Industrial Training Report

UNIVERSITY OF MORATUWA
Faculty of Engineering
Non-GPA Module 399: Industrial Training
INDUSTRIAL TRAINING REPORT

Kularathna M.P.D.S.C.
Registration No: 080246F
Department of Electrical Engineering
Lanka Electricity Company (Pvt) Ltd

Ceylon Electricity Board
Amithi Power Consultants (Pvt) Ltd
From 02nd of March 2011 to 03th of September 2011
Date of submission - 17th of September 2011
Training Report_______________________________________________________________________________________________________________
PREFACE
This report was prepared as a requirement at the end of our Industrial Training period.
This training was a great opportunity to expose ourselves to industrial environment, let us to apply the
knowledge we gathered at the university and to gain some experience about the industry.
I have included my experiences, skills and practices I gained for 24 weeks duration starting
from 28th February 2011 to 12th August 2011 about electrical engineering field as an electrical
engineering undergraduate trainee of the University of Moratuwa at Ceylon Electricity Board, Lanka
Electricity Company (Pvt) Ltd and Amithi Power Consultants (Pvt) Ltd.
The report consists of 3 major chapters. First chapter mainly includes Information about
Training Establishment. This Chapter begins with a brief introduction of each training places .Then
First chapter describes main functions, Organizational Structure and hierarchical levels, Present
Performance, Strengths, Weaknesses, profitability, Usefulness to Sri Lankan Society of each training
Establishments.
The second chapter describes daily entries in detail, it contains about the technical experience
and knowledge which I have gathered during my training period, in different places in CEB and
LECO. Also in there I have included many electrical designs involved in APCL and gathered
knowledge and experiences while involved in those designs.
The third or final chapter includes the conclusion of the report. This conclusion include an
assessment on the current Industrial Program which coordinated by University Of Moratuwa. There
have summarized training experienced which I gained for 24 weeks within Ceylon Electricity Board,
Lanka Electricity Company (Pvt) Ltd and Amithi Power Consultants (Pvt) Ltd. I added my comments
that describe how Industrial Training should change to provide a maximum merit to implant trainees.
Also I appended comments and suggestions that describe how industrial training program should
improve.
Kularathna, M.P.D.S.C.
Department of Electrical Engineering
University of Moratuwa
Kularat h naM . P. D . S . C .ii

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ACKNOWLEDGEMENT
Here my sincerely thanks go to the Industrial Training Division of University of
Moratuwa and National Apprentice & Industrial Training Authority (NAITA) for taking all the
necessary arrangements for making this training program a success and giving me this opportunity
to gain the in plant traineeships in Ceylon Electricity Board, Lanka Electricity Company (Pvt) Ltd and
Amithi Power Consultants (Pvt) Ltd.
I would like to express my gratitude towards all the Engineers, technicians, workers and other
staff of Ceylon Electricity Board in Samanalawewa Power Station, Sapugaskanda Thermal Plant,
Kelanithissa Power Plant, Kelanithissa Combined Cycle Power Plant, Generation & transmission
Planning division, Transmission Operation and Maintenance (Colombo region), System Control
Centre, Rathmalana GSS and Pannipitiya GSS for spending their valuable time and sharing their
knowledge to success my in plant traineeship.
Next I should convey my gratitude for who helped me in Lanka Electricity Company (Pvt) Ltd,
all the Engineers, technicians, workers and other staff of Maharagama Customer Service Centre,
Branch Office, Operation Division, Engineering Division and Ekala-Training Centre for enhancing my
knowledge about electrical engineering field and receiving necessary experiences and skills.
Next my special gratitude go to Mr. D.G Rienzi Fernando, Chairman and Managing Director
of Amithi Power Consultant (Pvt) Ltd for his decision to recruit engineering students as trainees and
support he gave in various ways to develop our practical knowledge and I would like to thank the
entire staff of the Amithi Power Consultant (Pvt) Ltd.
It’s very important to memorize and give my special gratitude my parents, my friends, and
especially my dear Mrs Suwanthri Katuwapitiya, be with me and help me in various ways to complete
my training report successfully.
Kularat h naM . P. D . S . C .iii

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Table of Contents
1. Introduction to the Training Establishment..........................................................................................1
1.1 Lanka Electricity Company (Pvt) Ltd......................................................................................1
1.1.1 Introduction to LECO...............................................................................................................1
1.1.2 History of the LECO................................................................................................................1
1.1.3 Vision and Mission of LECO...................................................................................................2
1.1.4 Organization Structure of the LECO........................................................................................2
1.1.5 Present Performances and Strength of the LECO....................................................................2
1.1.6 Profitability of the LECO.........................................................................................................2
1.1.6 Usefulness of LECO to Sri Lankan Society.............................................................................3
1.2 Ceylon Electricity Board.................................................................................................................3
1.2.1 Introduction to CEB.................................................................................................................3
1.1.2 Organization Structure of the CEB..........................................................................................4
1.2.3 Present Performances and Strength of the CEB.......................................................................4
1.2.4 Usefulness of CEB to Sri Lankan Society...............................................................................4
1.2.4 Suggestions for improvements.................................................................................................4
1.3 Amithi Power Consultants (Pvt) Ltd...............................................................................................5
1.3.1 Introduction to APCL...............................................................................................................5
1.3.2 History of the APCL................................................................................................................5
1.3.3 Organization Structure of the APCL........................................................................................5
1.3.4 Present Performances and Strength of the APCL....................................................................6
1.3.5 Profitability of the APCL.........................................................................................................6
1.3.6 Suggestions for improvements.................................................................................................6
1.3.7 Usefulness of APCL to Sri Lankan Society.............................................................................6
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2. TRAINING EXPERIENCES...............................................................................................................7
2.1 Training Experience in Lanka Electricity Company (Pvt) Ltd.................................................7
2.1.1 Maharagama LECO Depot.......................................................................................................7
2.1.1.1 HT maintenance................................................................................................................7
2.1.1.2 Consumer Breakdown maintains......................................................................................8
2.1.1.3 Field billing.......................................................................................................................8
2.1.1.4 Disconnecting process......................................................................................................8
2.1.1.5 Breakdown registry...........................................................................................................8
2.1.1.6 Equipments and Materials use in LECO Depots..............................................................9
2.1.2 Nugegoda LECO Branch Office........................................................................................10
2.1.2.1 LECO Construction work...............................................................................................10
2.1.2.2 Planning & construction.................................................................................................11
2.1.2.3 Job Costing.....................................................................................................................11
2.1.2.4 LV Planning....................................................................................................................12
2.1.3 LECO Head Office.................................................................................................................12
2.1.3.1 Engineering Division......................................................................................................12
2.1.3.2 Load forecast..................................................................................................................12
2.1.3.3 Planning..........................................................................................................................12
2.1.3.4 Load flow analysis..........................................................................................................11
2.1.4Operation Division.............................................................................................................11
2.1.4.1Distribution Control Centre.............................................................................................11
2.1.4.1.1 Task of system control centre..................................................................................11
2.1.4.1.2 Preparing reports......................................................................................................12
2.1.4.2 Ekala LECO Training Centre.........................................................................................12
2.1.4.2.1 Meter testing laboratory...........................................................................................12
Kularat h naM . P. D . S . C .v
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2.1.4.2.2 Tests apply on Energy meter...................................................................................16
2.1.4.3.1 Transformer Testing................................................................................................17
2.2 Training Experience in Ceylon Electricity Board.........................................................................19
2.2.1 Samanalawewa Hydropower Plant.........................................................................................19
2.2.1.2 Surge Chamber...............................................................................................................19
2.2.1.3 Power house....................................................................................................................20
2.2.1.5 Active power control......................................................................................................20
2.2.1.6 Reactive power control...................................................................................................20
2.2.1.7 Power Transformers.......................................................................................................21
2.2.1.8 Switchyard......................................................................................................................21
2.2.1.9 Auxiliary supply.............................................................................................................22
2.2.1.10 Governor.......................................................................................................................22
2.2.1.10 Battery bank..................................................................................................................22
2.2.2 Kelanithissa Thermal Power Plant.........................................................................................22
2.2.2.1 Small Gas turbines (GTs)...............................................................................................22
2.2.2.2 Synchronous Condenser Mode.......................................................................................23
2.2.2.3 Starting of Small Gas turbines (GTs).............................................................................23
2.2.2.4 115MW Large Gas turbine (GT)....................................................................................23
2.2.2.5 GIS..................................................................................................................................23
2.2.3 Kelanithissa Combined Cycle Power Plant............................................................................24
2.2.3.1 Starting the GTs..............................................................................................................24
2.2.4 Spugaskanda Power Plant......................................................................................................25
2.2.4.1 Overview of the Plant.....................................................................................................25
2.2.4.2 Fuel oil System...............................................................................................................26
2.2.4.3 Engine modules..............................................................................................................26
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2.2.4.4 Turbo Charger.................................................................................................................27
2.2.4.4 Generator........................................................................................................................27
2.2.4.5 Switch yard of the Power plant.......................................................................................28
2.2.4.6 Maintains........................................................................................................................28
2.2.5 System Control Centre...........................................................................................................29
2.2.5.1 System Stability Limits..................................................................................................29
2.2.5.2 System Operation...........................................................................................................29
2.2.5.3 Operation Planning.........................................................................................................30
2.2.5.4 Under Frequency Load Shedding...................................................................................30
2.2.6 CEB Head office Generation and Transmission Planning division.......................................31
2.2.6.1 Planning and Demand forecasting..................................................................................31
2.2.6.2 Generation Planning.......................................................................................................32
2.2.6.3 Transmission Planning...................................................................................................33
2.2.6.4 The load flow analysis....................................................................................................33
2.2.7 Rathmalana and Pannipitiya Grid Sub Station.......................................................................34
2.2.7.1 Rathmalana Grid Sub Station.........................................................................................34
2.2.7.3 Components in substations.............................................................................................35
2.2.7.4 Power Transformer.........................................................................................................35
2.2.7.5 Protection method of Power Transformer......................................................................36
2.2.7.5.1 Hot spot temperature...............................................................................................36
2.2.7.5.2 Bucholz relay...............................................................................................................36
2.2.7.6 On load tap changer........................................................................................................36
2.2.7.7 Dehydrate filter breather.................................................................................................36
2.2.7.8 Pressure relief Valve.......................................................................................................37
2.2.7.9 Switching in a switch yard..............................................................................................37
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2.2.7.12 Circuit Breakers............................................................................................................37
2.2.7.13 Current Transformers...................................................................................................38
2.2.7.14 Potential Transformers.................................................................................................39
2.3 Training Experience in Amithi Power Consultants (Pvt) Ltd.......................................................40
2.3.1Testing and Measurement.......................................................................................................40
2.3.1.1 Insulation Testing...........................................................................................................40
2.3.1.2 Cable Insulation Testing.................................................................................................41
2.3.2.3Relay testing....................................................................................................................42
2.3.2.3.1 Secondary injection and Primary injection test on relays........................................43
2.3.3 Capacitor Bank Designing.....................................................................................................44
Applicable Standard...................................................................................................................44
2.3.3.1 Energy survey Results....................................................................................................44
2.3.3.2 Recommendations..........................................................................................................45
2.3.3.3 Calculation and the Size of the Capacitor bank..............................................................45
2.3.3.4 Phase balancing..............................................................................................................47
2.3.4 Lightning Protection System Designing................................................................................48
2.3.4.1 Direct lightning...............................................................................................................48
2.3.4.2 Indirect lightning............................................................................................................48
2.3.4.3 Protection of structures against lightning.......................................................................48
2.3.4.4 Risk Level assessment for the building..........................................................................49
2.3.4.5 Methods of Air Termination System as per IEC............................................................51
2.3.4.6 Main Components of lightning protection system.........................................................53
2.3.5 Thermal Imaging....................................................................................................................55
2.3.5.1 Concept of Thermal Imaging..........................................................................................55
2.3.5.2 Importance of thermal imaging......................................................................................55
Kularat h naM . P. D . S . C .viii

