UNIVERSITY OF MORATUWA

Faculty of Engineering

Registered Module No: EE 3993

INDUSTRIAL TRAINING REPORT

Yugadanavi Power Plant

LTL Transformers (Pvt) Ltd

Ceylon Electricity Board

From: 18/01/2021 To 11/06/2021

Date of Submission: 18/07/2021

Abhishek V.H.R.

170013H

Department of Electrical Engineering

 Preface
This report contains knowledge and experience which I gathered during my industrial training
session. It was a 19 weeks training session. First 9 weeks I was assigned in Yugadanavi power
plant. After that I was assigned in LTL Transformers Pvt. Ltd for 3 weeks. Finally, I was
assigned in CEB for 6 weeks.

This report contains major three chapters. They are working establishments during my
industrial training. In each chapter consists of introduction about them, main functions of them,
SWOT analysis, organizational structure and my training experience. In addition to that
information which I have gathered during the training session.

In last chapter consists with the conclusion. I contain the opportunities and problems I have
faced during training period and I have included the how was the overall training program in
my point of view.

V.H.R.Abhishek

Department of Electrical Engineering

University Of Moratuwa

ii
 Acknowledgement

I learnt lots of things related to the electrical engineering and also management level things
from the industrial training. They will be very important to my future carrier.

So that, I would like to acknowledge Eng. T.A.Gamage, Director of Industrial Training

Division, The Department of Electrical Engineering and the National Apprentice and Industrial
Training Authority (NAITA) for making necessary arrangements to this valuable training
program.

Then I would like to express my gratitude to Prof. K.T.M.U.Hemapala, Head of Department of

Electrical Engineering and to Dr. Saranga K. Abeygunawardane, training coordinator of
Department of Electrical Engineering for their valuable guidance and the support.

Then I’m expressing my gratitude to the Mr. Kithsiri Egodawatte, Plant Manager of
Yugadanavi power plant, Mr. Kamal Peiris, EHS Manager of Yugadanavi power plant and
Miss. Sajini Aahakoon, our training coordinator, all the engineers and technical staff who
shared their experience and knowledge with us for their guidance and commitment for
arranging online lectures for us and arranging one-week physical training session in power plant
during those challenging situations.

Then I would like to express my gratitude to Mr. Rukshika Pathberiya, Former Factory
Manager, Mr. Ashoka Premarathne , Factory Manager, Mrs. Awishka Navodee, Miss. Thilini
Gunawardana, Manager of the Design Department and the Mr. Nipun and all the engineers and
technical staff for sharing their their experience and knowledge with us and for their guidance
for arranging our training session in LTL Transformers Pvt. Ltd.

And I would like to express my gratitude to Mrs. Chandani Premarathne for planning all over
training session make it success , Mr. K.P.R.D.S.K. Dharmadasa , Chief engineer and all the
engineers in Tr. O&M of Western province central for share their experience with us, all the
engineers and staff members in Colombo city DGM office and control center and all the
engineers who conduct the online lectures by making their valuable time for us.

And also I would like to thank all my colleagues, group members and my parents who has taken
a part with me and helped me in various conditions in the training period.

iii
 Contents
List of Figures .......................................................................................................................... vii

List of Tables .............................................................................................................................. x

Abbreviation .............................................................................................................................. xi

1.Yugadanavi power plant.......................................................................................................... 1

1.1 Introduction ...................................................................................................................... 1

1.2 SWOT Analysis................................................................................................................ 1

1.3 Basic operation ................................................................................................................. 2

1.4 Training experience .......................................................................................................... 2

1.5 Gas Turbine ...................................................................................................................... 4

1.6 HRSG ............................................................................................................................... 6

1.7 Steam Turbine .................................................................................................................. 9

1.8 Emergency Diesel Generator ......................................................................................... 11

1.9 Electrical System ............................................................................................................ 11

1.10 Sea Water Intake Plant ................................................................................................. 13

1.11 WTP ............................................................................................................................. 14

1.12 FOTP ............................................................................................................................ 16

1.13 ETP ............................................................................................................................... 17

1.14 MCW and CCW Systems ............................................................................................. 18

1.15 Auxiliary Boiler System ............................................................................................... 18

2. LTL – Transformers (Pvt.) Ltd. ........................................................................................... 19

2.1 Introduction .................................................................................................................... 19

2.2 Organizational Structure ................................................................................................ 19

2.3 SWOT Analysis.............................................................................................................. 20

2.4 Training Experience ....................................................................................................... 21

2.5 Production Process of the Transformer .......................................................................... 22

2.4.1 LV Winding............................................................................................................. 22

iv
 2.4.2 HV Winding ............................................................................................................ 24

2.4.3 Core Cutting ............................................................................................................ 26

2.4.4 Assembly Process 1 ................................................................................................. 27

2.4.4 Assembly Process 2 ................................................................................................. 28

2.4.5 Ovening ................................................................................................................... 28

2.4.6 Tanking.................................................................................................................... 28

2.6 Transformer Testing ....................................................................................................... 29

2.5.1 Routine Tests ........................................................................................................... 29

2.5.2 Type Tests ............................................................................................................... 36

2.5.3 Special Tests ............................................................................................................ 36

2.7 Design of Transformers .................................................................................................. 37

