“Industrial Training Report on Indian Oil Corporation

Limited, Gujarat Refinery, Vadodara”

In
Electrical Engineering Discipline
(6th June 2016 to 25 th June 2016)

By
“Final Year Student of Bachelor of Engineering in Electrical
Engineering Stream.”
Gujarat Technological University (GTU)
Prepared by
1. Najar Shah (K.J.I.T) 2. Mahendra Rajput (K.J.I.T)
3. Sapna Joshi (K.J.I.T) 4. Harshit Patel (I.T.M)
5. Mitesh Vaghela (K.J.I.T) 6. Manish Prajapati (K.J.I.T)

1
 CETIFICATE

This is certify that following student have successfully completed

their Industrial / vocational training in Indian Oil Corporation limited,
Gujarat Refinery, Vadodara Davison, during their summer vacation
from 6th June 2016 to 25 th June 2016.

1. Najar Shah
2. Mahendra Rajput
3. Sapna Joshi
4. Harshit Patel
5. Mitesh Vaghela
6. Manish Prajapati

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 INDEX

1. Cover page………………………………………………………1

2. Certificate……………………………………………………….2

3. Acknowledgement………………………………………………3

4. Gujarat Refinery (company profile)…………………………….5

5. Fire and Safety Training ………………………………………..8

6. Main function and Instrumentation department in IOCL……...10

7. Power plant operation (CGP-2)…………………………….…..13

8. Power plant operation (TPS)……………………………….…..27

9. Electrical Maintenance (SRU)………………………………….29

10. Electrical Maintenance (FCC)………………………………...29

11. Electrical Testing ………………………….………………….34

12. Electrical Workshop……………..……….…………….……..36

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 ACKNOWLEDGEMENT
Before proceeding to our vocational training report, we are really
thankful to GOD for making our vocational training successful.

We would like to thank Mr A. C. Shekhar for letting us enjoy this

experience of getting trained at Gujarat Refinery (Baroda). It has
helped us for grown up our practical knowledge about refinery.

Besides this, we would like to thank Gujarat Refinery, Indian Oil

Corporation Ltd for providing us a good environment and facilities to
complete our vocational training successfully.

We are also thankful to all the technicians and operators and other
staff of training department who speared their valuable time and took
effort explaining the working of various units and various equipment
of the plants. We greatly thankful for their co-operation. The
information provided by them has helped me a lot in our future. The
tremendous effort put by them have motivated me and made me gain
confidence in completing the vocational training.

Yours sincerely,
Najar Shah
Mahendra Rajput
Sapna Joshi
Harshit Patel
Mitesh Vaghela
Manish Prajapati

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 GUJARAT REFINARY

The Gujarat Refinery at Koyali in Western India is Indian Oil’s

second largest refinery. The refinery was commissioned in 1965-
1966.

Its facilities include five atmospheric crude distillation units. The

major units include CRU, FCCU and the first Hydrocracking unit of
the country.

Gujarat Refinery, operating with an installed crude processing

capacity of 13.7 million metric tonnes per annum, processes
indigenous and imported, both low sulphur and high sulphur grades of
crude oil. The product slate includes besides fuels, petrochemical
products such as Linear Alkyl Benzene (LAB), Polypropylene Feed
Stock, and Food & Polymer Grade Hexane.

Gujarat Refinery is implementing a mega project worth around

Rs.7000 crore to comply with the road map for supplying eco-friendly
Bharat Stage-III and IV compliant MS and HSD and to upgrade the
bottom of the barrel to improve the gross margin of the Refinery.

History

Following the conclusion of the Indo-Soviet Treaty of Friendship and

Cooperation in February 1961, a site for the establishment of a
2 million metric ton per annum (mmtpa) oil refinery was selected on
17 April 1961.[2] Soviet and Indian engineers signed a contract in
October 1961 for the preparation of the project. Prime Minister
Jawaharlal Nehru laid the foundation stone of the refinery on 10 May
1963.

The refinery was commissioned with Soviet assistance at a cost of

Rs.26 crores began production in October 1965. The first crude
distillation unit with a capacity of 1 mmtpa was commissioned for

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trial production on 11 October 1965 and achieved its rated capacity on
6 December 1965. Throughput reached 20% beyond its designed
capacity in January 1966.

President Sarvepalli Radhakrishnan dedicated the refinery to the

nation with the commissioning of second crude distillation unit and
catalytic reforming unit on 18 October 1966.