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2.3.5.3 Suitable for Thermal imaging in.....................................................................................56
2.3.5.4 Thermal imaging in LV switch board and Cables..........................................................57
2.3.5.4 Consider the following analysis of thermal images........................................................57
2.3.6 Electrical installation design..................................................................................................60
2.3.6.1 Lighting design And Switch placing.................................................................................i
2.3.6.1.1 Factors and procedure to consider while lighting design...........................................i
2.3.6.1.2 Utilization factor.........................................................................................................i
2.3.6.1.3 Maintenance factor....................................................................................................ii
2.3.6.1.4 Suitable lighting and fittings.....................................................................................ii
3. Conclusion...........................................................................................................................................iv
ANNEX 01..........................................................................................Error! Bookmark not defined.
Kularat h naM . P. D . S . C .ix

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List of Figures
Figure 1.1 – Product (Electricity) flow of electricity 03

Figure 2.1 – Isolation and Earthing of lines 07
Figure 2.2 – Insulated T-Off Connectors 09
Figure 2.3 – Pre Insulated Joints 09
Figure 2.4 – Pre Insulated Bimetal Lug 09
Figure 2.5 – Uninsulated Joint 09
Figure 2. 6 – H Type Compression Connector 09
Figure 2.7 – Hydraulic Crimper 09
Figure 2.8 – Ratchet Lever Hoist 09
Figure 2.9 – Surge Arrestor 09
Figure 2.10 – Structure of Branch 10
Figure 2.11 – Construction work done by the LECO 10
Figure 2.12 – Procedure of construction 11
Figure 2.13 – Disk of energy meter 15
Figure 2.14 – Megger test on transformer 18
Figure 2.15 – Power plant 19
Figure 2.16 – Dame Section 19
Figure 2.17– Surge Chamber 19
Figure 2.18 – AVR 21
Figure 2.19 – Samanalawewa Switch yard 21
Figure 2.20 – Small GT in Kelanithissa 22
Figure 2.21– HRSG 24
Figure 2.22– Sapugaskanda Power Station Engine Arrangement 23
Figure 2.23– Fuel oil System 26

Figure 2.24 – Turbo charger system 27
Figure 2.25 – Self Exciter 28
Figure 2.26 - Transmission planning process 32
Figure 2.27 – WASP-iV Software 33
Figure 2.28 – Model in PSS 34
Figure 2.29 – SF6 breaker 38
Figure 2.30 – Current Transformer (CT) 38
Figure 2.31 – Potential Transformer (CVT) 39
Figure 2.32 – internal arrangement of Megger tester 40
Figure 2.33– testing insulation levels of cables 41
Figure 2.34 Digital Insulation Tester 42
Figure 2.35_Secondary Injection test on relay 43
Figure 2.34_ Measured Active power and Reactive Power Apparent power against Time 44
Figure 2.37_ Measured each phase currents against Time 45
Kularat h naM . P. D . S . C .x
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Figure 2.38 – Phaser diagram before and after install the capacitor bank 45
Figure 2.39 – Measured each phase currents against Time 47
Figure 2.40 – Capacitor 47
Figure 2.41 – Selection of lightning protection system 49
Figure 2.42– Calculation of collection area 50
Figure 2.43– Protective angle method 51
Figure 2.44– Rolling sphere method 52
Figure 2.45– Distribution T/F in firing 54
Figure 2.46– Power T/F firing 54
Figure 2.47– Thermal Images of Electrical Systems 55
Figure 2.48– Thermal image of cable 57
Figure 2.49– Digital image of cable 57
Figure 2.50– Thermal image of LV breaker 58
Figure 2.51– Digital image of LV breaker 59
Figure 2.52– Lighting design 60
List of Tables
Table 1.1- Training Establishments 01
Table 2.1 – percentage error tests on Energy meter 17
Table 2.2 – System stability limits 29
Table 2.3 – Under frequency load shading schedule 31
Table 2.4 – Cable insulation levels 41
Table 2.5 – specific voltage level for insulation testing 43
Table 2.6 – Energy survey result summery 44
Table 2.7 – System variable before and after capacitor bank installation 46
Table 2.8 – Standards for lightning protection design 48
Table 2.9 –Max allowable Temperatures for LV panels. 56
Table 2.10 – Cable temperature Analysis in FLIR software 57
Table 2.11 – LV panel temperature Analysis in FLIR software. 58
Kularat h naM . P. D . S . C .xi

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1. Introduction to the Training Establishment
This industrial training programme module had specially been allocated in to two main sessions for
Electrical Engineering students, Total period for the industrial training program was 24 weeks and it
was divided in to two main sessions with a period of twelve weeks for each according to the schedule
given by the Industrial Training Division of Faculty of Engineering, University of Moratuwa.
Following table shows exactly time periods of the training Programme.
Table 1.1- Training Establishments
Sessio Training Establishment Allocated Period

n
1 Lanka Electricity Company (Pvt) Ltd 4 weeks
1.1 La
Ceylon Electricity Board 8 weeks nk
a
2 Amithi Power Consultant (Pvt) Ltd 13 weeks
Electricity Company (Pvt) Ltd
1.1.1 Introduction to LECO

LECO is the only one privet organization of Sri Lankan power sector having a license to carry out
power distribution function within the country. By purchasing power (11kV from primary substations)
from Ceylon Electricity Board and distribute to the customers in (400V) coastal belt from Negombo to
Galle excluding Colombo city, Dehiwala and Mount Lavinia. Now a day LECO area is in operation in
their seven branches, and got the authority to provide electricity supply to Kotte, Nugegoda, Kelaniya,
Moratuwa, Galle, Kaluthara and Negombo areas. Provides its service with 7 Branch Offices, 24
Customer service Centers, 2 Main Stores, Meter Test Lab, Technical Training Center and Transformer
Repair Workshop.
Kularat h naM . P. D . S . C .1
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1.1.2 History of the LECO

In 1984 LECO started their distribution functions in some cities of western and Southern coastal belt
between Negombo and Galle.By recognizing the weaknesses of Local distribution functions carried by
CEB such as unreliability of supplies, high electrical losses, unsatisfactory revenue collection
procedures and the required investments for system improvements, by avoiding these inconvenients
and unsatisfactories as a result of that the Lanka Electricity Company (Pvt) Limited was established in
September 1983 under the Companies Act.
1.1.3 Vision and Mission of LECO
Vision
“Enjoy being the light for the lives of people through innovative eco-friendly business”
Mission
“To provide the best energy solutions to the society through continuous innovations”
1.1.4 Organization Structure of the LECO

Organization structure of the LECO is given in ANNEX 01 (Organization Structure of LECO)
1.1.5 Present Performances and Strength of the LECO

 LECO won the National Quality Award in 2001 and Ceylon Petroleum Corporation Award
best energy conservation project.
 Maintaining supply voltage at customer premises within 216-244 volt (230 V±6%)
 Voltage drop is reduced by using more distribution transformers in low capacities instead of
using high capacity transformers and long distribution cables.
 LECO has reduced its system losses to 5.5%, which remained at over 20% when electricity
distribution was carried out by local authorities.
 LECO introduced for the first time in Sri Lanka the use of Arial Bundled conductors (insulated
conductors) for low voltage (11KV and 400V) distribution. There by reducing customer
outages significantly. This will help to reduce losses due to way leaves and unauthorized
tapping. This is also an achievement because to give this type of supply at consumer ends
planning and maintains should be done properly. As a business organization while profit
making, satisfaction of consumer also were been taken in to consideration.
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1.1.6 Profitability of the LECO

Company should have profits to run the company even at the beginning LECO runs as unprofitable
institution now it is a profitable company. This is due to their best business strategy by reducing
unwanted losses in their whole network of distribution and net work in the organization.
1.1.6 Usefulness of LECO to Sri Lankan Society

As a power supplying company their role in the country is appreciable for taking every possible effort
to supply much more reliable Electricity to consumer premises. Customers are treated well and
presently they are planning to improve the efficiency and quickness of their service. LECO is using
new technologies to enhance the quality and reliability of the power supply.
1.2 Ceylon Electricity Board
1.2.1 Introduction to CEB

Ceylon Electricity Board controls one of a major consumer requirement which is Electricity. As an
island wide large organization they bare the license and responsibilities of fulfilling the electricity
demand of whole country. This is operated under the Ministry of Power and Energy. A large portion
of the power generation, totally whole transmission functions and a large portion of distribution are
done by CEB. So the CEB acts main role in Power sector inside the country any aspect of
developments and civilization is always combined with Electricity therefore their functions are impact
for the development of the country.
To supply as possibly maximum service and for ease of management CEB has divided in to three
divisions according to their functionalities known as Generation, Transmission & Distribution
Divisions and distribution division has four distribution regions known as Colombo, Kandy, Galle and
Anuradhapura.
The product flow of electricity is as follows. Cash flowing is also in same but reverse direction its
happening. Also in consumer points are also produce electricity after introduce the two way metering
using solar photovoltaic and other means. It is negligible compared to total power flow.
Independent power producers
CEB Generation Small power purchase
Transmission network
CEB Distribution 4 Regions LECO distribution

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Figure 1.1 – Product (Electricity) flow of electricity

1.1.2 Organization Structure of the CEB
The organizational structure and hierarchical levels are shown in ANNEX 01 (Organization Structure
of CEB).
1.2.3 Present Performances and Strength of the CEB

The electricity transmission part is totally owned to CEB, large portion of the electricity generation is
also done by CEB. The large hydro complex such as Mahawelli and Laxapana has the most profit
making hydro power plants. Existing thermal capacity is 517 MW and hydro capacity is 1205 MW.
900 MW of Coal Power Plant is committing in Puttalam and 150 MW of committed hydro capacity in
Upper Kotmale. CEB is governed under Ministry of Power and Energy to supply reliable and quality
electrical power for the development of the country and improve the living quality of lives with all
about 14000 employees in different levels and skilled. Ceylon Electricity board got large number of
valuable assets spread all over the country and this is one of a largest organization in Sri Lanka.
1.2.4 Usefulness of CEB to Sri Lankan Society

CEB is so important to the Sri Lankan society since it is the governing authority of Sri Lankan
electricity Generation, Transmission and Distribution. All the communication systems, most of
functions in various kind of industrial, domestic and public are depending on the electricity supply. So
the reliable and efficient electricity supply is essential factor to the Society. This organization serves
the people in Sri Lanka by delivering an efficient and reliable supply to the community. Activities and
decision taken by this organization will directly affects to the economical development of the county.
This company always try to serve and satisfy the customers first and then they get the benefit of it.
And this company has created number of job opportunities and it helps to develop the life stand of
people. Therefore this company is very important to the Sri Lankan society and people can get a lot of
benefits through this company.
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1.2.4 Suggestions for improvements

Should avoid political recruitments and make the opportunity for only skillful workers. As I heard
there are many other unsuitable political involvements inside this organization and so many external
effects from many ways. This all involvements are as in past the organization will put in to trouble. At
present organization has well organized management structure as suitable for this type of organization
this. will make proffits Introduce new software systems to do the transmission network analyzing
tasks, forecasting tasks and other requirements.
Introduce an evaluation procedure for the workers and engineers to enhance their efficiency.
There should be a group to study and introduce new technologies by looking at the world.
There should be a quick and reliable good and tools supply procedure in a situation such as breakdown
in grid substation etc…
1.3 Amithi Power Consultants (Pvt) Ltd
1.3.1 Introduction to APCL

Amithi Power Consultants is one of a leading electrical design firm in Sri Lanka. Many types of high
voltage and low voltage design consultants are handled by APCL. So many local and also foreign
projects have design and consulted by APCL. As the owner and the managing director of this
company Mr. Rienzie Fernando does a great service in the company to leading and giving instructions.
1.3.2 History of the APCL

Mr. D.G. Rienzie Fernando, owner and the managing director of this company has established this
company in 1996 after retiring from the post DGM of CEB. Since that APCL has successfully
completed large number of projects and services in electrical field.
Vision
“Strengthen the capabilities of Sri Lankan Engineering professionals to the International Standards by
improving the status of Sri Lankan Electrical Engineering sector through continuous efforts”
Mission
“Cater the vacuum of consulting service in and out of the island, in the relevant electrical fields”
“To spread our wings over a foreign market to work to fill the increasing gap of engineering services”
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1.3.3 Organization Structure of the APCL