3.Ceylon Electricity Board (CEB) ........................................................................................... 38

3.1 Introduction .................................................................................................................... 38

3.2 Organizational Structure ................................................................................................ 38

3.3 SWOT Analysis.............................................................................................................. 38

3.4 Generation ...................................................................................................................... 40

3.3.1 Lakvijaya Power Plant ............................................................................................ 40

3.3.2 Hydro Power Generation ......................................................................................... 42

3.5 Transmission .................................................................................................................. 45

3.4.1 Training experience ................................................................................................. 45

3.4.2 Grid Substation ........................................................................................................ 46

3.4.3 Transmission Lines ................................................................................................. 49

3.6 Distribution – Colombo City Operation ......................................................................... 52

3.5.1 Training Experience ................................................................................................ 52

3.5.2 Distribution Network in Colombo City................................................................... 53

3.5.3 Bulk Supplies .......................................................................................................... 54

3.5.4 SCADA System....................................................................................................... 55

v
Conclusion ................................................................................................................................ 56

Annex – 1 ................................................................................................................................. 59

Annex - 2 .................................................................................................................................. 60

vi
List of Figures
Figure 1.1 – Yugadanavi Power Plant

Figure 1.2 – Taking an oil sample for the breakdown voltage test

Figure 1.3 – Taking an oil sample for the breakdown voltage test

Figure 1.4– Placing an oil sample compartment on tester

Figure 1.5– Gas turbine compartment of Yugadanavi power plant

Figure 1.6 – Major stages in gas turbine

Figure 1.7 – T-S diagrams for the Brayton cycle and the Rankine cycle

Figure 1.8 – HRSG in Yugadanavi power plant

Figure 1.9 – Arrangement of the tube bundles in HRSG

Figure 1.10 – Recirculating pump in HRSG

Figure 1.11– T-S diagram of a Yugadanavi power plant’s operating Rankine cycle

Figure 1.12 – Gland Steam Seal System

Figure 1.13 – Ejector

Figure 1.14 – Emergency Diesel Generator

Figure 1.15 – Unit Transformer

Figure 1.16 – Simple drawing of the electrical system of Yugadanavi power plant

Figure 1.17 – Velocity Cap

Figure 1.18 –Flow chart of WTP Filtration Processes

Figure 1.19 – Osmosis and Reverse Osmosis

Figure 1.20 – Untreated HFO tank and treated HFO tanks

Figure 1.21– Flow Chart of Mixer and Separator

Figure 1.22 – Diagram of MCW and CCW systems in Yugadanavi power plant

vii
Figure 2.1 - LTL Transformers (Pvt) Ltd.

Figure 2.2 – Prepare an oil sample for the oil breakdown test

Figure 2.3 – Separate source voltage test

Figure 2.4 – Separate source voltage test

Figure 2.5 – ID 1&2

Figure 2.6 – Mount the LV winding on the Former

Figure 2.7 – Put the stick barrier

Figure 2.8 – Tap positions

Figure 2.9 – Diagram of delta connection of the HV side with tap connections

Figure 2.10 – Main components of the transformer core

Figure 2.11 – Inserting winding into transformer limb

Figure 2.12 – Transformers after tanking

Figure 2.13- Test connection for insulation resistance testing between HV winding and earth

Figure 2.14 - Connection diagram of the vector group test

Figure 2.15 – Connection for test between HV and Earth and LV and Earth

Figure 2.16 – Connection for the no load test

Figure 2.17 – Connection for the full load test

Figure 2.18 – Transformer design program

Figure 2.19– Drawing of a designed transformer

Figure 3.1 – CEB logo

Figure 3.2 – wind barriers in Lakvijaya power

Figure 3.3 – General arrangement of the hydro power plant

Figure 3.4 – Mahaweli river basin power

viii
Figure 3.5 – Auto Transformer in grid substation

Figure 3.6 – Power Transformer in grid substation

Figure 3.7 – Transmission cables in grid substation

Figure 3.8 – Indicator of GIS arrangement

Figure 3.9 – Transmission Sector

Figure 3.10 - AIS

Figure 3.11 - GIS

Figure 3.12 - GIS

Figure 3.13 – Switchyard Equipment

Figure 3.14 – Transmission network in Sri Lanka

Figure 3.15 – Line Tower

Figure 3.16– Angle Tower

Figure 3.17 – Insulator

Figure 3.18– Vibration Dampers

Figure 3.19 – Vibration Dampers

Figure 3.20 – Space Dampers

Figure 3.21– Anti Climbing Devices

Figure 3.22 – RTU Panel

Figure 3.23 – HT Panel

Figure 3.24 – Distribution network of Colombo City

Figure 3.25 – LV Distribution from Feeder pillars

ix
List of Tables
Table 2.1 - Applying DC test voltages and recommended insulation resistances