The third 1 mmtpa distillation unit was commissioned in September

1967 to process Ankleshwar and North Gujarat crudes. In December
1968, Udex plant was commissioned for production of benzene and
toluene using feedstock from CRU. By 1974-75 with in-house
modifications, the capacity of the refinery increased by 40% to a level
of 4.2 mmtpa. To process imported crude the refinery was expanded
during 1978-79 by adding another 3 mmtpa crude distillation unit
along with downstream processing units including vacuum
distillation, visbreaker and bitumen blowing units. By 1980-81 this
unit started processing Bombay High crude in addition to imported
crudes. It was the first time that Indian engineers independently
handled a project of that scale.

To recover products from the residue, secondary processing facilities

consisting of fluidized catalytic cracking unit of 1 mmtpa capacity
along with a feed preparation unit of 1 mmtpa capacities, were
commissioned in December 1982. The refinery set up pilot distillation
facilities for the production of n-Heptane and light aluminium rolling
oils. To enable absorption of increased indigenous crudes the
refinery's capacity was further increased to 9.5 mmtpa.

In 1993-1994, Gujarat commissioned the country's first hydrocracker

unit of 1.2 mmtpa along with feed preparation unit-2 and hydrogen
generation unit-1 (GHC Complex), for conversion of heavier ends of
crude oil to high value superior products.

India's first diesel hydrodesulphurisation unit to reduce sulfer content

in diesel was commissioned in June 1999. A methyl tertiary butyl
ether unit was commissioned in September 1999 to eliminate lead
from motor fuels. The facility conceptualised and commissioned
South Asia's largest centralised effluent treatment plant by
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dismantling the four old ETP's. In June 1999. By September 1999 with
the commissioning of an atmospheric distillation unit, Gujarat
Refinery further augmented its capacity to 13.7 mmtpa making it the
largest public sector undertaking refinery of the country.

A project for production of linear alkyl benzene from kerosene

streams was implemented in August 2004. It is the largest grassroots
single train Kerosene-to-LAB unit in the world, with an installed
capacity of 1.2 mmtpa. To meet future fuel quality requirements, MS.
quality improvement facilities were commissioned in 2006.The
Residue Upgradation Project undertaken by the Gujarat Refinery was
completed by 2011 which increased the high sulfer processing
capacity of Gujarat refinery, improved the distillate yield as well
produce BS III & IV quality of MS and HSD. The Residue
upgradation project came in two parts namely, the south block which
consisted of HGU-III, SRU-III, DHDT and ISOM units and the north
block consisted of VGO-HDT and DCU units. To support the new
units a new Co-Generation Plant (CGP) and Heat Recovery Steam
Generation (HRSG) were also commissioned.

The refinery's facilities include five atmospheric crude distillation

units. The major secondary units include Catalytic Reforming Unit
(CRU), Fluidized Catalytic Cracking Unit (FCCU) and the first
hydrocracking unit of the country. Through a pipeline to Ahmedabad
and a pipeline connecting to the BKPL. Pipeline and also by rail and
truck, the refinery primarily serves the demand for petroleum
products in western and northern India.

When commissioned, the refinery had an installed capacity of

2 mmtpa and was designed to process crude from Ankleshwar, Kalol
and Nawagam oilfields of ONGC in Gujarat. The refinery was
modified to handle imported and Bombay High crude. The refinery
also produces a wide range of specialty products such as benzene,
toluene, MTO, food grade hexane, solvents and LABFS.

7
 Fire and Safety Training

Fire and safety refer to the precautions that are taken to prevent or
reduce the likelihood of a fire that may result in death, injury or
property damage, alert those in a structure to the presence of fire in
the event one occurs, better enable those threatened by afire to
survive, or to reduce the damage caused by a fire. Fire safety
measures include those that are planned during the construction of a
building or implemented in structures that are already standing.
Threats to fire safety are referred to as fire hazard. A fire hazard may
include a situation that increases the likelihood a fire may start or may
impede escape in the event a fire occurs.
FIRE & SAFETY REGULATION

1) No smoking except at the prescribed smoking booths.

2) Mobile phones, litter, torch etc. are prohibited in battery area.
3) Spark arrester is compulsory for every vehicle.
4) Do not sit/eat/rest in inside unit. Particularly near running
equipment.
5) In case of any fire dial 7333/6333.
6) For ambulance dial 7444/6444.
7) Fire call can be given through fire alarm. Fire alarm point provided
along the road.
8) Know emergency siren code.
9) During emergency move to the closest assembly point. Total 13
assembly point is in the refinery.
10) Do not touch any running or open equipment.
11) No photography/videography allowed inside refinery.
12) Work permit

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Safety PPE (Personal protective equipment) is compulsory.