The organizational structure is shown in ANNEX 01 (Organization Structure of Amithi power
consultants).
1.3.4 Present Performances and Strength of the APCL

This firm supplies their services in the electrical sector locally and internationally some of very giant
project which APCL has handled are Brandix Apparel City in India, Niyagala Open University
Project, Design and project supervision of Embilipitiya Substation and the transmission line. Lighting
Sri Lanka- Hambantota Project, Senok Wind Power Station, Ambewela wind Power Station. Under the
guidance of Mr.Rienzie Fernando and director board
APCL team of expertise is always in alert about new technologies and latest updates of standards
about electrical engineering. These days they are doing a power plant design project in Iraq.
Apart from that Safety audits, electrical testing are also performed
1.3.5 Profitability of the APCL

Since the beginning of this organization was a profitable organization due to the dedication and
determination of the all staff members.
1.3.6 Suggestions for improvements

There is some points in my view to improve the profitability and that it does not going to compete
with other organizations. It performs its job which they got and do not run for projects. And they do
not carefully about spreading their name over the country. That is over time hours are not given to the
employees and this would effect to motivation of employees worse.
1.3.7 Usefulness of APCL to Sri Lankan Society

APCL supply high quality and reliable services of electrical engineering field. They contribute to earn
foreign currency in to our country because they are involved in foreign projects also. Most important
thing is that this place makes skilled professionals in Electrical Engineering field by providing
working opportunities to make their carrier path while earning their salary.
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2. TRAINING EXPERIENCES
2.1 Training Experience in Lanka Electricity Company (Pvt) Ltd
2.1.1 Maharagama LECO Depot
2.1.1.1 HT maintenance
In any kind of maintains in their HT lines that the depot should ask for a work permit. Control centre
plan interruptions and allows them to do maintains the HT lines as minimum no of consumer are
affected for the power cut and CSC are received docket by mentioning every details. There is a sketch
of positions to be switched to isolate required portion of net work by load break switches. After
completed the maintain network is re arranged according to control center information they always in
connection with control centre through radio communication links.
At maintain procedure first they isolate through LBSs, the required line part and earth each end of line
through bare conductor connectors. At an end of line all three phase lines are connected conductors
and clamped to single conductor and grounded.
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Figure 2.1 – Isolation and Earthing of lines

There are reasons to consider for additional protection using earth the conductors even isolated lines.
 If voltage is generated in low voltage side of consumers it will stepped up into 11 kV lines.
 If another 11kV line above, induced voltages may be in the lower line.
 Normally HT lines are induced due to inductive behavior and may charge due to capacitor
behavior at some points.
 The load break cutoff may reconnect (rare) due to unusual occurrences.
2.1.1.2 Consumer Breakdown maintains
Always depot Technical staff is in alert about consumer calls about their supply problems. They are
ready to response for these interruptions as possible as quickly normally these consumer breakdowns,
maintains and complains are regards as follows,
 Burning of MCB due to high current flowing
 Energy meter related requests
 400V Lines, Poles and consumer supply line related requests
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2.1.1.3 Field billing
According to the supply connection or on the other word according to the tariff, customers are
categorized as domestic, general purpose, industries, temporary and religious.. Domestic bills are
counted by the revenue officer and bulk consumer bills are prepared by customer service
superintendent.
2.1.1.4 Disconnecting process
Branch office informs the list of disconnections to the Customer Service Centre with the ACC No,
substation (transformer), address, name, and bill amount. The bill is checked in the computer at the
CSC also before going to disconnection to see whether he paid the bill at a just a moment before. After
disconnecting the bill is handed over to the consumer. When that bill has paid, the branch will inform
the Customer Service Center to reconnect it here LECO charge additional fine for the inconvenience.
2.1.1.5 Breakdown registry
Consumer complains of breakdowns may be a tree fallen down to the line, MCB has burnt, meter is
not working, or No supply etc… That complains are recorded with persons went to resolve the
problem, vehicle, day & time, place, equipments used etc…
2.1.1.6 Equipments and Materials use in LECO Depots
There was large number of equipments and materials in the depot store room, few of them are as
shown in below
Insulated T-Off Connectors
These are suitable for line tapping from aerial bundle conductors. It is safe
even live conductors are also possible to tapped. Normally use to tape to
connect consumer supply lines. Figure 2.2 –
Insulated T-Off Connectors
Pre Insulated Joints
These are suitable for joining two L.V. bundle conductor lines in mid span. After
stripping of conductors as length marked on the body of the joint, inserted two
conductors in both end and use hydraulic crimper to tighten.
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Pre Insulated Bimetal Lug Figure 2.3 – Pre Insulated Joints

These are used for connecting bundle conductor to a copper pad or to transformer
studs. After stripping of conductor as length marked on the body of the joint,
inserted the cable end and use hydraulic crimper die to tighten.
Figure 2.4 – Pre
Insulated Bimetal Lug
Uninsulated Joint
These are suitable only for uninsulated neutral conductor joining. Same
crimping die used on the neutral and phase joints. Figure 2.5 –
Uninsulated Joint
H Type Compression Connector for Overhead Lines

These are used to tap off uninsulated ABC conductors
Figure 2.6 – H Type
Compression Connector
Hydraulic Crimper Ratchet Lever Hoist Surge Arrestor
Used in above mention jointing
Figure 2.7 – Hydraulic Crimper Figure 2.8 – Ratchet Lever Hoist Figure 2.9 – Surge Arrestor
2.1.2 Nugegoda LECO Branch Office
A branch office is doing all stuff of works under the supervision of the Branch Engineer. Normally at
upper levels of organization structure Engineers are having large experiences they have here in
industry for a long time. Basically branch office carry out LV Planning, handling construction works,
job costing, Estimation preparation, route survey, customer services, service from accounting division,
and administrative functions inside the office etc. There are several depots under any Branch office all
super vision of depots are also under the branch office.

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Branch Manager
Branch Engineer Administrative officer (head)
Chief Accountant
Electrical Engineer Administrative staff
ACC/assistant General
ACC/assistant revenue collection
Computer Supervisor
Chief technical officer, draftsman and that staff
Staff
Figure 2.9 – Structure of Branch
2.1.2.1 LECO Construction work

LECO Construction works
LECO Required Consumer Requested

System Development New connection
System Maintains Shifting poles
Meter changing
Change connection etc.
Figure 2.10 – Construction work done by the LECO

Branch office involves in planning, development, maintain of LV System and to provide the consumer
requested services
2.1.2.2 Planning & construction
Branch office considers the planning of the LV distribution system (400V network). According to the
level of work, who involves in the planning surveying and construction is dependent. Their Surveying,
job costing of new constructions are doing under Electrical Engineer and hand over to the branch
engineer for the approval. Contribution from the branch office for the procedure of construction is as
follows.

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Consumer request Route Survey Estimation by TO Recommendation and approval Select a contractor
Construction File is sent to CSC
Figure 2.12 – Procedure of construction
According to the consumer request, a survey is done in order to identify how the job to be done
according to the location if only necessary.
Once the survey completed legal permissions should be taken from required authority to place poles
and to erection of lines, this takes much time and while job costing is done and estimation prepared.
Then with the approval a contractor is selected and through the CSC constructions are done.
2.1.2.3 Job Costing
Standard cost manual is referred in cost estimations to get the standards cost given by the PUCSL. In
the standard cost manual there are prices of each and every one of items used in distribution
construction. Cost can be basically categorized in to four types, Material cost, Labor cost, and
Construction cost and Over head cost. For each specified jobs these costs are represented using above
4 types of costs and they are denoted by Index called KIT (KIT numbers). According to the job there
is the cost value in the cost manual.
 MKIT - KIT Index to denote the Material
 LKIT - KIT Index to denote the Labor
 CKIT - KIT Index to denote the Construction cost
 VKIT - KIT Index to denote the Variable cost (Over head cost)
By entering theses KIT indexes according to the job we can calculate the cost for any construction
using computer software called “PRONTO” or possible to calculate the cost manually also. PRONTO
make it easy the jobs costing.
2.1.2.4 LV Planning
Planning the LV distribution systems after secondary substations in the other word 400V network
planning, this is done to supply recommended voltage level at the consumers end by considering the
length of conductors and consumer loads. Hence the voltage drops of conductors are calculated. If not

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satisfied the voltage levels new secondary substation or tie line is proposed to supply quality
electricity to consumers.
2.1.3 LECO Head Office
2.1.3.1 Engineering Division
Basically this division does the system development, procurements handling for the following. For the
system development process they forecast the future energy demand and the other thing is planning
the network as suitably for distribute that energy. Then do the load flow analysis to identify the system
under worst cases and identify the required upgrades in the network. If the present primary substations
are not enough then have to go for new primary substations. For the above upgrading financial
analysis do using the above reports.
2.1.3.2 Load forecast
There are four possible method/ models for Load forecasting

 Judgmental method
 Time trend Model
 Regression Model
 Econometric Model
LECO uses time trend and regression models, in this process present and past 10 years data uses and
assuming liner system forecasted the future demand.
2.1.3.3 Planning
Under the planning network of 11 kV system is modeled and then do the load flow analysis to plan the
network system as suitably. Network spread over LECO area have mapped in the mapping process
GPS is used to find the exact coordinates of the locations. For that they have equipment which can
communicate with satellites. At the construction of each poles, transformers, LBS etc they are
included in to map with their details.

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2.1.3.4 Load flow analysis
Load flow analysis is done for the overall peak because peaking time for each transformer is different.
So the maximum demand of each transformer is multiplied by a factor called “contribution to the
peak” (65% for industrial, 80% for domestic). Then get the addition of loading of all the transformers
at the peak and compare with the actual feeder loading near the primary substation.
Then we can use the voltage near the primary substation, active and reactive power of each
transformer as inputs to the software PSS (Power System Simulator). And run the software to find the
required details such as feeder loadings, voltage drops, and losses. If there are problems with results,
simulate the network with available proposals to avoid those issues. In this way the load flow analysis
is done for five years future while increasing the loads of transformer according to the forecasting and
proposed solutions to the problems and unwanted system behavior.
2.1.4Operation Division
Operation division does the maintaining of the present system to supply consumer required Electrical
energy in efficient manner.
2.1.4.1Distribution Control Centre
2.1.4.1.1 Task of system control centre
Whole 11kV LECO distribution network system is controlled according to the command given by this
centre current status of the whole distribution system can be seen from the control centre. Each and
every one of breakdowns and interruptions and repairs are informed to here according this information
always they update the single line diagram (MIMIC panel).
Scheduled interruptions are requested by branch officers to the control centre. Then they study the
situation and select the optimum way to shift loads and isolate power lines as possible as minimum the
number of consumers affected from the interruption and the day which they allow. For giving
permission for interruption they prepare a switching instruction and send them to the depot through
branch office.
2.1.4.1.2 Preparing reports
Service call report and Electricity supply outage reports are prepared here

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Service cal report

Service cal report contains all the service calls and they are sorted in few categories as flows.
 Branch wise
 Customer Service Centre wise
 Type of fault wise
 Time of the day wise
They check number of calls per 100 consumers and average restoration time. It includes detailed
report and group of each branch.
Outage report
Outage report contains all outage details both due to interruptions and breakdowns. Using those
details, they calculate following reliability performance measurement indices.
 SAIDI - System Average Interruption Duration Index
 SAIFI - System Average Interruption Frequency Index
 CAIDI - Consumer Average Interruption Duration Index
 MAIFI - Momentary Average Interruption Frequency Index
Each index is calculated for each and every branch. Also get final average value for company. This
report can be used to get the whole idea about the performances of the LECO distribution system.
2.1.4.2 Ekala LECO Training Centre
2.1.4.2.1 Meter testing laboratory
At the meter testing place where they repair the faulted energy meters by replacing the damaged parts
with relevant parts of other broken meters. Finally testing and small adjustments has done in order to
send for the use. In the meter testing lab there are testing benches, that benches for testing more meter
at simultaneously, only analog meters are tested in this type of test bench.
In this laboratory bulk meters are programmed also.