Table 2.2 - Connection for the DC resistance test

Table 2.3 – Applying test voltage according to the relevant winding

Table 3.1 - Space requirement for the substation according to type

x
 Abbreviation
AC – Alternating Current

AIS – Air Insulated Substation

CCW – Closed Cooling Water

CEB – Ceylon Electricity Board

CT – Current Transformer

DC – Direct Current

DDP – Diamond Dotted Paper

DM – Demineralized Water

ETP – Effluent Treatment Plant

FOTP – Fuel Oil Treatment Plant

GIS – Gas Insulated Substation

HFO – Heavy Fuel Oil

HP – High Pressure

HRSG – Heat Recovery Steam Generator

HT – High Tension

HV – High Voltage

ID – Internal Diameter

LNG – Liquefied Natural Gas

LP – Low Pressure

LT – Low Tension

LV – Low Voltage

LVAC – Low Voltage Alternating Current

xi
MCW – Main Cooling Water

MV – Medium Voltage

ONAF – Oil Natural Air Forced

ONAN – Oil Natural Air Natural

PUCSL – Public Utility Commission of Sri Lanka

rpm – Rounds Per Minute

RTU - Ring Terminal Unit

SCADA – Supervisory Control And Data Acquision

UG – Under Ground

VT – Voltage Transformer

WTP – Water Treatment Plant

xii
1.Yugadanavi power plant
1.1 Introduction
Yugadanavi power plant is a combined cycle power plant which is located in Kerawalapitiya
in Sri Lanka. LTL Holdings Ltd is owned the Yugadanavi power plant. Yugadanavi power plant
consists two gas turbines with 100MW capacity of each and one steam turbine with 100MW
capacity making its total plant capacity as 300MW. It generates approximately 1800GWh
annually to the national grid.

Figure 1.1 – Yugadanavi Power Plant

Yuganadavi power plant project was fast tracked in late 2005 by Ministry of Power and Energy
as a solution for the forecasted energy shortage problem in 2008. This power plant project was
begun in November 2007. It completed constructions of its 200MW first phase within 10
months and President Mahinda Rajapakse ceremonially inaugurated the phase 1 of the power
plant on 8th December 2008. Second phase of the power plant is completed in later February
2010.This power plant built over a 25 acres site. It is estimated that construction cost of the
power plant is 300 million US dollars.

1.2 SWOT Analysis

Strengths

Yugadanavi power plant is the major thermal power plant in Sri Lanka. It’s contribution to the
country’s energy sector is very important. That is the major strength of the power plant. And
also government also owned this power plant. In addition to that, power plant has good energy
consumption and it maintained the required environment conditions. Furthermore, Yugadanavi
power plant has well experienced and skilled technical staff. Therefore, workforce also become
its main strength.

1
Weaknesses

Since power plant is operated according to the CEB demand requirements, power plant doesn’t
always run its full capacity. Therefore, plant factor slightly reduced due to that.

Opportunities

There are plans to replace the HFO with LNG as the fuel of power plant. This will reduce the
carbon emission and fuel cost of the power plant. In addition to that, it will increase the
efficiency of the power plant.

Threats

Environmental regulations must be maintained in the power plants. If some quantities are not
within the acceptable limits of the regulations it will cause lot of legal issues.

1.3 Basic operation

Yugadanavi power plant is a combined cycle power plant. Both gas turbines and steam turbines
are used in combined cycle power plants. In this method, efficiency can be increased up to 60%
from same amount of fuel than a traditional simple cycle power plant.

Basically in this power plant, steam turbines are used wasted heat which are emitted from the
gas turbine and produces electricity. Gas turbine operates based on Brayton cycle. In there, first
gas fuel is compressed using turbine and then produced compressed gas is combusted in the
combustion chamber. After that hot pressurized gases are utilized to drive high speed turbine
which is coupled to a generator. Finally, those hot gases which is emitted by the gas turbine are
used to heat the water in a HRSG of steam turbine system before it leaving the plant. Then
produced steam inside the boiler is used to drive steam turbine and generate electricity. This
power plant is capable of using HFO, Diesel and LNG as fuels. But normally, HFO is used as
a fuel. In Yugadanavi power plant there are two gas turbines, two HRSGs and one steam turbine
commonly known as 2+2+1 configuration.

1.4 Training experience

I have assigned 9 weeks training session under the Yugadanavi Power Plant. Due to the recent
Covid-19 pandemic situation, 8 weeks of the training sessions are done as the online sessions.
In addition to that we have one-day plant visit during the first week and one week inplant
training session on last week.

2
In online sessions, engineers at the Yugadanavi power plant gave basic idea about the
operations of every compartment of the power plant. In addition to that assignments are given
for the every online sessions which are encouraged us to study deeply about those compartments
and operations and search for the additional information. Every assignments were graded and
sent to us during the training session.

In plant training was held at last of the training and we are undergoing it after the PCR test due
to the safety criteria of the power plant. Accommodations, foods and transportation are provided
by the power plant. We were able to see every compartments of the power plant and their
operations, in this training session. Engineers who are assigned to each compartments descibed
about those things and we were able to ask questions them and clarified our doubts. In addition
to that we were able to see a routine test of a transformer in our training session. Throughout
the training session, I had opportunity to understand the basic operations and the reasons for
doing them in the power plant. Also we had chance to familiarize with workers, operators and
engineers and clear our doubts and understand their workscope. And also we had a chance to
did oil breakdown voltage test in transformer. And we did insulation resistance testing in
motors.

In oil breakdown voltage test, first

oil sample has to be taken from the
transformer. When we fill the oil for
the compartment, we intentionally it
collects when it flows on the
compartment wall. Figure1.2 and 1.3 –
Taking an oil sample for
Then it placed on the tester. In this
the breakdown voltage
testing voltage between two electrode is increased until
test
arcing happens. Ths test is done 6 times for one oil sample
with 2 minutes gaps. And then take the average.

