER IERULE -39(2) OF PAGE-22

 PROPER METHOD OF CABLE GLANDING

ARMOR & CONE

18.0:POWER & CONTOL CABLES THEIR LAYING-
SIZING & URRENT CARRYING CAPACITY

Single core –
2 core -3 core
& 4 core cables
& Multi core cables
 3 & 4 CORES ARMOR & UNARMORE POWER &
CONTROL CABLES IN CUT VIEW & DESCRIPTION
RATING OF POWER & CONTOL CABLES
 TYPES OF CABLES AS PER IS: 1554(PART-1)

Type of Conductor Voltage Grade Uses

cable
Purpose

Power Cables PILC Copper or 3.3KV and  High voltage

Alum above Incoming Power
supply from HT
Breaker to
transformer and
Power Cables XLPE Copper or 3.3KV & above for high voltage
Alum equipment

Power Cables XLPE Copper of 1.1KV  For LT power

OR Alum cables from LT
PVC side of the
transformer to
PMCC panel and
Motor control
centre
Control Cable PVC Copper only 1.1KV For all control circuits
Lighting & signals.
 CURRENT RATING OF POWER & CONTOL CABLES
IN AMPERES FOR DIFFERENT SIZES & TYPE

CROSS SECTIONAL AREA CURRENT RATING IN AMPS

in (sq mm)
COPPER/ALUMINIUM AT 40 Deg C IN AIR/
AT 30 Deg C in ground
1.5 Sq mm Copper12A/ Alumina 9A
2.5 Sq mm Copper15A/Alumina 12A
4 Sq mm Copper18A/Alumina 15A
6 Sq mm Copper 20A/Alumina17A
10Sq mm Copper 24A/Alumina 20A
16 Sq mm Copper 32A/Alumina 27A
25 Sq mm Copper 50A/Alumina 38A
35 Sq mm Copper 70A/Alumina 45A
50 Sq mm Copper 100A/Alumina 80A
70 Sq mm Copper 140A/Alumina 120A
95 Sq mm Copper 190A/Alumina155A
120 Sq mm Copper 240A/Alumina 180A
150 Sq mm Copper 300A/Alumina 225A
185 Sq mm Copper 370A/Alumina 255A
225 sq mm Copper 450A/Alumina 365A
240 sq mm Copper 500A/Alumina 421A
300 sq mm Copper 600A/Alumina 460A
400 sq mm Copper 800A/Alumina 600A
 METHODS FOR LAYING & FIXING THE CABLES ON
TRAYS CABLES AS PER IS: 7090

 The conventional Methods for Cable laying are:-

a) Lying direct in Ground

b. Drawing in ducts.

c. Lying on Racks in air

d. Lying on Racks in side Cable Tunnel / Trenches

e. Laying along building or structure

  14.8
THE DEPTH AT WHICH THE HT & LT CABLES ARE
TO BE BURRIED UNDER GROUND

 Desired minimum
High voltage depth
cables 3.3KVoftolying
11KVfrom Ground to the top
0.97-1000 mmof the
cable s as follows:
Rating
 High voltage cables 22KW to 33KV 1.05m
Rating:
 Low voltage control cables 0.75m
 Cables at Road crossing 1.00m
 Cables at Railway level (Measured 1.00m
from bottom of slippers to the top of
pipe)

 SAFETY CLEARANCES WHILE LAYING THE CABLES

 The desired minimum clearances are to be maintained

 POWER TO POWER CABLE: NOT NECESSARY
 POWER CABLE TO CONTROL CABLES: 0.2m
 POWER CABLES TO COMMUNICATION: 0.3m
 POWER CABLES TO GAS & WATER PIPE LINE:0.3m
19.0: EARTHING & BONDING AS PER IS:3043-1987

PIPE EARTHING ELECTRODE

 PLATE EARTHING ELECTRODE
 EQUIPMENT EARTHING & BONDING
ARRENGEMENT AS PER IS:3043-1987
 LOOPED EARTHING AS PER IS: 3043-
FIGURE-16