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Jail Bearing
Disk
Magnetic Bearing
Damper Magnet Spring Suspension
Figure 2.13 – Disk of energy meter

Disk is divided into 100 parts and the disk is on a magnetic repulsion force. Other bearing type is jail
bearing which has a small point at the end of the shaft and directly contacted with the base by means
of these friction on rotation is reduced as maximum possible. The meters are mounted on the meter
testing bench. And small adjustments are done. Permanent magnet is pushed towards the disk to slow
down the speed, pulled to speed up. Voltage coil is adjusted with low load and no adjustments for
current coil.
2.1.4.2.2 Tests apply on Energy meter
Single phase and three phase mechanical and digital meters are tested here to confirm a single
phase meter 3 tastings are conducted.
 Percentage error test
 Creep error test
 Dial test
2.1.4.2.2.1 Percentage error test

This test should be done by applying rated voltage with different currents and power factors as shown
in below. If the required error percentage is not meet, then adjust the Voltage and current coil
positions by rotating the screw given in the energy meter and again do testing until reach the required
error percentage or below that level.

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Table 2.1 – percentage error tests on Energy meter
Applying current power factor (pf) Condition for confirmation
5% base current Unity ok if error is between in ±2.5%

100% Base current Unity ok if error is between in ±2%
Maximum current Unity ok if error is between in ±2%
100% Base current 0.5 lagging ok if error is between in ±2%
2.1.4.2.2.2 Creep error test

Apply 80% to 110% of rated voltage with no current input to the current coil about 20 minutes. If the
disk cannot complete at least single revolution meter is considered as acceptable for creep test (no
creep error). If the disk completed one or more rotation adjust the damping magnet and test again until
meet the required error less condition.
2.1.4.2.2.3 Dial test

Apply current and rated voltage and all testing meters are connected to flowing 1kWh and counting
the revolutions of the disk to ensure weather the applied energy is indicated correctly and the indicated
in registry correctly.
2.1.4.3 Transformer repair centre
2.1.4.3.1 Transformer Testing
2.1.4.3.1.1 Megger test

Transformer were testing to find winding insulation failure using megger tester resistance was
measured between each winding by applying high voltage
Check the Megger reader before test. Then Keeping voltage at 2500 V
 Test HV wingding to earth insulation level.
 Test HV wingding to LV wingding insulation level Keeping voltage at 1000 V
 Test LV to Earth insulation level 500 or above insulation level is ok

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Neutral Terminal Megger tester
Phase Terminals
Transformer Cover
Primary Winding
Secondary Winding
Figure 2.14 – Megger test on transformer
2.1.4.3.1.2 Ratio test

400 V is applied to the HV side and
 Check the voltage of phase to neutral for each phase.
 Phase to phase for each tap position of the tap changer.
 For each phase to neutral voltage should same
 For each phase to phase voltages should be same

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2.2 Training Experience in Ceylon Electricity Board
2.2.1 Samanalawewa Hydropower Plant

Samanalawewa hydro power plant is possible to contribute of 120MW normal power output to the
national power system. Power generation is done by using 60MW salient pole two synchronous
generators. 10.5 kV output from generators are setup into 132kV using two power transformers.
Through the switch yard this is connected to Balangoda and Embilipitiya Double circuit lines.
Power plant
Following shows a brief sketch of power plant
Figure 2.15 – Power plant

Dame
power tunnel
Penstoke
Surge Chamber
Figure 2.16 – Dame Section

Rock fill clay core type dam has maximum height of 100m and length of 480m
2.2.1.2 Surge Chamber

Figure 2.17– Surge Chamber

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The surge chamber is to bear the sudden pressure impact when the main inlet valve (MIV) is closed at
the power house. Otherwise the penstock may be damaged. There are different types of surge
chambers, this surge chamber is orifice type one.
2.2.1.3 Power house
Water coming through the pen stoke is blocked by main inlet valve (MIV). The flow of water is
controlled due to power variations by the wicket gates. There are three turbines to produce electricity.
The type of turbine is Francis. Name plate data of turbine and generator are as follows.
GENERATOR TURBINE
 Output: 70.6MVA/60.1MW  Type: Francis
 Output voltage: 10.5kV  Speed: 500 rpm
 Power factor: 0.85  Output: 70.2MW
 Rated Speed: 500 rpm  Vertical shaft turbine
 Excitation: 120 V and 1400 A
 12 poles salient pole type synchronous
generator
2.2.1.5 Active power control
According to variation of load connected to transmission net work is varying time to time therefore
system frequency is trying to change simultaneously. It is possible increase or lower the power output
by varying mechanical input given to the generator. For this Water flow is controlled by turbine
governor. Wicket gates are opened when more active power is required. This is a closed loop system
coupled with the speed of the turbine.
Samanalawewa power station is possible to use for frequency controlling when water level is
sufficient in the reservoir.
2.2.1.6 Reactive power control
AVR is used to regulate the terminal voltage in a set value. Excitation is increased when the terminal
voltage is decreased. Excitation is given by using a battery bank at the starting of generator and then it
is switch in to excitation transformer of the generator output.

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The excitation for the rotor field is obtained from a 10.5-kV/270-V 600-kVA transformer rectified by
thyristors and controlled by voltage regulator. The star point of the stator windings is earthed through
a 8.5-kV/250-V transformer rated at 24 kVA.
Power Transformer
132kV
10.5kV
Generator
AVR Generator Excitation

+Firing circuit
Excitation
transformer FCB Battery
Bank
Thyristor bank
Figure 2.18 – AVR
2.2.1.7 Power Transformers
There are two main power transformers which are use to step up the generated voltage 10.5 kV up to
132 kV one for each generator. They are71 MVA transformers vector group is YND11 and cooling
system is ONAN/ONAF.
2.2.1.8 Switchyard
The 132kV double circuit transmission lines are connecting from Embilipitiya and Balangoda
through switchyard. Simple single line sketch of switch yard is as follows. (Even here is not consist all
equipments) G G
Balangoda Balangoda
line-1 line-2
Bus Bar1
Bus Bar2

Embilipitiya Embilipitiya
line-1 line-2
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Figure 2.19 – Samanalawewa Switch yard

Switchyard consists of two basbars ,SF6 circuit breakers, isolators, surge arrestors etc. The
breakers in the switchyard can be connected to either busbar. Local control is also available for
emergency and maintenance purposes. A mechanical interlock system is provided through out the
electrical system.
2.2.1.9 Auxiliary supply
Auxiliary supply means power required for the plant premises for lighting, maintain for office etc. For
the more reliability there are three systems available auxiliary transformers for the station gives output
of 400 V. in addition there is a stand by auxiliary transformer. In emergency case or blackout there is a
diesel generator to give station supply.
2.2.1.10 Governor
Governor mainly consists of regulator, actuator and a SSG. The regulator is of the PID type. It consists
of speed sensing circuit and PID circuits and a power amplifier circuit. When the unit speed changes
the actuator immediately responds to the electrical signal from the regulator which converts the speed
change of the unit to the electrical signal and operates the converter to control the guide vane
servomotor. The guide vane opening is changed to change the generator output so as to keep the unit
speed at the rated speed.
Speed sensing is provided by a SSG which is installed at the top of the generator housing.
The main governor characteristics:
 Range of speed droop: 0-10%
 Governor dead time: less than 0.25 sec
 SSG frequency: 1000 Hz
2.2.1.10 Battery bank
Batter bank is essential for a power station. Battery voltage is120 V. those are NiCad (Nickel
cadmium) batteries.
 Excitation at the start
 Turbine auxiliaries

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 Transformer auxiliaries
 Governor auxiliaries
2.2.2 Kelanithissa Thermal Power Plant

Colombo is the main load centre of the Sri Lanka therefore it is very better the power station near the
load centre. Kelanithissa power station is in the Colombo. In Kelanithissa power station there are six
20MW small gas turbines and 115MW one large gas turbine generator (GT). One of small turbine is
damage heavily and out off working. Total available capacity is 215 MW even though they are not
possible to work in their full load capacity. Only two of GTs was running in synchon (synchronous
condenser) mood to supply KVar to the system.
2.2.2.1 Small Gas turbines (GTs)
Compressor compressed inlet air and insert in to combustion chamber atomized diesel fuel particles
are mixed with compressed air. This mixer diesel is ignited in combustion chamber. From the
combustion process makes a high pressure and high temperature output this is directed to turbine and
rotate the turbine. Then it couples to a synchronous generator so the electrical power is generated. This
is the normal energy conversion process in any kind of gas turbine.
Apart from that, this20 MW small GTs having disengaging gear box therefore they are possible to run
in synchon mode.

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Baring motorcompressor
Starting diesel engine exhaust air
Disengaging gear boxturbine Disengaging gear box
Generator
Inlet air
Fuel inlet Combustion chamber
Figure 2.20 – Small GT in Kelanithissa

Due to heavy weight of the rotor if it allows to cool gas turbine that the rotor may sag and again
starting may dangers and may cause damages to the machine. This is avoiding by a process called
baring. Baring is even if the gas turbine shut down its rotor is regularly rotate at very low speed to
avoid this sagging.
2.2.2.2 Synchronous Condenser Mode
Sometimes the generators run in this mode. In this mode generator provide reactive power requirement
to the national grid. While in this mode generator absorbs active power from the grid and generate
reactive power to maintain the magnitude of the voltage. At this stage turbine shaft is departed from
the generator shaft. Then the generator shaft rotates alone by taking active power from the grid.
2.2.2.3 Starting of Small Gas turbines (GTs)
At the starting of these GTs up to 100rpm speed they are running using a diesel engine. At this speed
fuel atomized gas injects to the combustion chamber and start the firing. Until come to 3000rpm diesel
engine does not disengage the gas turbine and then the diesel engine is removed. Then turbine is speed
up until a speed of 5100 rpm is acquired then synchronize machine to grid.

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2.2.2.4 115MW Large Gas turbine (GT)
This 115MW generator is also having same operation principle, differences are it consists of 1MW
high torque motor to start the GT and due no disengaging gear box to disengage generator and turbine.
Baring and other all process are required in here also. Starting process of this GT is as same as the GT
start in combined cycle power plant GT.
2.2.2.5 GIS
In plant premises there are 220kV and 132kV two GIS. GIS means gas insulated switch, all the
switching functions are possible as in normal outdoor switch yard. This type of GIS is most suitable
for urban area where less space taken for the system. Insulation gas medium is SF 6. Breakers, isolators
and bas bars all components are inside the pressurized SF6 medium.
2.2.3 Kelanithissa Combined Cycle Power Plant

In Kelanithissa Combined Cycle Power plant synchronous generator coupled to the gas turbine
generates with max power output of 115MW. Exhaust of that can run a steam turbine generator and
which has max power of 50MW. Main GT is same as the large GT in Kelanithissa power plant. In
combined cycle power plant the special unit is the HRSG (Heat Recovery Steam Generation) and
steam turbine. Exhaust flue gas from the gas turbine contain large heat energy. That heat energy is
extracted in HRSG to run steam turbine without wasting that heat energy
Exhast without
steam producing
To HRSG
feed water tank
Exhaust from GT
Steam power generation Compressur
Generator
Cooling Water Generator

Combustion Camber
High Pressure
Turbine
Low Pressure Air inlet Fuel inlet
Turbine
HRSG Gas Turbine
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Figure 2.21– HRSG
2.2.3.1 Starting the GTs
First GT is running using 1MW (cranking) motor into a 27% of its full speed (The rated speed of the
turbine is 5100 rpm) and then slows down in to a 14% of its full speed .The diesel mixed gas is
injected and an electric spark is given to start the burning process. Then cranking motor is speed up
into 60% of GTs full speed, then control the fuel to bring up the turbine speed into 5100rpm so the
speed of the turbine is reduced through gear box to connect to generator. After the magnitude of the
voltage is varied by changing the excitation the frequency and the phase shift is matched through the
Synchroscope. When all these three conditions fulfilled the breaker is closed.
2.2.4 Spugaskanda Power Plant
2.2.4.1 Overview of the Plant
Sapugaskanda Power Station produces electricity which unit cost is the lowest thermal generation cost
compared to plants belong CEB. All are reciprocating cargo engine, these types of engines normally
produce large acoustic pollution and vibration this is due to reciprocating mechanism. Even though
maintains are heavily required, this plant does the lowest cost thermal electricity power generation.