And in insulation resistance test basically it measures the

resistance between windings – earth, winding – winding
and two poles of the same winding in three phase windings
using megger tester. Finally we had a viva about Figure 1.4– Placing a oil sample
Yugadanavi power plant to evaluate our training. compartment on tester

3
1.5 Gas Turbine
As a combined cycle power plant, gas turbine is the first stage in electricity generation in
Yugadanavi power plant. Generally, HFO is
used as the fuel in gas turbine. Basically,
outside air is sucked by the gas turbine and
compressed it and combusted it. Then
combusted gas is used to rotate the gas turbine
which is coupled with the generator and
produce electricity.

Yugadanavi power plant has two gas turbines

with 100MW of each capacity. Both gas
Figure 1.5– Gas turbine compartment of
turbines are General Electric France
Yugadanavi power plant
production and model is PG 9171/Frame
9E/MS 9001E. Both of them have multi fuel handing capacity such as HFO, diesel and LNG.
There are two starting motors for each gas turbines with 1000kW capacity which are operating
at 6kV AC voltage. In addition to that gas turbines are covered by the casing which provides
the isolation from the outside.

Gas turbine is operated in open brayton cycle. There are four major steps in brayton cycle.

1. Compression
2. Combustion
3. Expansion
4. Heat rejection

Figure 1.6 – Major stages in gas turbine

4
Compression is done in the compressor. There are two main components in compressor named
compressor rotor and compressor stator. There are 17 stages of rotating blades in gas turbines
in Yugadanavi power plant. Each blades are constructed to compress the air. Altogether,
compressor compress the air 12:1 ratio.

Combustion is done in the combustion chamber. There are 14 DLN 1 type can combustion
chambers and 4 flame detectors and 2 spark plugs. Compressed discharge air is directed
upstream to enter inside the combustion chambers. After that it mix and burn with fuel which
produces hot gasses which will drive the turbine These combustion chambers are arranged
around the periphery of the compressor discharge casing. Those combustion chambers are dual
fuel capable which can handle either gas fuel or liquid fuel.

Expansion which is the third stage of the Brayton cycle is done in the turbine section. In turbine
section there is three turbine stages. Each turbine section consists with stationary nozzle set and
rotating buckets set. Nozzle set is directed hot gases to the rotating buckets with proper angle.
Therefore, hot gases’ heat energy is converted into kinetic energy inside this part. These nozzels
and buckets are covered with thermal barrier coating to protect it from outside because it handle
extreme hot discharge gases. Gas turbine is generally rotates in 3000rpm speed and it couple
with the generator which produces the electricity.

In yugadanavi power plant, exhaust flu gas is then entered to the HRSG. This flu gas contains
lot of heat energy therefore that energy is used inside HRSG. There are lot of subsystems inside
the gas turbine which provide protection, control and maintaining the gas turbine such as,

 Speedtronic Mark VI controlling system

 Liquid/Gas fuel system
 Generator exciter/protection/synchronizing system
 Water injection system
 Lubrication oil/lifting oil system
 Ventilation system
 Fire protection system
 Inlet air/IGV system
 Fuel heating and filtering system

5
1.6 HRSG

Figure 1.7 – T-S diagrams for the Brayton cycle and

the Rankine cycle
HRSG is the place where open Brayton cycle and the Rankine cycle are combining. Brayton
cycle’s 4-1 process is a heat rejection process and this is the last step of the gas turbine process.
Normally, heated air will discharge to the atmosphere in the gas turbine. This heated air carries
considerable amount of heat energy which is wasted. Therefore, in HRSG this heated air is used
to heat addition step of the rankine cycle (rankine cycle’s 2-3 process). So that, in that way
HRSG is combining Rankine and Brayton cycles together.

In Yugadanavi power plant, there are two vertical type

HRSGs.

Normally, exhaust flu gas temperature is around 520oC. In

HRSG, heat energy which carries by the flu gas effectively use
for the steam generation. There are six tube bundle sections
inside the HRSG for heat exchanging process is done
systematically.

● LP Economizer ● HP Economizer

Figure 1.8 – HRSG in ● LP Evaporator ● HP Evaporator

Yugadanavi power plant

● LP superheater ● HP Superheater

Feed water is sent to the economizer section to preheat it before introducing to the system. Then
preheated feed water is sent to the LP drum. LP feed water in the LP drum then send to the LP

6
evaporator. In this tube section, LP water is heated to the saturation point. Saturated vapor is
again sent to the LP drum. After that LP steam which is taken from the LP drum is sent to the
LP super-heater. LP steam becomes dry steam and its temperature is further increased in this
tube section hence becomes super-heated steam. Finally super-heated LP steam is sent to the
LP turbine. Normally, this superheated steam at 230 oC temperature and 7 bar pressure.