 There are three mandatory PPE : shoes, helmet, goggles.

 Use of PPE such as safety belts, hearing aids, hand glove,
aprons, gas mask etc. also there.

For working in chemical industry a industry must have the following

permit
1. Hot work permit.
2. Cold work permit.
3. Height work permit.
4. Confined space permit.
5. Excavation work permit.
6. Radiography.

9
 Main function and Instrumentation department in
IOCL

 Provide and maintain automatic control and monitoring
processes in different plants of refinery.
 Provide and maintain automatic safety systems to ensure safe
plant operation/startup/shutdown.
 Provide and maintain process and environment monitoring
analyzers to ensure product quality, increase efficiency and meet
environmental commitments.
 Planning related activities.
 Engineering related services jobs including procurement.
 Preventive maintenance scheduling.
 QMS/EMS/OHSMS related activities.
 Process modification scheme implementation, engg assistance
foe new plants etc.
 Absorption of new technology.
 Skill up gradation of personnel.
 Interfacing with other departments for coordinated functioning

 INSTRUMENTATION USED IN REFINERY:

1. TEMPERATURE MESUREMENT:

Bimetallic gauge:

A bimetallic temperature gauge employs a sensor bimetallic strip by

name.

10
A bimetallic strip is used to convert a temperature change into mechanical
displacement. The strip consists of two strip of different metals which expand at
different rates as they are heated usually steel and copper. The strip s are joined
together throughout their length by riveting brazing or welding. The different
expansion forces the flat strip to bend one way if heated and in the opposite
direction if cooled below its initial temperature. The metal with the higher
coefficient of thermal expansion is on the outer side of the curve when the strip
is heated and on the inner side when cooled. It is connected to a pointer in order
to detector the temperature.

This sensor is utilized to show the temperature locally.

 RTD

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Resistance temperature detectors (RTDs) are typically made of nickel,
copper, or platinum. Temperature is determined by measuring
resistance and then using the RTD‟s resistance vs. temperature
characteristics to extrapolate temperature.

They’re the once to use when applications requires accuracy, long-

term electrical (resistance) stability, element linearity, and
repeatability. The device can work in a wide temperature range –
some platinum sensors handle temperature from -328 to 1202.

PRINCIPLE OF OPERATION:

RTDs are manufactured from metals whose resistance increases with

temperature. Within a limited temperature range, this resistivity
increases linearly with temperature:

Rt = R0[1 + a(t – t0)]

Where:
Rt = resistivity at temperature t
R0 = resistivity at a standard temperature t0
a = temperature coefficient of resistance ( )
IEC/DIN grade platinum: a = 0.00385//
Reference grade platinum: a = 0.003926// (max.)

Thermistor

Normally NTC type of thermistor is used. Resistance of thermistor

decreased with increase in temperature. It is non-linear type device so
rarely used.

Thermocouple

In 1821, Thomas See beck discovered the operating principle of the

thermocouple: If two dissimilar metals are joined at one end, a
voltage (the See beck voltage) proportional to the temperature
difference between the joined and open ends is generated.

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 Power plant operation (CGP-2)

1. GAS turbine overview

1.1 Functional Description

Figure 1 Gas Turbine Side View

1. Inlet Casing
2. Thrusts and Journal Bearing
3. Variable Inlet Guide Vanes
4. Compressor Rotor Blades
5. Reverse Flow Combustion Chamber
6. Transition Piece
7. Turbine Nozzle
8. Buckets
9. Exhaust Diffuser
10. Compressor Forward Casin g
11. Compressor Wheel
12. Compressor After Casing
13. Duel Fuel Nozzles
13
 14. Turbine Exhaust
15. Axial Flow Compressor
16. Combustion System
17. Turbine Section

As described by the below figure a Gas turbine operates by

(i) Stage 1 Continuously drawing fresh air through inlet air
filters.
(ii) Between stage 1 and 2 Compressing this air to higher
pressure.
(iii) Between stage 2 and 3 Adding and burning fuel in the
compressed air to increase its energy level.
(iv) Stage 3 Directing this high pressure, high temperature air
to an expansion turbine that converts the gas energy to the
mechanical energy of a rotating shaft.
(v) Stage 4 The resulting low pressure, low temperature gases
are discharged to atmosphere / heat recovery steam
generator (HRSG).