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Sapugaskanda Power Station
SECTION A SECTION B
4x20MW (installed capacity)
SEMT Pielstick-France
V-type engine each having Section B1 Section B1
18 cylinders 4x10 MW (installed capacity) 4x10 MW (installed capacity)
Commissioned in1984 MAN & B&W - Germany MAN & B&W - Germany
4x16 (currently running capacity) Inline-type engine each having Inline-type engine each having
8 cylinders 8 cylinders
Commissioned in1998 Commissioned in1999
4x9 (currently running capacity) 4x9 (currently running capacity)
Figure 2.22– Sapugaskanda Power Station Engine Arrangement

Total installed capacity is 160 MW. But currently these engines are not possible to run on that amount
of full load due to reducing their capabilities this is called derating of system of generation.
 Thermal problems (reducing the efficiency of the cooling system)
 Reduce the efficiency of engine
 Generator winding efficiency reduce
This type of reasons cause to decrease the capacities of generation units
For the Electricity generation process, there are large no of other systems are also contribute in many
ways. Specially Fuel oil system, Lube oil system, cooling water system, fire protection system, steam
or hot water system, engine modules, generators, control panel systems, Transformers, switch yard
etc.. These are called auxiliary system.
2.2.4.2 Fuel oil System
Storage
Fuel Oil Centrifuge
Refinery
Fuel treatment house
Treated oil

Fuel module
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Figure 2.23– Fuel oil System

The engines started by diesel and continuous running with Lanka Heavy Furnace Oil (HFO). To avoid
freezing the HFO the fuel lines are coupled with Heat tracking line (hot water line). Both lines are
covered with glass wool insulation. Air to fuel ratio is 14.1: 1 and free air is compressed by turbo
charger. Then charged air is cold to raise the density of air in order to insert more air mass into the
cylinder. Then charged air temperature is about 550C and after the compression stroke of the engine
the temperature of the compressed air is about 5000C.
2.2.4.3 Engine modules
There are two types of engines are in section A and section B as shown in Figure of Engine
arrangement these are cargo type heavy engines therefore at the starting of engines compressed air
should be injected in to the cylinder according to a sequence and drive the engine before combustion
process until come to speed which suitable for combustion (before diesel inject). Four strokes this
engines should be maintain, not only engine modules all the subsystems are maintain and test
according to a plan after taking outages.
Turbo charging is concept available in engine to increase the efficiency of the combustion process and
then overall efficiency.
2.2.4.4 Turbo Charger
Exhaust out of the engine emit large amount of heat energy, using this energy a turbine is driven and
the axis of that turbine is coupled to a compressor to pressurize inlet air supply to combustion process
this will increase the efficiency of the engine.
Air lesser heat and pressure

Atmospheric air inlet
Compressor Shaft Turbine

Engine outlet hot airEngine Inlet compressed air after cooling
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Engine head
Figure 2.24 – Turbo charger system
2.2.4.4 Generator
In section A all generation module consists generators are salient pole 14 poles machine, their
excitation current is supplied with the pole mounted PMG (Permanent Magnet DC Generator)
excitation level is controlled by AVR to stabilized required voltage output.
In section B all generation module consists generators are also salient pole14 poles machine, their
excitation current is supplied self exciter. Its operation is as follows, inside the generator having 5-
phase auxiliary winding, due to residual current in windings a current induces in that auxiliary
winding. That current is rectified through rectifier system and control through AVR and energizer the
exciter winding in exciter stator winding. Exciter rotor produces 3-phase current and this current is
rectified through rotating rectifier system and finally that DC current energized the generator
excitation level and now it is possible to control the excitation level from AVR.

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Figure 2.25 – Self Exciter
2.2.4.5 Switch yard of the Power plant
Generation voltage is 11 kV and stepped up to 132kV by 5×50MVA transformers. Generated power is

transferred to Biyagama grid substation by using a double circuit lines.
2.2.4.6 Maintains
As mention in early this type of engine required heavy maintains in very efficient manner to manage
the plant for next future years, minimize the efficiency reducing and reduce the unplanned outage of
machines. Not only for this plant normally any plant should have the following maintain procedures to
achieve the above mentioned goals.
 Conditional Maintains
 Preventive Maintains
 Routine Maintains
 Breakdown Maintains
Preventive and Routine maintains are scheduled maintains monthly, daily or according to running
time. Conditional maintain is using measurements and check up determined required maintain before
breakdown. Even the machines are maintained carefully there may be some break downs at that kind
of breakdown maintains are called breakdown maintains.

Training Report_______________________________________________________________________________________________________________
2.2.5 System Control Centre

System control centre is the place where is controlling the whole Sri Lankan Electricity Transmission
line including Power plants and Grid substations. According to the electricity demand System control
centre command power plants to connect the system or dispatch the plant from the system. Always
monitor the system frequency, system voltage, amount of Active power and reactive power, and
condition of main breakers. This center communicates with all plants and Grid Substations especially
with frequency controlling machine to keep the system stability.
2.2.5.1 System Stability Limits
System frequency should be 50 Hz ±1% and main system voltages should be as follows
Table 2.2 – System stability limits
System Voltages Required Voltage Limitations
220 kV Between +5% to -5% error range
132kV Between +10% to -10% error range
33kV Between +2% to -2% error range
System control centre control only 220kV and 132kV net work only.
If the demand active power is greater than the generation power, frequency decreases and vice versa.
There system control operators orders power station to increase their active power feed to the system
when the voltage drops they adds reactive power to the system.
Kothmale, Laxapana and Samanalawewa operate as frequency control centre of Sri Lankan power
system. Hydro plants are taken as frequency control due to the less responding time and more
controllability. Frequency control plant normally operates at half lord of its capacity. Droops setting at
the power plant is changed to frequency control mood
2.2.5.2 System Operation
System operation means the controlling process of whole power system by communicating with all
plants and Grid Substations. This is the task should done by the operation Engineer of the system
control centre. Plant connection and dispatching is not a random task. It is done according to a
planning process.

Training Report_______________________________________________________________________________________________________________
2.2.5.3 Operation Planning
According to the load curve, to satisfy the demand generation should be planned by considering losses
also. For maintain of plant, grid substation or Transmission line outage planning should decide in the
systematical way to minimize to disturbances to the system.
Choosing of thermal power plants is depends on start/stop cost and unit cost of the thermal plants. But
decisions relevant hydro power plants are more complex. The main hydro power complexes are
Mahawelli and Laxapana hydro power complexes. So the raining pattern of the year must be
considered in order to select the more suitable complex. The Laxapana complex is totally owned to
CEB and can be use the water in the complex at any time. But Mahawelli complex is not only for
power generation. Priority of the usage in Mahawelli complex is as follows.
 Drinking water
 Environmental
 Irrigation
 Power generation
So the operation of the power plants of Mahawelli complex should follow the plans got by water
management meeting. The water levels of the reservoirs and ponds and cascading arrangement of the
ponds are also considered by the system control engineer in order to select the running power plant.
There is a parameter called water value depends on water level which is affecting to the power plant
selection.
Normally system control Engineers works with historical data and with their past experience.
According to the predicted demand curve they inform power station to connect, remove, increase and
decrease their power. For that they make daily dispatch schedule and send them to the relevant power
stations individually.
2.2.5.4 Under Frequency Load Shedding
Under Frequency Load shading concept is important if suddenly large load connected to system or if a
plant trip off due to fault. Then that system becomes unstable at such moment frequency controlling
machine also may not possible to bear the impact. Frequency is decreasing rapidly this may cause
cascade tripping of generators and may cause total black out, system can regain the stability by

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reducing loads from the system. Feeders should cut off automatically to reduce the load. According to
following table feeders are cutoff by breakers.
Table 2.3 – Under frequency load shading schedule

Frequency (Hz) Schedule of Load cut out
48.75 05% of the load cut out from the system
2.2.6 CEB Head office Generation and Transmission Planning division

Generation and transmission planning is very important to generate and transmit sufficient amount of
electricity to satisfy the consumer demand according to the growth demand (National Power and
Energy demand forecast). CEB is the authorized institute in our country to develop and maintain an
efficiently coordinated economical electricity supply system for the country. According to CEB plans
its generation, Transmission and distribution expansions in order to provide reliable quality electricity
to entire country at affordable price.
2.2.6.1 Planning and Demand forecasting
First step of planning process is forecasting the future electricity demand for upcoming 20 years by
investigating 10 years past data and considering the forecasting models this is called National Power
and Energy Demand Forecast. There are two methods,
 Time trend method
 Econometric methods
CEB generation planning unit uses econometric method. For the forecasting it is required variable like
population, GDP Average Electricity demand, Electricity price etc. The forecast is done by
considering following 3 major categories of consumers.
 Domestic
 Industrial ,General Purpose and Hotel
 Street lighting and religious

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National power and energy demand forecast
Distribution development plan

Grid wise demand forecast
Capacity enhancements
Generation expansion plan and transmission expansion proposals
System studies
Generation expansion plan
Satisfactory No
Yes
Long term transmission expansion plan
Figure 2.26 - Transmission planning process
2.2.6.2 Generation Planning
Generation planning should be prepared in order to fulfill the above forecasted electricity demand by
considering National Power and Energy Demand Forecasting, recommendations and environmental
factors are also taken in to consideration. This planning is called the Long Term Generation Expansion
Plan (LTGEP). In the case of demand forecast they are using software called WASP-iV. The inputs
and outputs to the software are as follows.

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Existing Generation Plan
Retirements of Plants
Technology of plant
Committed Plants
Candidate Plants
WASP-iVSoftware
PROCESS
OUTPUT
Capacity
INPUT
Year
in
Figure 2.27 – WASP-iV Software
Even simply sketched the generation planning using WASP-iV as above, it is not an easy task due to
that software not being user friendly. Output of the generation planning is the very best suitable model
software is doing complex calculations and estimations.
2.2.6.3 Transmission Planning
Transmission planning is required to ensure the reliability of transmission network to match with load
growth and future generation hence estimate the investment required to implement transmission
developments. As mention above the objectives of transmission planning are,
 Ensure reliable and stable power system
 Estimating the investment
In order to above objectives on transmission network system, they are preparing a Long Term
Transmission Expansion Plan. The key inputs are National Power & Energy Demand Forecast, Long
Term Generation Expansion Plan and Regional medium voltage plan (distribution regions). Load flow
analysis is done to identify the satiability of the system at each year according to the previous
planning.
2.2.6.4 The load flow analysis
Load flow analysis is done using software called PSS/E. They model whole the network including all
the grid substations (Load bus), Power Stations (Generator bus) and one Power Station called Slack
bus which is balancing the equation,
Generation = Load + Losses
At the transmission planning following planning criteria are considered in load flow analysis
 Thermal maximum Night peak  Hydro maximum Night peak
 Thermal maximum day peak  Hydro maximum day peak

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In following manner model whole the network including all the considerable loses loads and sources
Figure 2.28 – Model in PSS

By identifying required upgrading next step of the Transmission planning is finding of the financial
facilities to carry out the required updating.
2.2.7 Rathmalana and Pannipitiya Grid Sub Station
Grid Substations are essential in any electrical transmission network to distribute through 33KV
feeders that process is done by this types of grid substations which are spread over the country and
connected to transmission system. The grid substation is converting 132 kV or 220 kV to 33 kV by
using step down transformers. But if 33 kV generations are available that power come through feeders
and step up in that step down transformer in reverse direction actually power flowing direction is not
possible to say exactly according to power requirement it flows.
2.2.7.1 Rathmalana Grid Sub Station
Rathmalana grid substation receives 132kV double circuit line from Pannipitiya and using 132/33kv,
31.5MVA three transformers step down the voltage to feed 9 feeders. Three of them are spare, there is
single bus bar for 132 kV and single bus bar 33kV normally two transformers are on load and other
one is the backup transformer
2.2.7.2 Pannipitiya Grid Sub Station
33kV 12 feeders are feeding by this Pannipitiya grid substation double circuit 220 kV Biyagama line is
connected to 220 kV switch yard, 132 kV switch yard is connected to double circuit Rathmalana line,
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Dehiwala 132 kV underground line, Horana 132 kV line Mathugama 132 kV line and to the 220 kV
yard through 220 kV/132 kV transformers these are single phase Auto transformers. Even there are
tertiary winding it is not in use present for any use full work. There is a capacitor bank in Pannipitiya
Grid substation it is also not working.
2.2.7.3 Components in substations
Basic components in substations are as follows,