LOOPING EARTHING FOR MOTORS & STARTERS

EQUIPMENT & PROTECTIVE CONDUCTOR
EARTHING

FROM THIS FIGURE

IT IS CLEAR THAT ELECTRICAL
EARTHING CANNOT BE
SEGREGATED FROM
STRUCTURE & INSTRUMENTS IN
ANY CONDITION AS ALL
ELECTRODES ARE GOING TO
EARTH & MORE OR LESS ON THE
SAME POTENTIAL
 DETAILS OF EARTHING
CONNECTIONS IN HIGH VOLTAGE

 ELECTRICAL EARTHING CAN NOT BE SEGREGATED FROM THAT OF

STRUCTURE EARTHING IN ANY CONDITION
EARTH TESTER USED FOR MEASUREMENT
OF EARTH RESISTANCE
 The resistance to earth of an electrode is dependent on the electrical
resistivity of the soil. In which it is installed and the measurement of
earth resistance shall be as per “ OHMS-LAW” which says that current
is directly proportional to the voltage & inversely proportional to
the resistance--------I= V/R

 Normally to improve soil condition an artificial treatment of soil is done

by the following methods:
By adding coke in 30-40mm size
By adding salt solution around electrode in the ratio 1Kg salt:10Lt water
don’t put direct salt inside the pipe may corrode the pipe heavily & may
also block the water spray holes in the pipe
By adding BENTONITE/NAUSADAR around each pit 150gm mixed with
2-lt water

Moisture content is one of the controlling factors in earth resistivity and is

expressed in percent by weight of Dry soil

RECOMMENDED
PRACTICES

 Minimum spacing between 2 Earth electrodes shall be at least 2 meters

as per IS;3043

Earth Grid shall be 2 meters away from building Column and to be buried at
a depth of 600mm & in case it should not be directly laid on the ground may
cause shock hazards & fire if laid on dry grass in case of heavy current flowing
through the Grid in case of fault

Interconnection of GI strips in the earth Grid should be done by welding

overlapped instead of BOLTING HOW EVER WHERE WELDING IS NOT FEASIBLE USE
DOUBLE BOLTED CONNECTIONS
Overlapped welded Joints / Portion should be painted with zinc-rich paint
(EPULUX-4 or Black bitumen paint to avoid rusting

The connections of the grid strips with the earth electrodes shall be made
in such a way through C-type clamps & Link it shall be possible to isolate
the earth electrode and measure its earth resistance (Refer earth pit
drawing for details)
Earth strip of the Lightning arrestors provided on the 2Pole / 4 Pole
structure shall be connected to 2Nos of separate & distinct EARTHING pits
and not to be connected to the EARTHING grid directly
 20: STATIC ELECTRICITY &
METHOD OF STATIC DISCHARGE

 Static Electricity is a phenomenon of electrification of

materials through physical contact and separation

 That gives rise to positive and Negative charges so formed

 In short, static electricity results from removal of

electrons from the atoms of one material and absorption
of these electrons by the atoms of another material,
during physical contact on separation of two dissimilar
materials
 GENERATION OF STATIC
ELECTRICITY

 Electricity is generated whenever there is a relative movement

or separation between two dissimilar surface in intimate
contact or between surfaces which are identical but which
have differing surface properties due to pressure of
containments

 In oil industry, generation of static electricity takes place

while flowing of hydrocarbons liquid through pipes

 The liquid hydrocarbons give up electrons which are in turn

received by the pipe carrying the liquid. Thus the hydrocarbons
become positively charged and the pipe is charged Negative
 Moving vehicles
 Liquid hydrocarbons flowing through pipes at high
velocities.
 Movement of people wearing synthetic garments.
 an opening in a pipe or hose
Spraying or coating
Filling tanks –drums-cans
STATIIC ELECTICITY
STATIIC ELECTICITY
STATIIC ELECTICITY
STATIIC ELECTICITY
STATIIC ELECTICITY
STATIIC ELECTICITY
21.0:LIGHTINING & POTECTION
LIGHTNING STROKE
LIGHTNING STROKE
LIGHTNING STROKE
LIGHTNING STROKE
LIGHTNING STROKE
LIGHTNING STROKE
LIGHTNING STROKE
LIGHTNING SURGE PROTECTION
SURGE PROTECTION RELAY DISSIPATION OF
SURGE CURRENT
22.0: ELECTICAL ACCDDENTS
ELECTICAL ACCDDENTS
ELECTICAL ACCDDENTS
LOTO SYSTEM
THANKS