Figure 2 Gas Turbine Operating Principle

When the turbine starting system is actuated and the clutch is

engaged, ambient air is drawn through the air inlet plenum assembly,
14
filtered and compressed in the 17 stage axial flow compressor. For
pulsation protection during startup, the 11th-stage extraction valves
are kept open and the variable inlet guide vanes are in the closed
position. When the turbine reaches 95 % speed, the variable inlet
guide vanes are opened to the normal turbine operation position.
Compressed air from the compressor flows into the annular space
surrounding the ten combustion chambers, from which it flows into
the space between the outer combustion casing and the combustion
liners and enters the combustion zone through metering holes in each
of the combustion liners.
Fuel from an off-base source is provided to ten equal flow lines, each
terminating at fuel nozzle located at the individual combustion
chamber. Prior to being distributed to the nozzles, the fuel is
accurately controlled to provide an equal flow into the ten nozzle feed
lines at a rate consistent with the speed and load requirements of the
gas turbine. The nozzles introduce the fuel into the combustion
chambers where it mixes with the combustion air and is ignited by
one or both of the spark plugs. When fuel is ignited in one
combustion chamber flame is propagated, through connection
crossfire tubes, to all other combustion chambers. After the turbine
reaches operating speed combustion chamber pressure causes the
spark plugs to retract to remove their electrodes from the hot flame
zone.
The hot gases from the combustion chambers expand into the ten
separate transition pieces attached to the aft end of the combustion
chamber liners and flow from there to the three-stage turbine section
of the machine. Each stage consists of a row of fixed nozzles
followed by a row of rotatable turbine buckets. In each following row
of moving buckets, a portion of the kinetic energy of the jet is
absorbed as useful work on the turbine rotor.
After passing through the third-stage buckets, the gases are directed
into the exhaust hood and diffuser, which contains a series of turning
vanes to turn the gases from an axial direction to a radial direction,
thereby minimizing hood losses. The gases then pass into the exhaust
15
plenum and are introduced to atmosphere through the exhaust stack.
Resultant shaft rotation is used to turn the generator for electrical
power generation.

1.2 Support System

Support system of Gas Turbine typically includes following:
1. The Lube Oil System for furnishing normal lubrication and
absorbing the heat rejection of the gas turbine.
2. The Hydraulic Supply System which provides the necessary
hydraulic flows and pressures for control devices on the turbine.
3. The Trip Oil System used in hydraulic trip oil system which acts
as an interfacing medium between valves and hydraulic oil for the
positive and fast operation.
4. The Cooling Water System which is used as a cooling agent for
lube oil and DM water.
5. The Starting System including the starting device here Diesel
Engine and the required logic sequence for starting the gas turbine
and bringing it up to a speed such that GT is able to run on its own.
6. The Cooling And Sealing Air System which provides the
necessary airflow from the turbine compressor to the other parts of the
turbine rotor and stators to prevent excessive temperature build up
and prevent bearing oil leakage.
7. The Fuel System which supplies and controls the flow and directs
the fuel to the fuel nozzles in the gas turbine combustors according to
the load demand. The fuel system includes NG, HSD and
NAPHTHA. Duel fuel is also possible with one fuel being NG and
other being HSD or NAPHTHA.
8. The Atomizing Air System provides sufficient pressure in the air
to atomize the liquid fuel i.e. to break the thick and continuous fuel jet
to fine droplets permitting ignition and combustion with increased
efficiency.

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9. The Ventilating and Heating System provides the ventilation of
hot air from compartments so that various devices in these
compartments work in the allowable compartment temperatures.
10. The Fire Protection System is provided to extinguish fires in the
compartments, in case any fire takes place. Separate fire protection
system is provided for Gas Turbine and Generator.
11. The Inlet and Exhaust System provides atmosphere air to be
brought into the compressors through inlet ducting and let exhaust
gases to atmosphere or to heat recovery steam generators.
12. The Hazardous Gas Detection System is provides for detection
of hazardous gas leakages here NG which is used as a fuel.
13. Compressor Water Wash System is provided to wash the
compressor for any foreign material contamination on its blade and
buckets. Washing can be done online or offline.
14. Water Injection System is provided for controlling of the NOx
gases formation caused by burning of Nitrogen and Oxygen at very
high combustion temperature (exceeding 2800 0F).