 Transformers (Main and auxiliary)
 Breakers
 Isolators
 Current Transformer (CTs)
 Potential Transformers (CVTs)
 Bus bars
 Feeders
 Earthing mechanism
 Protection system
 Control panels
2.2.7.4 Power Transformer
Normally transformers are critical and expensive components in grid substation. Therefore protection
is essentially required to limits damages to transformers while the operating condition because high
cost and long outages if transformers failed. Failures of transformers are categorize as follows,
 Winding failures
 Core faults (core insulation failures)
 Terminal failures
 On load tap changer failures (mechanical, electrical, short circuit, over heat)
 Abnormal operation condition (over fluxing, over load, over voltage)
 Other external faults

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2.2.7.5 Protection method of Power Transformer
Types of protection use in transformer to minimize damages due to above faults

 Electrical protection (Over current protections, earth faults, Differential over excitation
protection)
 Mechanical protection (Bucholz relay, pressure relief valve, pressure relays)
 Thermal protection (Heating due to over exciting hot spot temperature)
2.2.7.5.1 Hot spot temperature
In design of transformer designer decides the hottest location in the winding, protection mechanism
can be used in this position to sense the temperature at this point and then alarming or tripping setting
is in used to protect from overheating the transformer.
2.2.7.5.2 Bucholz relay
Critical protection for large oil filed transformer with oil conservator. This gas and oil actuated relay is
protecting transformer against internal faults. It is two stage relay with first alarm and then at the
second stage trip the transformer.
2.2.7.6 On load tap changer
On load tap changer is necessary to maintain a constant voltage on LV terminal for varying load
conditions. This is achieved by providing taps generally in HV side due to lower current level in HV
side. Normally OLTC is a separately apart from the transformer tank it uses separate oil conservator.
No transformer oil are use together to mix the reason is OLTC when change taps make arc then the oil
filled in OLTC is always cause to rapid changes, therefore OLTC uses separate tank and separate oil
conservator. The difference of OLTC from No-load Tap changer is No-load tap changer cannot tap
changing at loaded time. (In power plant uses these no-load tap changers)
2.2.7.7 Dehydrate filter breather
To flow transformer oil from conservator to transformer tank, there should be a pressure in to
conservator this pressure supplied by filling air in to the conservator but moisture and dust particle

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should be removed. So this in coming air through this dehydrate filter, to remove dust particle first
air comes through air medium and then to remove moisture air comes through silica gel medium.
2.2.7.8 Pressure relief Valve
In an internal fault if tripping is not occurred there may generate high pressure inside the transformer,
due to this high pressure inside the transformer it can be exploited. This will cause large disasters and
damages to other properties also. This is prevented by having week point on transformer tank wall this
is the pressure relief valve.
2.2.7.9 Switching in a switch yard
Grid substations have switching, protection and control equipment. Switching is an important function
performed by a substation. There are two events of switching which are,
 Unplanned switching
 Planned switching
For maintain purpose planed switching is done, inside the grid station or for outside maintains.
Unplanned switching events are occurring due to system disturbances, faults in equipments and hence
for protection. Switching functions are done in switch gears (isolator, breaker). Isolators are manually
or remotely at no load condition. Breakers are the special switching elements constructed to switch at
on load condition, these breakers are also having both remote and manual operation functions, and
they are quick response therefore, in system disturbances breakers are switching for protection
2.2.7.12 Circuit Breakers
This switching element has the switching ability at fault conditions and also at normal conditions.
Breakers are manually or remotely possible to be operated at normal condition. At the operation
condition due to high voltage and high current arc can produces, but due to switching doing in arc
quenching medium and possible disturbances and damages are prevented.
Arc quenching mediums are,
 Vacuum
 Air
 SF6
According to the voltage level quenching medium vary for breakers.
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For the quick operation at system faults there is a charging mechanism to break the switch instantly.
 Spring charged breaker
 Pneumatic breaker
 Hydraulic breaker
Due to stored energy in some means in above mechanisms at tripping condition suddenly relies the
contacts in SF6 medium.
Figure 2.29 – SF6 breaker
2.2.7.13 Current Transformers
Figure 2.30 – Current Transformer (CT)

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2.2.7.14 Potential Transformers
Figure 2.31 – Potential Transformer (CVT)

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2.3 Training Experience in Amithi Power Consultants (Pvt) Ltd
2.3.1Testing and Measurement

At the Amithi power consultants following tastings were performed.
 Insulation Testing
 Continuity Testing
 Earth loop impedance
 RCD functioning
 Earth Resistance
2.3.1.1 Insulation Testing
Testing of insulation resistance is strongly required for assure the safety of personal, electrical
equipment and other properties, normally this test is done on
 Cables
 Motor and Generators
 Single phase and 3-phase Transformers etc
Comparing with standard insulation level for electrical systems, we can recommend the systems if the
insulation level is greater than the standard levels.
Megger meter is the testing equipment used to measure the insulation resistance value.Normally
insulation level should be mega Ohm values under testing. To measure suchvery high value resistance
equipment uses very large DC voltage and then possible to measure considerable (measureable)
amount low current constant voltage source is applied to the resistance to be measured and the
resulting current is read on a highly sensitive ammeter circuit as shown in figure.
Very high sensitive Ammeter Very high Voltage source
Figure 2.32 – Internal arrangement of

Megger tester
Megger tester
Terminals

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Digital meters are calibrates to measure the resistance directly because injective voltage sources is
known.
2.3.1.2 Cable Insulation Testing
Testing insulation level of cables in domestic industrial is recommended for safety and as preventive
maintains of cables especially in industrial electrical systems it is more required. For testing insulation
between cables other end of cable should be cut out the connections from breakers.
L1
N L2
E L3
Figure 2.33– Testing insulation levels of cables
Likewise all combinations are measured and note down as below (result of a test in Elakanda fishery
Harbor)
Table 2.4 – Cable insulation levels

L1 - L1 - L3 - L3 -
L1- N L1- E L2 -L3 L2 - N L2 - E N- E
L2 L3 N N
DB1
63A
to 263 440 197 165 272 270 16 2 93 145
MCB
SDB1
Normally LV cables should have insulation level greater than 1MΩ but abnormal deviations are also
taken in to consideration and inform to recheck the cable insulation layer damages.
Following Voltage limits are apply for that specific voltage level for insulation testing
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Table 2.5 – specific voltage level for insulation testing

Equipment or Cable
DC test Voltage(V)
Rating(V)
24 to 50 100
50 to 100 250
100 to 240 500
240 to 550 1000
2400 2500
4100 5000
Below is shown the Megger tester with details that we used in cable testing.
Digital Insulation Tester
Insulation resistance: AC voltage and conductor resistance
measurement
Insulation test mode: Comparator, memory, auto-hold and
discharge function
All test modes: Live-line alarm (Exchange AC voltage
measurement)
Easy to view, function-free display
Figure 2.34 Digital Insulation Tester
2.3.2.3Relay testing
For the relay testing Omicron secondary injection kit was used. As shown in below, this equipment
contains more good advantages.
Omicron Testing kit (Omicron CMC-256-6 - Relay Test Set)
OMICRON secondary injection test sets and measurement devices is more popular in Electrical
Industry, Railway as well as for Relay and Measurement Device Manufacturers due to having
following features. It is,
 Portable
 Reliable operation
 Accurate measurement
 Possible to connect to any PC which having a serial port

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2.3.2.3.1 Secondary injection and Primary injection test on relays
Secondary injection and Primary injection tests are normally conducted to check the operation of the
breaker and other protective relay devices. In primary injection test relatively high current is applied to
the primary side. This is done to prove that current transformers and protective devices are all properly
connected.Secondary injection test is normally conducted by applying relatively small current in
secondary side and therefore possible to check the correct operation of relays devices
2.3.2.3.1.1 Secondary Injection test on relay

As shown in figure connect the test device probes across RCD tripping signal output which is
connected to the breaker for tripping if fault current occurs. To make a fault current put a wire through
CT and connect it to current output of OMICRON device. And connect the Personal computer through
the serial port which has installed the software. Then increase the given loop current and measure until
trip off using PC measure the tripping current. And consider setting current and apply that until
tripping and if current vales and time delays are not suitable. Set current and do the test until the
recommended level observe.
Figure 2.35_Secondary Injection test on relay

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2.3.3 Capacitor Bank Designing

Industrial tariff is charged for maximum demand also reason is when Consumer uses reactive power
supply authority have to generate reactive power, the larger current draws. Therefore industrial
Electricity bills are very high. Not being that reactive power consumes in loads this power supplied
using Capacitor bank.
Applicable Standard
IEC 61000-3-6
2.3.3.1 Energy survey Results
As per The Energy Survey a Power Analyzer (Data Logger) was fixed for One day Time Period of full
working hours (06:10:00 - 15:40:00) and followings are the Collected Data after analyzed.
The Average values of each phase is as follows at the measuring stage
Table 2.6 – Energy survey result summery
Phases Maximum Maximum KW Maximum Maximum Maximum
Current KVar KVA KVA
Red phase 1605.75 242.879 277.307 370.733 370.733
Yellow 1750.67 28.699 288.816 406.175 406.175

phase
Blue phase 1720.24 257.901 304.1 401.81 401.81
1400
1200
1000
800
600
Avg.
400 KW
Avg.
KVA
200

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Figure 2.36_ Measured Active power and Reactive Power Apparent power against Time
Above figures shows the variations of measured data (about power) against time and we can have a
good idea about the reactive power variation.
2000
1800
1600
1400
1200
1000
800 1Avg. Amp
2Avg. Amp
600
3Avg. Amp
400
200
0

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Figure 2.37_ Measured each phase currents against Time

Above figures shows the variations of measured data of phase currents against time and by carefully
observing we can have a good idea about unbalances of the phase.
2.3.3.2 Recommendations
Installation of capacitor Bank

It is recommended to install a Capacitor Bank to Improve the Power factor (power factor correction)
and then the Demand will get lower than 1171.659KVA.
2.3.3.3 Calculation and the Size of the Capacitor bank
767.097 KVA767.097 KVA
Figure 2.38 – Phaser diagram before and after install the capacitor bank
S 1=√ P12 +Q 12
S 2=√ P 22+Q 22
P1
cos ∅ 1=
S1
P2
cos ∅ 2=
S2
∆ Q=Q1−Q2
Table 2.7 – System variable before and after capacitor bank installation

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Before Installation of Capacitor After Installation of Capacitor

Description
Bank Bank
Average Demand at
S 1=1171.659 KVA S 2=767.57 KVA
maximum reactive power
Power at maximum
P 1=765.946 KW P 2=765.946 KW
Reactive power
Reactive power at
Q 1=870.225 KVar Q 2=50 KVar
maximum Reactive power
Power factor angle at

co s ∅ 1=0.6537 cos ∅ 2=0.99788
maximum Reactive power
Power factor at maximum

∅ 1=49.18 ∅ 2=3.7348
Reactive power
Here we assume that capacity of each capacitor is 50KVar (25KVar two capacitors connected in
parallel) therefore KVar tolerance can be consider as 50KVar
According to the Calculation size of the
Capacitor bank to be installed ¿ 820.225 KVar
Monthly Average Saving of Demand ¿ S 2−S 1=1171.659−767.57
¿ 404.089 KVA
404.089
Current Reduction by installing capacitor bank ¿
230× 3
¿ 585.636 A
2.3.3.4 Phase balancing
It is recommended to balance the phase circuits to proper phase balance