In addition to that, LP feed water is separated from the LP drum and its pressure is increased
using feed water pump and it became HP feed water. There are two HP feed water pumps in
each HRSG with 1200kW power rating in Yugadanavi power plant (one motor is operating and
other one is as a standby pump). Normally, 70% of the LP water is used foe the HP water system
and LP feed water’s pressure is increased to 90 bar using this feed water pump. Then HP feed
water is sent to the HP economizer to preheat the HP water. After that preheated feed water is
sent to the HP drum. Then HP water is separated from the HP drum is sent to the HP evaporator
and HP feed water is heated up to its saturation point in this tube section. Again saturated steam
is sent back to the HP drum. As the final stage HP super-heater is taken HP steam from the HP
drum and heated it. Then steam becomes super-heated steam and it is sent to the HP turbine.
Generally super-heated steam which is sent to the HP turbine is having 512 oC temperature.

Figure 1.9 – Arrangement of the tube bundles in HRSG

7
There are many special concerns which have to consider for the safety operation and for
durability of the HRSG.

 Soot blowing

While heat is transferring from the flu gas to the feed water, soot deposits on the heating
surfaces of the HRSG such as tube bundles. As a result these bundles are act as a heat insulator
and heat transferring process become less efficiency. Therefore, less heat transfers to the feed
water which leads high fuel consumption and reduce the overall plant efficiency. Therefore,
deposited soot have to be blown away in order to keep plant efficiency in optimum range. Soot
blower is used to remove the soot which is deposited on tube bundles. Superheated steam is
taken as the medium for soot blowing process. This process is done once for every 8 hours.

 Avoiding cold corrosion

Exhaust flue gas from the gas turbine having around 520oC temperature and it used to convert
water to steam by heat addition. But flue gas temperature cannot be reduced below special
temperature known as Sulfur dew point. Because then SO3 combines with the water vapor and
condensates Sulfuric acid (H2SO4) on the metal surface of the HRSG which causes corrosion
known as the acid corrosion or cold corrosion. Therefore, HRSG designs to maintain exhaust
flue gas temperature at 160oC in order to avoid acid corrosion. Lowest flue gas temperature
occurs at upper part of the HRSG. Therefore, if flue gas temperature become lower than acid
dew point, it will occur at the upper part of the HRSG. So, water which is going out from the
LP economizer is mixed with the supply water of the LP preheater through recirculating pump
in order to maintain preheater inlet water temperature greater than acid dew point. Therefore,
inlet water temperature of the LP preheater always maintains higher than acid dew point in
order to ensure that flue gas temperature doesn’t become lower than acid dew point.

Figure 1.10 – Recirculating pump in HRSG

8
1.7 Steam Turbine
Generated steam at the HRSG then entered into steam turbine and in this heat and kinetic energy
of the steam is converted into rotational kinetic energy of the turbine. Steam turbine is coupled
with a generator and as a result it generates the electricity. Steam which are going into the steam
turbine are operating in Rankine cycle.

In Yugadanavi power plant, there are 2 rankine cycles are operating simultaneously. As shown
in the figure below, both LP steam cycle and HP steam cycle are oprerating.

In Yugadanavi power plant, there is a

SC5 model reaction/impulse and axial
exhaust & condensing type turbine which
has two pressure stages (LP-7 bar and HP-90
bar) with extraction. There are 15 HP stages
and 5 LP stages in this steam turbine. It can
deliver 108MW net power output and rotate
3000rpm speed. Steam turbine generator is
9A5 type three phase two pole 142.2MVA
Figure 1.11– T-S diagram of a Yugadanavi
rated generator which is manufactured by
power plant’s operating Rankine cycle
ELIN(Austria). It is Totally Enclosed Water
to Air Cooled (TEWAC) generator with
375V field voltage and 892A field current.

There are lot of subsystems except steam system in the steam turbine.

 Gland steam seal system

In steam turbine, there is a portion at front and rear sides where the rotor exits the turbine casing
named gland. This gland provides a labyrinth path which makes harder to escape steam from
the turbine casing or enter the atmospheric air into the turbine casing.

9

Figure 1.12 – Gland Steam Seal System
At the start up, steam source control valve is
open and supply steam to the gland both HP and
LP sides. Therefore, instead of atmospheric air
get into the turbine, steam is entering to the
turbine. Rest of the steam will get into the gland
steam exhauster.After the start up, steam inside
the turbine is try to escape from the turbine in
HP side of the turbine. Therefore, gland sealing
steam must be stopped and all the steam which
escape from the HP side gland will be gone to
the condenser or gland steam exhauster. But
gland steam still has to supply to the LP side
gland.

 Condensate air removal system

This system removes non-condensable gases with the attached water vapor which serves as gas
carrier and establish vaccum in the condenser. This system consists with two holding ejectors
and one hogging ejector.

Venturi effect is the principle of the ejector. In ejecor, high pressurized stream (motive) is
accelerated through a nozzle. Then that stream’s velocity gets higher at the nozzle’s tip which
creates a lower pressure zone at there. This pressure is lower than the suction fluid which comes
through the suction branch. Therefore, due to this pressure difference suction fluid is sucked
into the ejector.

Figure 1.13 – Ejector

10
  Turning gear system

Turning gear system is used shutdown operation in the turbine. This will give some space to
uniform cooling of the turbine rotor by keep rotating the turbine around 6rpm speed in 2-3 days
after turbine is slowed down to pre-determined value. Otherwise heavy rotor tends to bend and
sag if turbine rotor sits gravity after the power generation.