17
 2. Constructional features

A Gas Turbine unit mainly consists of

1. Air inlet system
2. Accessory gear compartment
3. Turbine compartment
4. Load gear compartment
5. Generator and exciter compartment
6. Exhaust system

2.1 Air Inlet System

The air inlet system consists of an integrated, self-cleaning filter

house and support structure, an inlet ducting system and an inlet plenum
leading to the compressor section of the turbine. Inlet air enters the inlet
compartment and flows through the ducting, with built-in acoustical
silencers and trash screen, to the inlet plenum before entering the turbine
compressor. The elevated intake arrangement provides a compact
system and minimizes pickup of dust concentrated in the air near the
ground. All external and internal surface areas of the inlet system are
either coated with a corrosion preventive primer or galvanized for
corrosion protection.
2.1.1 Inlet Compartment
The inlet filtration compartment and its integrated support structure
sits on a separate Foundation just upstream of the control compartment.
The filter house is a self-cleaning design consisting of a number of
filtration modules which flow upward to a tapered clean air plenum.
Air filters
It consists of a single stage air filter utilizing surface acting cellulose
and/or synthetic base high efficiency paper media. These highly
efficient filter elements are used to achieve Compressor inlet air flow
requirements. During normal operation, a duct cake is gradually
formed on the surface of the filter media, creating airflow restriction.

18
The filter elements are re-generated to ensure an acceptable low level
of Del-P across filters by injecting compressed air into a selected
number of elements in reverse flow direction for cleaning the duct
cake formed on filter surface. A programmable electrical control unit
activates and modulates the self-sequencing system for filter cleaning
initiated on either time basis or on pressure drop basis or on
combination of both.
Filter pairs (cylindrical and conical) are arranged horizontally to
improve cleaning during operation. In this way the dust particles
which are pulsed off the filter elements are allowed to fall down out
more freely and thus re-entry of fine dust particles are reduced by
positive downdraft within the system.

Figure 3 Horizontal Filter Assembly

The clean air plenum has an aft outlet flange which connects to the
inlet ducting. Each filtration module contains numerous single-stage,
high efficiency, self-cleaning filter elements.

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In GT#4 and GT#5 no. of installed filters is as following-
No. of horizontal filter assembly lines 15
No. of vertical filter assembly lines 12
Total duplex filters 15X12 = 180

Air Processing Unit (APU)

This compartment contains a self-cleaning filtration unit with high
efficiency filter cartridges that are cleaned sequentially by pulses of
pressurized air during turbine operation. Compressor discharge air
from the gas turbine compressor 17 th stage is supplied to the self-
cleaning inlet filters for use as pulse air during the cleaning cycle. Air
from the compressor discharge contains lots of moisture, which will
not clean air filters effectively, if injected directly. So air dryer is used
to treat 17 th stage compressor discharge air, before using it for pulse
cleaning. A brief description of APU is given below.

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Figure 4 Air Processing Unit (APU)

As shown in figure even after passing through the pre-filter (moisture

separator), the compressed air still contains vapor moisture, which are
subsequently removed by air dryer. Dryer contains activated alumina,
which has a natural tendency to establish equilibrium with its
surrounding by absorbing moisture from incoming wet air. The
compressed air passes through towers by means of pneumatically
operated control valves (CV1, CV2, CV3) which in turn are actuated
by solenoid valves (SV1, SV2, SV3) with timer. Wet air enters from
bottom and come out from top as dry air. When the timer is switched
‘ON’, the solenoid valve SV1 will actuate the 3-way valve CV1 for 5
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minutes, thereby directing the compressed air to tower-B.
Simultaneously (after 5 sec), the 2-way valve CV2, which is
connected to tower-A will open. This will de-pressurize tower-A and
is placed for purging for 3 minutes. After 3 minutes, the valve CV2
will close and tower-A will then pressurize in next two minutes
through needle valve. At the end of 5 minutes, tower changeover
occurs, and compressed air from pre-filter now flows to tower-A, by
means of 3-way control valve CV1. Simultaneously (after 5 sec), the
2-way valve CV3, which is connected to tower-B will now open and
tower-B is placed on purging for 3 minutes. Subsequently CV3 will
close and tower-B is pressurized in next 2 minutes. So, it is standard
10 minutes cycle for a tower i.e. 5 min drying-3 min purging-2 min
pressurization, and after 5 minute tower changeover occurs.
2.1.2 Inlet Ducting and Silencing
The air inlet ductwork connecting the inlet compartment to the
compressor inlet consists of an expansion joint, extension ducting,
silencer, down elbow, a transition duct and the inlet plenum and
plenum side extensions. The extension ducting and silencer runs
horizontally above the control and turbine accessory compartments
and is supported on its own steel support structure. The flow is then
directed down and transitioned into the inlet plenum by the elbow and
transition ducts. The inlet silencer consists of an acoustically lined
duct containing silencing baffles constructed of a low-density
insulating material which is encapsulated by perforated sheet steel.
The acoustic lining in the walls of the silencer duct and the walls of
the ducting downstream of the silencer have a similar construction.
The vertical parallel baffle is specifically designed to eliminate the
fundamental compressor tone as well as attenuating the noise at other
frequencies. There is a stationary trash screen within the transition
duct with can be accessed for cleaning and inspection through a
removable access panel on the side of the elbow. The inlet ducting
makes use of materials and coatings in their construction which are
designed to make them maintenance free. The perforated sheet and
internal stiffeners used in the silencers and lined ductwork are