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2000
1800
1600
1400
1200
1000 1Avg. Amp
800
2Avg. Amp
600
3Avg. Amp
400
200
0
1 3 5 1 3 5 1 3 5 1 2 4 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
6: 6: 6: 7: 7: 7: 8: 8: 8: 9: 9: 9: 0:0. 0:3. 0:5. 1:0. 1:2. 1:4. 2:0. 2:2. 2:4. 3:2. 3:4. 4:0. 4:2. 4:4. 5:0. 5:2. 5:4.
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Figure 2.39 – Measured each phase currents against Time

Above figures shows the variations of measured data of phase currents against time and by inspection
it is clear that the red phase is mostly made up of low current. Therefore it is can be made up by
changing few load circuits of phases.
Therefore it is recommended to conduct a Proper Phase balancing system for Sub distribution boards
to stabilize the currents in each phase and it will compensate over current tripping of the breaker.
To get 50KVar capacitors 25KVar capacitors are parallel connected. Therefore the minimum
capacitance 50KVar the and tolerance is 50KVar.Accordingly there are 17 steps of connecting stages
of capacitors Following figure shows the internal capacitor arrangement of 50KVar three phase
capacitor
RYB
RYB

2x25KVar Capacitor 50KVar Capacitor
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Figure 2.40 – Capacitor

According to load variation contactors are actuated using PLC. According to the analysis Capacitor
bank should be with Capacitors of 850kVAR in 17 Steps (35 No’s of 25kVAR Capacitors). The
Capacitor bank to include multiple steps and to be engaged automatically depending on the power
factor (reactive power).
2.3.4 Lightning Protection System Designing
Protection of against lightning is consider in following two ways
2.3.4.1 Direct lightning
Due to making low resistance path through structures there is a possibility of directly lightning strikes
on the building structure phenomena is called the direct lightning. In this design I have consider the
protection system design for direct lightning
2.3.4.2 Indirect lightning
Lightning on supply cable due to capacitive coupling and magnetic induction and that surge, lightning
effects coming indirect way, this phenomenon is the indirect lightning. For the protection from indirect
lightning, surge arrestors or surge diverters can be installed
2.3.4.3 Protection of structures against lightning
This design is to provide the protection for structures against direct lightning strikes. IEC 61024 and
IEC 61662 standards give the standards procedure to follow while design a Light protection system.
Table 2.8 – Standards for lightning protection design

IEC 61024-1 Protection of structures against lightning
General principals
IEC 61024 -1-1 Protection of structures against lightning

Part 1: General principles – Section 1 Guide A

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Selection of protection Levels for lightning protection systems
IEC 61024 -1-2 Protection of structures against lightning

Part 1-2: General principles – Guide B
Design, installation, maintenance and inspection of lightning protection systems
IEC 61662 Assessment of risk damage due to lightning
2.3.4.4 Risk Level assessment for the building
For every structure considered by the designer of the LPS protection shall decide whether or not an
LPS is needed. If it is designer should select a proper level of protection.
Start design
Collect data
Structure dimension and position
Environmental Factors
Ground Flash Density (g)
Class of structure (Protection Level)
Calculate followings
Collection Area ()
Tolerable lightning Frequency ()
Lightning strike frequency ()
Lightning protection system is not required

Is NO
Calculate
Efficiency
Design a Lightning protection system According to protection class (level)

Efficiency Select suitable Air termination methods
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Figure 2.41 – Selection of lightning protection system
Risk Level assessment Calculation

Number of ground flashes (Ground Flash Density)
N g=0.04 × T c 1.25 per km 2 per year
Where Ng = no of ground flashes per km2 per year
Tc = isokeraunic level(should be taken from isokeraunic map)
Number ofLightning strike frequency (Nd)
N d =N g × A e ×10−6 per year
Where Nd = direct lightning strokes on to a structure per year [Lightning strike frequency]
Ng = annual average ground flash density
Ae = equivalent collection area of a structure (m2)
Collection area ( Ae ) Calculation
YES
Model- I
Rectangular block
Model- 2
Equivalent collection area for a structure where a prominent part encompasses all portions of the l
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Model- 3
Equivalent collection area for a structure where a prominent part encompasses all portions of the
Figure 2.42– Calculation of collection area

Tolerable lightning Frequency Nc
5.5× 10−3
N c=
(C 1 ×C 2× C 3 ×C 4 ×C 5)
C1 =Environmental Coefficient C4=Structure Contents
C2 =Structural coefficient C5=Lightning Consequences
C3=Structure Occupancy
(Values of each coefficient are given in ANNEX)
2.3.4.5 Methods of Air Termination System as per IEC
Protective Angle method

The protective angle method is suitable for simple structure or for small parts of bigger structures.
This method is not suitable for structures higher than the radius of the rolling sphere relevant to the
selected protection level.
Air termination
Protected Area
Structure to be protected
Figure 2.43– Protective angle method

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Rolling Sphere Method

Rolling Sphere Method is suitable for complex shaped structures
Air termination
Protected Area
R
Unprotected Area
Structure to be protected
Front view Plan view
Figure 2.44– Rolling sphere method

By considering unprotected area we have to re design by inserting extra air termination system or by
changing the positions of present system.
Mesh Size Method
The Mesh method is for general purpose and it is particularly suitable for the protection of plane
surfaces
2.3.4.6 Main Components of lightning protection system
Air terminals
Use air terminals in the form of vertical air rods for the protection of prominent roof top features or
equipment. Use strike pads to expose concealed conductors
Air terminal bases
The air termination network is the point of connection for a lightning strike. It typically consists of a
meshed conductor arrangement covering the roof of the structure.
Conductors
The down conductor system is the means of carrying the current of a lightning strike safely to the earth
termination network.

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Conductor fixings
Select the correct system of fixings for each part of the conductor system. Fixings are available for a
wide range of modern construction materials, stone, plastic and metal.
Conductor jointing clamps

Select a component for the interconnection of multiple conductors or for changes of direction. Jointing
clamps will ensure a low resistance, corrosion resistant connection.
Test clamps
In order to allow periodic disconnection and testing of the earth termination network, select a test
clamp to be placed within the run of each down conductor.
Earth electrodes
Choose an earth electrode to suit the ground conditions in the locality of the structure. Electrodes are
available in the form of rods and plates (lattice or solid).
Earth rod clamps
Select a high copper content alloy earth rod clamp for the connection of the earthing conductor to the
earth rod. In this below ground application, the clamp must ensure a good electrical contact and resist
corrosion throughout the lifetime of
Earth inspection chambers
Select an earth inspection chamber to protect the earth electrode connections. High strength chambers
are available in plastic and concrete
Bonds
Bonding is the most commonly employed method of avoiding the damaging effects of side flashing.
All continuous metalwork should be considered for bonding. All metallic services, eg:- cable
armoring, gas, water or steam piping, entering the building should also be bonded as directly as
possible to the earth termination network.

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2.3.5 Thermal Imaging
2.3.5.1 Concept of Thermal Imaging
Temperature and electricity, there is a relationship between each other if any system uses Electricity
normally temperature of the system is rising. What if a high current flows in the system? the
temperature rises largely. Same as above scenario in many cases of faulty electrical systems get heat.
This temperature system temperature rises. Thermography is the process where calibrated thermal
imaging equipment is used to image and measure the temperature of various objects and according to
emission Infrared levels. Images are analyzed using computer in software to find over heated points
one in following manner, predicts the status of the current carrying objects, moving objects, and
thermal transfer barriers etc. Actually not only for electrical system observation but also various type
of thermal analysis this imaging possible to be used.
Figure 2.45– Distribution T/F in firing Figure 2.46– Power T/F firing
To prevent these sorts of disasters thermal Imaging is an important part of predictive and preventive
maintenance.
2.3.5.2 Importance of thermal imaging
To prevent these sorts of disasters thermal Imaging is an important part of predictive and preventive
maintenance. It is an accurate, easy, save lots of money and valuable time. Factory environment

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thermal imaging is recommended in once a year. This predictive maintenance system can avoid lots
of your unforeseen hazards and make the production continuous. Further energy conservation can
be perfect as the energy loss points can be identified. Similarly for power stations and the connected
lines to national grid can be checked to avoid unnecessary outages due to some component failure.
The failing components can be identified and replaced the same in a planned way. Further jumper
defects can be predicted silly of the line and get the replacement in a planned maintenance work.
The power supply authorities can avoid fires occurring on the authority connection point /meter point
which may be a frequent occurrence in some areas. All this ensures the increase in productivity and
reducing down time for repair/replacement and labor needed for that.
2.3.5.3 Suitable for Thermal imaging in
 Transmission and distribution equipments

 Power Generation Plants
 Grid substations
 Switch boards, switch gear, Relays, breakers and fuses
 Capacitor banks
 LV cables
 Motor control centre
 Induction motors /all types of motors, motor bearings and shafts
 Air conditioning plants
 Gas Pipes/Thermal Fluid pipes/
 All the electrical, mechanical and civil installations etc.
Figure 2.43– Thermal Images of Electrical Systems

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2.3.5.4 Thermal imaging in LV switch board and Cables
At the imaging time no need to remove the enclosures since the thermal camera has the capability to
detect IR through the cabinet to an extent. For fine details open cabinet images could be obtained. If
something inside is hotter it transfers the heat to the outer cover through IR and convection and spots
heat signatures on the cover.
Before the test, camera equipment should to be calibrated according to the ambient temperature,
relative humidity, and distance between camera and imaging component. After completing of test
these thermal images is analyzed using FLIR software in computer to find temperatures of any point of
the images. It is easily possible to identify abnormal temperature rises.
By comparing with standard temperature allowable in standards for any equipment the final decision
can be taken whether the equipment is failing or not and then decisions are made of faulty with the
experience of the analyzing engineer.
2.3.5.4 Consider the following analysis of thermal images
Average ambient temperature of the plant area at the imaging time period is 280C.
According to the IEC standards IEC60439-1, clause 7.3 table 2– Temperature-rise limits
Table 2.9 –Max allowable Temperatures for LV panels.

Temperature Rise/
Ambient Max allowable Temperature /(0C)
Apparatus (0C)
Temperature/(0C)
Metal Plastic Metal Plastic
Conductors 28 - - 70
Conductor terminals 28 70 - 98 -
Operating parts 28 15 25 43 53
Enclosures 28 30 40 58 68
Consider following Thermal image of cable running in to a DB

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Sp3 33.4
Sp2 27.2
Sp1 26.4
Figure 2.48 –Thermal image of cable Figure 2.49 –Digital image of cable
Table 2.10 – Cable temperature Analysis in FLIR software
Max allowable Temperature according

spot Temperature /(0C) Location
to the Standard/(0C)
Sp1 26.4 98 Refer digital image
Sp3 33.4 98 Red Circled
Operating temperatures of the three cables points are below than the maximum allowable
operating temperature indicated in the standard. But it can be noted that the temperature of Sp3 is little
bit higher than Sp1 and Sp1 temperatures but that all cables are carrying equal currants. So it’s
obvious that, for the temperature increment of Sp3 is not due to carrying high currant. This
temperature rise is due to contact at the end of upper DB termination connection point may not contact
well or sometime contamination of dust particles around termination point might be the reason for this.
So it is recommended to check for the proper cable termination and clean the cable termination area
for dust.
Consider following Thermal image of cable running in to a DB

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Sp2 37.3
Sp3 43.2
Sp1 27.2
Sp4 36.1
Sp5 35.9
Figure 2.50 –Thermal image of LV breaker Figure 2.51 –Digital image of LV breaker
Table 2.11 – LV panel temperature Analysis in FLIR software.
Max allowable Temperature in

spot Temperature /(0C) Location
Standard/(0C)

Operating temperatures of the two cables and operating parts are below than the maximum allowable
operating temperature indicated in the standard. But it can be noted that the temperature of left side
breakers is little bit higher than compared to others those incoming cables are also having high
temperature. This temperature rise may due to higher current flowing through this breaker than other
breaker also at cable termination connections to breaker may loosen and they may not contact well. So
it is recommended to check for the proper cable termination.