1.8 Emergency Diesel Generator

Emergency diesel generators are used at a blackout
situation or grid maintenance situation to maintain power
plant at a standby condition. There are three Caterpillar
3516 (1460kW) and Caterpillar 2250 (1600kW) type, V-16
4 stroke water cooling emergency diesel generators in
Yugadanavi power plant.In diesel generator set, contains
container housing, diesel engine, generator, CT, VT, air
Figure 1.14 – Emergency Diesel
filter system, cooling system, fire fighting system and fuel
Generator
oil system.

1.9 Electrical System

As we discussed previously, Yugadanavi power plant has 300MW capacity which 200MW
supply by two gas turbines and 100MW supply by steam turbine. If we consider about the
electrical system of the power plant, there are several components which have to play major
role in electrical system.

 Generator
-Brand – ELIN 9A5
-142.2MVA, 14.5kV, 0.8pf, 3000rpm
-Totally enclosed, water to air cool generator with brushless excitation.
 Unit Transformer
-Two 130MVA transformers for gas turbines and one 140MVA transformer for steam
turbine.

11
 -Step up transformer - 14.5kV to 220kV
-ONAF cooling system and YNd11 vector group
-On load tap changers
 Station Transformer
-Two 10MVA transformers for two Gas turbines
-Step down transformer - 14.5kV to 6kV
-ONAN cooling
 Distriution Transformer Figure 1.15 – Unit Transformer
-Two 3.5MVA transformers and four 2.5MVA
transformers
-Step down transformer – 6kV to 400V
 DC Battery Banks
-Five DC battery banks with two banks with 2116Ah capacity, two banks with 244Ah
capacity and one with 385Ah capacity.
-Two DC bus bars with 125V

System A System B
Figure 1.16 – Simple drawing of the electrical system of Yugadanavi
power plant
Above diagram shows how the electrical system is arranged in Yugadanavi power plant.
Auxiliary loads of the power plant are connected to the 400V (LV) bus. Emeregency diesesl
generators are connected the 6kV (MV) bus.

12
SUE 3000

SUE 3000 fast transfer device plays major role in electrical system. It is used to ensure that
continuous power supply to busbars. It automatically changes the power supply from a main
incomer to a standby incomer very fast. There are two system named A &B which are fed by
two separate 6kV power lines. These two lines connect as a one bus by bus coupler which is
located middle of the bus. SUE 3000 device control this bus coupler and two circuit breakers
which are located in 6kV power lines.

System A and system B are energizes by two separate gas turbines. Imagine due to some failure,
system B is not any longer energize. Then SUE 3000 identify that system B has voltage drop
and closed the bus coupler to supply power to system B by system A. Likewise, SUE 3000
maintain continuous power supply.

1.10 Sea Water Intake Plant

Water required for the water treatment plant and main cooling system is taken by sea. Sea water
is supplied by the sea water intake plant. Sea water intake plant is installed separate from the
power plant which is located near to the sea shore.

Velocity cap is installed in the sea 400m away from the seashore
to suck sea water in. Velocity cap has high effective area to reduce
the velocity of the intake sea water and sea water flows in to the
velocity cap due to the gravity.

After that sea water line connects to the sand trap as two lines. In
the sand trap, sand and other large particles of the sea water will
settle down. To do this process effectively, its has sloped floor and Figure 1.17 – Velocity
trapped sand removes manually. Cap

After that there is a three stage filtration in sea water intake plant. Those filtrations are done by,

● Bar screen

● Revolving chain screen

● Multidisc screen

These are mechanical filtration processes which removes different sizes of deposits.

13
There are three pumps to pump sea water to the power plant. All of them are manufactured by
KSB and vertical, submersible type pumps. Two of them are main pumps which have 1440m3/h
flow rate and 135kW power rating. Other one is a auxiliary pump which has 250m3/h flow rate
and 19kW power rating.

Chlorinator

Generally, sea water intake contains various microorganisms, bacteria, protozoan hence they
would affect to a bio film formation on the surface of membrane. (When carbon source and
nutrients are available in surface then, bacteria colony grows on that surface called biofilm
formation.) So it is required to eradicate the bacteria and micro-organisms before entering the
membranes to prevent biofouling. Electro-chlorination system is used in sea water intake to
make Sodium hypochlorite (NaOCl) which will use as a effective killer of bi-organism. It can
be use for control algae, bacteria and fungus in intake sea water.

Chemical Reaction in Chlorinator

2Cl- → Cl2 + 2e (at the anode)

2H2O + 2e → 2OH- +H2 (at the cathode)

1.11 WTP
In WTP, sea water convert into DM water which means all the ions and solid particles are
removerd from the water. DM water required to several uses in power plant such as,

 Make up water for the steam cycle

 Cooling water for the CCW
 Water injections to gas turbine (to avoid NOx emissions)
 For FOTP
 Fire water system

14
WTP takes 250m3/h sea water from sea water intake plant and produce 50m3/h DM water. Then
stores produced DM water in DM water tank which has 1200 m3 capacity.

Figure 1.18 –Flow chart of WTP Filtration

Processes
 Clarifier

Removing suspended solids like dirt, slit and micro organisms by settling them from a water
stream called clarification. Coagulation, Flocculation and Sedimentation are main steps in
clarification.