22
fabricated of galvanized steel. The carbon steel walls are painted with
multiple coats of zinc-rich, corrosion inhibiting paint.

2.2 Accessory Gear Compartment

Most of the mechanical and electrical auxiliary equipments necessary

for starting and operating the gas turbine are contained within the
accessory compartment. Several major components of the accessory
compartment includes-
2.2.1 Starting Means
Gas turbine is fully independent machine when running on loaded
condition, but to start-up a standstill gas turbine some external means
are needed. This may be done by a motor or diesel engine. In this gas
turbine diesel engine is used. Diesel engine alone is not sufficient to
break away such huge mass. So torque converter and ratchet
assemblies are used to achieve this. During the starting sequence, the
gas turbine is driven through the accessory gear by the diesel engine,
torque converter output gear and the starting clutch. The starting
clutch assembly and the engagement cylinders are mounted on the
accessory gear assembly. The accessory gear is permanently coupled
to the turbine compressor shaft by a flexible coupling. The starting
system provides power for both cranking and turning during gas
turbine start up and shutdown cycles. In the starting cycle there are
three primary functions provided by the starting system:
(i) Start the gas turbine rolling (breakaway from standstill);
(ii) Accelerate the gas turbine to a speed where it can be fired
(iii) After the turbine has fired, further-accelerate it to a self-
sustaining speed (a speed at which gas turbine develops net positive
power output).
Starting system components include:

Diesel Engine
When operating, the diesel engine draws combustion air from
the accessory compartment through a filter into the turbocharger

23
inlet. Air dampers, located downstream of the turbochargers are
equipped with a manual emergency shutdown latch. Engine coolant
exchanges its heat with the Gas Turbine cooling water system. The
flow rate is controlled by thermostats on the engine. The engine
operates on a completely self-contained lube oil system. Lube oil
pressure can be read on a panel mounted pressure gauge and is
monitored by pressure switch 63QD-1. A fuel tank for the diesel
engine has been fabricated in the accessory compartment. The main
fuel pump driven by the Diesel engine itself draws fuel from canister
and pumps it through a filter and into the injector’s headers. Each
fuel injector draws the required amount of fuel from the headers,
while the excess fuel (used to cool the injectors) is returned to the
canister and through the overflow drain back to the tank. There is a
manual “priming” pump installed in parallel with the high lift pump.
Engine starter 88DS-1 is a direct current motor that engages with the
engine through a Benedix clutch. Engine speed is controlled by the
positioning of a lever on the variable speed governor. The positioner
is a hydraulic cylinder controlled by solenoid valves 20DA-1 and
20DA-2. A small engine driven pump, pressure limited by relief
valve VR13-1, supplies a controlled flow rate of engine oil for
cylinder operation. When 20DA-2 is energized, the governor lever is
driven to and held at the maximum speed position. When 20DA-2 is
de-energized, the lever is returned to the idle position. Energizing
20DA- 1 when the lever is anywhere between the end positions,
stops the positioner travel and holds the lever at the existing position
(governing at an intermediate speed). This system allows control of
the gas turbine cranking speed. Except under certain emergency
conditions, the engine is only stopped with the governor lever in the
idle position. Following an emergency shutdown, the engine can be
safely restarted regardless of governor lever position; but the
operator has the option of manually resetting the lever before
attempting a restart. The engine stop device is an "energize-to-stop"
solenoid (20DV-1) connected to the governor that when energized
activates the shutdown mechanism and stops the engine. Electronic,
logic in the control panel provides automatic sequencing of 88DS-1,