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2.3.6 Electrical installation design

Design of electrical installation should be done according to some standards. Normally
BS7671 IEE Regulation is used. According to the consumer requirement following procedure
is follows to do installation design.
 Lighting, switches and Socket outlets

 Pump, lift, AC like special equipments
 DB layout
 Load calculation cable selection
 Single diagram
 BOQ and specification preparing

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2.3.6.1 Lighting design And Switch placing
Lighting system design should be done by considering occupancy to keep required (enough) light, as a
designer should have a good idea about the civil structure of each room and its main tasks for that
designer should get detailed drawing of the building. Different places require different amount of Lux
levels for a proper functionality. According to consumer requirement designer should do the optimum
lighting design, for that normally there are standards light levels for different places.
2.3.6.1.1 Factors and procedure to consider while lighting design

L - Length of the Room
Hm - Mounting Height of Fitting (from working plane)
W - Width of the Room
UF = Utilization Factor
MF = Maintenance Factor
E = Lux Level Required
F = Total Flux (Lumens) from all the Lamps in one Fitting
MF = Maintenance Factor
Where N = Number of Fittings
Figure 2.52– Lighting design
2.3.6.1.2 Utilization factor
The Utilization Factor is the proportion of light flux emitted by the lamps which reaches the working
plane. For the calculation, I have taken it as 0.5
Kularat h naM . P. D . S . C .i
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2.3.6.1.3 Maintenance factor
Due to the dust and other issues, the initial lighting level decays over time. Therefore this factor
represents the room condition. For the calculations, I have taken Maintenance factor as 0.8
2.3.6.1.4 Suitable lighting and fittings
At the design cost minimization, architectural beauty and so many other factors are also taken into
consideration. Therefore suitable lighting and fitting should be selected also by considering Wattages
of bulbs. There are several types of lights are available such as incandescent, fluorescent, compact
fluorescent (CFL), mercury vapor bulbs and LED lights. But in our designs never used incandescent
bulb due to huge inefficiency
Above calculated number of luminaries are then placed on the AutoCAD drawing at this stage we
should consider the architectural beauty according to the occupancy of the place. After placing the
lights, the required switches for light operating should be placed by considering accessibility, ease of
use and interior beauty. Switches are also have different design according to the consumer requirement
select the switch at the switch placing consider that single circuit must not contain more than 10-12
lights.
2.3.6.2 Socket outlets and DB layout
Ease of accessibility, possible hazards and disturbances to interior beauty, by considering
possible equipments may use in the building, socket outlet and DB should be selected and
placed. In distribution board locating consider the distribution of the circuits
2.3.6.3 Load calculation
After finishing the lights, sockets and switches layout, a load calculation is done. The load calculation
differs from application to application.
As an example, for the shopping complex, the lighting diversity factor is taken as unity. In a house,
this can be taken as 0.6 to 0.8.according to application and the consumer type this thing have to be
decide by the designer. Also the sockets load is also taken considering the diversity factor.
2.3.6.4 Selecting Protection Devices
By determining the loads for circuit wise, floor wise and DB wise etc we have to decide the total lights
and sockets load, plus any additional loads the protection devices are selected. The main breaker is
selected such that it is greater than the maximum load. To select that breaker, total load of each floor is
Kularat h naM . P. D . S . C .ii
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calculated. Then an MCB or MCCB is selected depending on the level of control needed. Also the
RCCB’s are selected considering the main breaker and depending on the earthing system used.
2.3.6.5 Cable Selection
Cable size should be selected that voltage drop at connection points of equipments not exceeding 4%
from at supply point. For the cost minimization minimum as possible cross sectional area of the cables
should be selected. By considering no of cores, insulation type, armoring application temperature,
cable laying method etc suitable cable detail should be selected as given in BS7671.
It is given in standards as follows,
 Iz>I b
 1.45 I z >1.125 I n
 I n> I b
Where I z =current carrying capacity of conductor withderating factor
the
I n=nominal current of device
current
I b=design current
All these conditions should be satisfied.
2.3.6.6 Single Line Diagram
Single line diagram is the diagram given the detailed and summarized diagram of each db and the
equipment inside the DBs protection devices. Conductor detail and all these are how to connect to
each other. This diagram gives the enough details for technician to decide the constructions.
2.3.6.7 Bill of Quantity (BOQ) and Specification report
BOQ is consist of each and every one of items should be used to construction each items cost of them,
labor and required function cost are available there. This is very important part of a project not only
for do quotation for the project but also for analyze the project cost and estimate the real value of the
profit of the project. it is not required to put the cost details in BOQ by the design engineer. Anyway
this includes the some short details about equipments and standards procedures.
Kularat h naM . P. D . S . C .iii

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3. Conclusion
The University of Moratuwa Engineering Faculty, the Department of Electrical engineering and the
National Apprentice & Industrial Training Authority(NAITA) is doing a great job in arranging
industrial training to the engineering undergraduates in order to expose our a future in industry and
putting the base of the future carrier buildings.
I started my industrial training period on 28th February 2011 and since then I had my training for 25
weeks up to 02nd September 2011. This was my first working experience in any sort of company or
industry with exactly exposing to the Electrical Engineering field. I think I gathered knowledge and an
experiences which are very different from what I have learnt from the university and different from
each other in three different places. I am personally happy to be an undergraduate trainee in CEB,
LECO and APCL.
This training period was a great opportunity for me to get a real idea about the electrical industry. Now
I have taken that real idea about the working environment. I was in an academic environment at the
university therefore I hadn’t enough practical exposure at university such as in industry. But the
having that theoretical knowledge of electrical system always it make me easy to realize and
understand that practical work by compare both together, in such time some hypothetical theories.
Therefore it is an important part of the degree program and I recommend and appreciate this type of
training module.
As a very large organization in Sri Lanka I was very happy to say I got the chance to become an
undergraduate trainee in that organization. From my experience at CEB what I feel is that the
Engineers and other level of professionals did maximum as possible with wasting their valuable time
to give something for us even though we had no more chance to get hand on experiences in CEB. As a
suggestion I like to suggest that time period for one place at CEB should increase at least to two weeks
because we had allocated only single week for Kelanithissa power plant, Kelanithissa combined cycle
power plant and two GIS and switch yard. In such time we are not possible to get good experience at
each place. Anyway within that eight week in CEB we got the maximum as possible. Even I have
studied about Electrical machines, power generation and power transmission actual idea of what we
are learning at the university is got at the training and at most time comparing theories and practical
Kularat h naM . P. D . S . C .iv

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work carried out. So it was a great opportunity to me as a future my carrier in this Engineer field. By
involving different level of skilled and different level of professional in CEB we got great experiences.
In LECO as a trainee, I got many experiences about the power distribution functions. LECO is a well
organized company which is involving distribution functions in the country, as for undergraduate
electrical engineer useful training was provided by LECO in four week training period. In that four
week training period I got lot of experience and knowledge about many distribution equipments used,
distribution functions and procurements etc. Due to being in several training place different kind of
experiences were taken. Engineers and technicians helped in various ways to understanding of their
functions. Through LECO training I could get practical knowledge and experiences, Definitely this
knowledge and experiences will be more important in my future
In plant traineeship was scheduled in Amithi Power consultants (PVT) LTD within last 13 weeks. I
was able to get a real industrial exposure through this Amithi Power Consultants which is one of the
leading electrical design firm in Sri Lanka. Any low voltage and many high voltage designs and
consultants are handled. So many local and foreign projects have been designed and consulted by this
company. In such company I was able to get my third industrial training that it was a great opportunity
for me. Within this 13 weeks training period in the company I was able to gain lot of experiences. Day
by day I was able to learn something new about the electrical engineering. I had no idea at very
beginning about most of designs but according to procedure they followed to training I was able to get
the good knowledge about designing.
During my training period, I understood the nature of the role of an engineer at the work field. What
are the responsibilities for him, the position of an engineer at different managerial levels and how he
works with workers who belongs to upper and lower managerial. Before the training and at the
beginning I had no idea about the industry but now, after completing the training I feel the difference
and how the theoretical knowledge apply in industry to perform in industry. Due to variety of training
place I got different experiences.
Kularat h naM . P. D . S . C .v
Training Report_______________________________________________________________________________________________________________
Kularat h naM . P. D . S . C .vi

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UNIVERSITY OF MORATUWA

INDUSTRIAL TRAINING REPORT

Lanka Electricity Company (Pvt) Ltd

Kularat h naM . P. D . S . C .ii

Kularat h naM . P. D . S . C .iii

1.1 Lanka Electricity Company (Pvt) Ltd......................................................................................1

1.1.1 Introduction to LECO...............................................................................................................1

1.1.2 History of the LECO................................................................................................................1

1.1.3 Vision and Mission of LECO...................................................................................................2

1.1.4 Organization Structure of the LECO........................................................................................2

1.1.5 Present Performances and Strength of the LECO....................................................................2

1.1.6 Profitability of the LECO.........................................................................................................2

1.1.6 Usefulness of LECO to Sri Lankan Society.............................................................................3

1.2 Ceylon Electricity Board.................................................................................................................3

1.2.1 Introduction to CEB.................................................................................................................3

1.1.2 Organization Structure of the CEB..........................................................................................4

1.2.3 Present Performances and Strength of the CEB.......................................................................4

1.2.4 Usefulness of CEB to Sri Lankan Society...............................................................................4

1.2.4 Suggestions for improvements.................................................................................................4

1.3 Amithi Power Consultants (Pvt) Ltd...............................................................................................5

1.3.1 Introduction to APCL...............................................................................................................5

1.3.2 History of the APCL................................................................................................................5

1.3.3 Organization Structure of the APCL........................................................................................5

1.3.4 Present Performances and Strength of the APCL....................................................................6

1.3.5 Profitability of the APCL.........................................................................................................6

1.3.6 Suggestions for improvements.................................................................................................6

1.3.7 Usefulness of APCL to Sri Lankan Society.............................................................................6

Kularat h naM . P. D . S . C .iv

2.1 Training Experience in Lanka Electricity Company (Pvt) Ltd.................................................7

2.1.1 Maharagama LECO Depot.......................................................................................................7

2.1.1.2 Consumer Breakdown maintains......................................................................................8

2.1.1.3 Field billing.......................................................................................................................8

2.1.1.4 Disconnecting process......................................................................................................8

2.1.1.5 Breakdown registry...........................................................................................................8

2.1.1.6 Equipments and Materials use in LECO Depots..............................................................9

2.1.2 Nugegoda LECO Branch Office........................................................................................10

2.1.2.1 LECO Construction work...............................................................................................10

2.1.2.2 Planning & construction.................................................................................................11

2.1.2.3 Job Costing.....................................................................................................................11

2.1.3 LECO Head Office.................................................................................................................12

2.1.3.1 Engineering Division......................................................................................................12

2.1.3.2 Load forecast..................................................................................................................12

2.1.3.4 Load flow analysis..........................................................................................................11

2.1.4.1Distribution Control Centre.............................................................................................11

2.1.4.1.1 Task of system control centre..................................................................................11

2.1.4.1.2 Preparing reports......................................................................................................12

2.1.4.2 Ekala LECO Training Centre.........................................................................................12

2.1.4.2.1 Meter testing laboratory...........................................................................................12

2.1.4.2.2 Tests apply on Energy meter...................................................................................16

2.1.4.3.1 Transformer Testing................................................................................................17

2.2 Training Experience in Ceylon Electricity Board.........................................................................19

2.2.1 Samanalawewa Hydropower Plant.........................................................................................19

2.2.1.2 Surge Chamber...............................................................................................................19

2.2.1.3 Power house....................................................................................................................20

2.2.1.5 Active power control......................................................................................................20

2.2.1.6 Reactive power control...................................................................................................20

2.2.1.7 Power Transformers.......................................................................................................21

2.2.1.9 Auxiliary supply.............................................................................................................22

2.2.1.10 Battery bank..................................................................................................................22

2.2.2 Kelanithissa Thermal Power Plant.........................................................................................22

2.2.2.1 Small Gas turbines (GTs)...............................................................................................22

2.2.2.2 Synchronous Condenser Mode.......................................................................................23

2.2.2.3 Starting of Small Gas turbines (GTs).............................................................................23

2.2.2.4 115MW Large Gas turbine (GT)....................................................................................23