Coagulation and flocculation processes are used to separate the suspended solids portions from
water. They are two steps and flocculation is done after coagulation. In coagulation process,
negative charges on non-settable solids are neutralized using coagulant chemicals with opposite
charges to the suspended solids. After the neutralization, small suspended particles are able to
stick together. Temperature, pH level, dissolved oxygen, nature of coagulant, retention time
and concentration of coagulant affected to the coagulation. In flocculation, a gentle mixing
stage increase the particle size and create larger aggregates which makes easy the separation.
Sedimentation is a settling stage, suspended solid particles remove from the water using gravity.

 Dual media Filter

Further suspended solids, turbidity and silt can be remove using dual media filter. There are teo
main parts in dual media filters; composite pressure vessel and graded beds of sand anthracite.
Using this sand bed suspended solids can be removed from the water.

 Ultra filter

In ultra filter, raw water is going through semi-permeable membrane which has pore size in
0.01 micron range. In this method, water can be futher filter out.

15
  Sea Water RO and Brackish Water RO

Figure 1.19 – Osmosis and Reverse Osmosis

In these two stages, principle is same. Reverese osmosis is applied in here. In osmosis, water is
flow from lower contaminant concentration side to higher contaminant concentration side
through a semipermeable membrane. But in RO, water is forced to flow higher contaminant
concentration side to lower contaminant concentration side by applying external pressure on
higher contaminant concentration side. The output water from the sea water RO is called
brackish water and in this level, water is drinkable. Main difference between sea water RO and
brackish water RO is the maginitude of the applying pressure.

 Mixed Bed Unit

Ion exchange method is used in here. In mixed bed unit, both anions and cations resin are
existed. When water flows through this ionic contaminants of water are exchanged for the H+
and OH- ions on the resin beds. As a result, this produces highly purified DM water. After this
DM water’s conductivity is about 0.15µS/cm range.

1.12 FOTP
Yugadanavi power plant has high HFO requirement because it has to operate
continuously.There are two untreated HFO tanks with each capacity is 10000m3. In addition to
that there is one diesel tank with 2500m3 capacity wnich required for the start-ups and
shutdown.

16
 After untreated HFO is treated in FOTP, treated HFO
is stored in separate tanks. There are three treated HFO
tanks which has each capacity is 2500m3.

First, untreated oil transferred to FOTP using tranfer

pump and mixed with demusifier and water. Then
untreated HFO is going through a regenerative heater
which having heated-up treated HFO. Then It further
Figure 1.20 – Untreated HFO tank
heated up to 98oC.
and treated HFO tanks

After that untreated HFO goes two stages of mixer and separator. In this untreated HFO is
mixed with DM water then Na and K in the HFO is dissolved in water. Then Fuel and water is

Figure 1.21– Flow Chart of Mixer and Separator

separated using separator by centrifugal force. In first stage separated water is sent to the ETP.
In second stage, Fuel is mixed with DM water and separated water is sent to the first stage mixer
to mix with untreated HFO. Finally treated HFO is taken from second stage’s separator and
send to the treated HFO tank after going through the regenerative heater.

1.13 ETP
In ETP, waste water which is generated by different processes is converted into coastal
discharge limits in order to discharge to sea.Waste water is generated in mainly FOTP water
washing, tank drain, GT washing processes. Oil is extracted from this oily water using oil
skimming belt.

17
1.14 MCW and CCW Systems

Figure 1.22 – Diagram of MCW and CCW systems in Yugadanavi power plant

MCW is supplying cooling water for the condenser and CCW cooler for absorbing heat from
CCW system. Sea water is used in MCW system. When cooling water absorb heat from the
steam in condenser, it send back to the cooling tower to cool down.There are two cooling towers
in Yugadanavi power plant which consist four cooling cells for each tower. Cooling water cool
down in here due to evaporation.There are two MCW pumps to pump cooling water to
condenser, which has 12450m3/h capacity and 950kW power rating. In addition to that, there,s
a another pump called auxiliary cooling water pump to pump cooling water to CCW cooler
which has 1400m3/h capacity and 115kW power rating. In CCW cooler, cooling water absorbs
heat from CCW system’s cooling water. DM water is used in CCW system. There are separate
CCW pumps to pump DM water to equipment coolers like gas turbine lub oil and generator
cooling, steam turbine lub oil and generator cooling, and HRSG terminal point.

1.15 Auxiliary Boiler System

In Yugadanavi power plant, there are two HFO fired three pass wet back type auxiliary
boilers.Main usages of these auxiliary boilers are produce steam for the gand seat steam system
and ejectors and provide hot water to the fuel oil treatment plant.

There are pressurized hot water system, fuel oil preheating system, boiler make up pump system
nytrogen admission system, ring main pump system and chemical dosing sytem under auxiliary
boiler system.

18
2. LTL – Transformers (Pvt.) Ltd.
2.1 Introduction
LTL – Transformers (Pvt.) Ltd. was established in 1982 with CEB as a joint venture with the
intention of making transformers which required for the Sri Lanka inside the country for easier
to maintenance processes. ABB AS of Norway was developed the production line of the LTL
– Transformers (Pvt.) Ltd at the early days, but later they follow their own technology. In
present, it has a high reputation as a quality transformer manufacturer in the world. CEB is the
main customer of the LTL which has around 50% of their total productions. In addition to that
LTL has local private sector customers and foreign customers too. They manufactured
transformers which are in 5kVA – 5MVA power rating range. Distribution transformers
(mainly), Power transformers, Auxiliary transformers, Earthing transformers, Dual ratio
transformers and Isolation transformers are the types of transformers which is manufactured by
LTL. Except for transformers they manufacture switchgear panels up to 33kV. (Bus bar
chambers and feeder pillars).