24
 20DA-1, 20DA-2 and 20DV-1 for normal unit startup, for normal
and emergency engine shutdown and for exercising and/or test of the
engine.
To protect the system hardware, the logic also monitors the
starting clutch position (33CS-1), the engine lube oil pressure
(63QD-1) and the engine speed. Necessary ALARMS and / or
TRIPS are built into the control system. The engine will operate at
constant speed when the unit is between 2300 and 2700 rpm during
the startup sequence this is the crank speed range of the turbine.
Routinely checking the engine speed in this speed range will provide
a good check on engine performance level in that a persistent speed
decrease of more than about 35 rpm from the "normal" indicates a
need to have the engine serviced by a qualified mechanic.
Diesel Engine Operation After the starting clutch is engaged,
88DS-1 is energized to start the engine. The engine idles through the
warm-up cycle and then 20DA-2 is energized to accelerate the
engine to maximum speed for unit breakaway (requires assistance of
the hydraulic ratchet). Following breakaway, 20DA-2 is de-
energized to decelerate the engine to approximately 1900 rpm at
which point 20DA-1 is energized to hold constant engine speed until
the gas turbine is sequenced through the end of warm-up. Then
20DA-1 is de-energized and 20DA-2 energized to accelerate the
engine back to maximum speed (and power) for acceleration of the
unit to self-sustaining speed. At a unit speed of about 3100 to 3200
rpm, the clutch automatically disengages and 20DA-2 is de-
energized. The engine returns to idle speed, idles through a cool-
down period, and stops when 20DV-1 is energized for several
seconds.

Ratchet System Operation

With the pump in operation and solenoid valve 20CS-1 energized, oil
from the turbine main lubrication system is ported to the starting
clutch and the ratchet system. This causes the ratchet mechanism to
operate continuously as the hydraulic self-sequencing control
25
automatically shifts the oil flow between the forward and reset strokes
of the ratchet mechanism. A forward stroke advances the starting
clutch about 47 degrees during the 10 second duration. The reset
stroke is of about 4.5 second duration. Operation for unit cool down is
automatically sequenced by the control panel. Once every three
minutes, the mechanism is operated, through one complete cycle. The
cycle is terminated in the forward stroke position to lock the clutch in
the engaged position.
Ratchet operation is normally required to achieve breakaway of the
unit rotor system during the unit startup sequence. With the starting
mean (here Diesel Engine) at maximum power, 88HR-1 and 20CS-1
are energized for continuous operation until breakaway is achieved. If
breakaway is not achieved within three minutes, the ratchet system is
de-energized. The ratchet system can also be manually operated by
use of "Jog" switch 43HR-1 located in the accessory compartment.
Actuation of the "Jog" switch interrupts and terminates operation in
any automatic sequence. Switch actuation energizes 88HR-1 and
20CS-1 and maintains both in an energized state as long as switch
contact is maintained. Release of the switch immediately de-energizes
both 88HR-1 and 20CS-1 independent of the ratchet stroke position.
Excessive continuous ratchet operation and/or jogging ("inching the
rotor") by use of the "jog" switch can seriously affect the life of
88HR-1 and/or 20CS-1.

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 Power plant operation (TPS-2)

A thermal power station is a power plant in which heat energy is

converted to electric power. In most of the world the turbine is steam
driven. Water is heated, turns into steam and spins a steam turbine
which drives an electrical generator. After it passes through the
turbine, the steam is condensed in a condenser and recycled to where
it was heated; this is known as a Rankine cycle. The greatest variation
in the design of thermal power stations is due to the different heat
sources, fossil fuel dominates here, although nuclear heat energy and
solar heat energy are also used. Some prefer to use the term energy
centre because such facilities convert forms of heat energy into
electrical energy.[1] Certain thermal power plants also are designed to
produce heat energy for industrial purposes of district heating, or
desalination of water, in addition to generating electrical power.
Globally, fossil-fuel power stations produce a large part of man-made
CO2 emissions to the atmosphere, and efforts to reduce these are
varied and widespread.

Types of thermal energy sources

Almost all coal, nuclear, geothermal, solar thermal electric, and waste
incineration plants, as well as many natural gas power plants are
thermal. Natural gas is frequently combusted in gas turbines as well
as boilers. The waste heat from a gas turbine, in the form of hot
exhaust gas, can be used to raise steam, by passing this gas through a
Heat Recovery Steam Generator (HRSG) the steam is then used to
drive a steam turbine in a combined cycle plant that improves overall
efficiency. Power plants burning coal, fuel oil, or natural gas are often
called fossil-fuel power plants. Some biomass-fuelled thermal power
plants have appeared also. Non-nuclear thermal power plants,
particularly fossil-fuelled plants, which do not use co-generation, are
sometimes referred to as conventional power plants.

Commercial electric utility power stations are usually constructed on

a large scale and designed for continuous operation. Virtually all
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Electric power plants use three-phase electrical generators to produce
alternating current (AC) electric power at a frequency of 50 Hz or 60
Hz. Large companies or institutions may have their own power plants
to supply heating or electricity to their facilities, especially if steam is
created anyway for other purposes. Steam-driven power plants have
been used to drive most ships in most of the 20th century until
recently. Steam power plants are now only used in large nuclear naval
ships. Shipboard power plants usually directly couple the turbine to
the ship's propellers through gearboxes. Power plants in such ships
also provide steam to smaller turbines driving electric generators to
supply electricity. Nuclear marine propulsion is, with few exceptions,
used only in naval vessels. There have been many turbo-electric ships
in which a steam-driven turbine drives an electric generator which
powers an electric motor for propulsion.

Combined heat and power plants (CH&P plants), often called co-
generation plants, produce both electric power and heat for process
heat or space heating. Steam and hot water

28
 Electrical Maintenance

In electrical maintenance we had visited two plants i.e. FCC and

SRU. In which we show a different component of indoor substation
and study about their single line diagram, schematic diagram etc.

We also see different switches, contactor, vacuum circuit breaker,

Induction motor etc.
Different components and their Name plate as follow:

1. Transformer:-

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2. Induction motor:-

3. Vacuum circuit breaker:-

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Electrical maintenance is the upkeep and preservation of equipment
and systems that supply electricity to a residential, industrial or
commercial building. It may be performed by the owner or manager
of the site or by an outside contractor. The work is commonly
performed on a schedule based on the age of the building, the
complexity of the electrical system or on an as-needed basis.

The main areas of general electrical maintenance commonly include

the power outlets and surge protectors, generators and lighting
systems. These supply sources are checked for structural integrity as
well as internal stability. The maintenance plan normally includes the
regular replacement of burned out fluorescent and incandescent lights.
Many building managers in recent years have refitted their lighting
systems with energy saving bulbs and elements.

Preventive maintenance is also generally part of a building’s upkeep.

This plan ordinarily includes the scheduled inspection of large
systems and equipment by a professional electrician. The purpose of
these periodic assessments is to fix small problems before they
escalate into large ones. This is particularly important at plants,
hospitals and factories that heavily rely on these systems for daily
operations.

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 Electrical Testing

Electrical testing is a vital procedure. Electrical testing is an essential

task and can be difficult so it's necessary to let a professional do
it. The electrical test report is displayed in a test certificate which is a
legal document. The certificate is similar to a fault log report but it
also contains a count of occurrences of each fault.

Electrical testing over temperature is the industry standard for testing

a component’s functional and parametric requirements at the
recommended manufacturer’s or specific industry extreme operating
temperatures. Electrical testing is an essential task and can be time
consuming and inconvenient as the power has to be turned off for
some tests. We can generally work around your limitations to losing
power in the office, home, workplace.

Inspection provides the ideal opportunity for checking the general

condition of the equipment and that all parts are in sound condition.
Our skilled team provides a comprehensive testing and inspection
service, ensuring that anything from a mobile home to a factory
complex is running as safely and efficiently as possible.

A periodic inspection report will reveal if any circuits or electrical

equipment are being overloaded, locate any potential electrical shock
risks and fire hazards in an installation, identify any defective DIY
electrical work, or highlight any lack of earthing or bonding.

In electrical testing there are different instruments are used for

assurance of electrical equipments some of them are as follow

1. Megger

2. Oil tester kit

3. Multimeter

4. Clamp On meter

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5. CT and PT

6. Relay test kit

7. Earthing and Discharge rode

Besides these there is lots of protection system and methods are used
for electrical testing.

All test are conducted as per procedure describe in manual.

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 Electrical Workshop
The fortunes of the heavy electrical industry have been closely linked
to the development of the power sector in India. The heavy electrical
industry has under its purview power generation, transmission,
distribution and utilisation equipments. These include turbo
generators, boilers, turbines, transformers, switchgears and other
allied items. These electrical equipments (transformers, switchgears,
etc.) are used by almost all the sectors. Some of the major areas where
these are used include power generation projects, petrochemical,
refineries, chemical plants, integrated steel plants, non-ferrous metal
units, etc.

The design, engineering and construction of industrial plants involves

a multi-disciplinary team effort. The goal is to design safe and
dependable processing facilities in a cost effective manner. The fact is
that there are very few formal training programs that focus on design
and engineering of Electrical systems of such big plants. Therefore,
most of the required skills are acquired while on the job, reducing
productivity and efficiency.

The objective of this course is to provide the delegates the basic

knowledge and skills in this discipline to facilitate faster learning
curves while on the job.

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