Figure 2.1 - LTL Transformers (Pvt) Ltd.

Vision :- “A great global company through technology & people”

Mission :- Delight the customers by providing transformers & switchgear panels on time
with excellent quality.

2.2 Organizational Structure

Attached to the report as Annex 1.

19
2.3 SWOT Analysis
Strengths

LTL is the main supplier of transformers to the CEB and LECO, so they have very less
competition within the country and they has constant demand for the transformers within Sri
Lanka. It is the main strength of LTL. And also in international market, LTL transformers are
recognized as quality and durable transformers as a result they has good demand in lot of
countries. LTL has well experienced and skilled technical staff. Therefore, workforce also
become its main strength. In addition to that, they has sufficient facilities for the production
process and testing process of the transformers.

Weakness

Materials which are used for manufacturing transformers are imported from the abroad. As a
result LTL transformers cost became little bit higher compared with the Chinese and Indian
ones. It is major weakness. And also LTL doesn’t manufactured transformers which has higher
ratings than MVA. That also another weakness because sri Lankan companies has to purchase
those from the foreign companies.

Opportunities

LTL is now installing a new oven. This oven can be ovening, vacuuming and some other testing.
Therefore, LTL efficiency will be increased. Then they can supply more transformers than
current supply. And they replaced their old machines by new machines which makes their
production process faster.

Threats

There is a chance to Chinese and Indian companies take the control local market due to LTL’s
high prices and limitation of the transformer ratings.

Suggestions to Improve

As a trainee I have witnessed that some dispatched and test failed transformers are kept in
outside without any shelter. Therefore, as my opinion providing proper shelter for those
transformers is essential because it will affect to the quality of the transformer.

20
2.4 Training Experience
I have assigned 3 weeks training session under LTL transformers (Pvt.) Ltd. On first week we
studied the pre-recorded online sessions of our previous batch who had the first part of the
training at there and after that we have two weeks of in-plant training

In first week we studied the pre recorded videos regarding general awareness cooperate
straucture and history of the LTL transformers (Pvt.) Ltd, winding and assemble process of
transformers, tank fabrication/galvanizing/painting and tender/imports. We got a basic idea
about how the things are done in there with the help of those videos.

In plant training was held at nest two weeks and we are undergoing it after the PCR test due to
the safety criteria of the company. We were able to see the workshop of the company in fist
day. They gave us little introduction about the transformers’ assembly process while show the
process stages and machines which are used in workshop. After that we met the factory manager
Eng. Rukshika and he gave us an assignment to make a video about the workshop’s machine.
In order to that he gave separate machines and assembly stages for six of us. He provide all the
process manuals, machine manuals and permission to record the assembly stages in workshop.
I got the Chinese HV winding machine. We spent our first week and half of the week to study
the assembly process of the transformers, organizing and arranging the given information about
the machine, record the relevant videos and making the video. After that we handover all the
videos to Mr. Ashoke.

In second week we had a sessions about market and sales, customer satisfaction and main stages
of sales process and about the transformer tests. Under the transformer tests session, we had an
opportunity to see insulation resistance test, ratio test, DC resistance test, no load test, full load
test, separate source voltage test, induced over voltage test and oil breakdown test (routine tests)
of the transformers. In addition to that we have small sessions about design process of the
transformers and material selection and purchasing process of the transformers.

Figure 2.2 – Prepare an oil sample for Figure 2.3 & 2.4 – Separate
the oil breakdown test source voltage test

21
2.5 Production Process of the Transformer
There are seven major stages in the production process of the transformer.

1. LV winding
2. HV winding
3. Core cutting
4. Assembly stage 1
5. Assembly stage 2
6. Ovening
7. Tanking

2.4.1 LV Winding
First step of the production transformer is the LV winding. LV winding is wounded around the
wooden or steel object known as former. This former has elliptical shape. Former’s dimensions
are varied with the transformer’s design therefore, formers are came with different sizes and
dimensions. After detaching the LV winding from former an ebonite plate (A plate cut from a
machine according to design specifications) named “jig is inserted to the LV winding. If the
“jig” cannot be inserted inside the LV winding the LV winding will not fit the core as per
design. Copper foil/copper coil, DDP (Diamond Dotted Papers), Insulation papers, LV leads
are used for LV winding.

There are two main materials used as conductor in LV winding. They are copper foil and copper
coil. This copper coil is not a round shaped coil, it is a rectangular shaped coil. There are
separate two machines to winding these two conductors as LV winding. Copper coil can be
used as conductor where comparatively low current is flow through them but if current gets
larger, it is efficient and practical to use a copper foil as a conductor.

The reasons for using copper foil:-

 Increased reliability.
 Reduced size and weight.
 Higher ambient temperature operating capabilities.
 Improved electrical efficiency.
 Resistance to electrical stress is increased.
 Better overall regulation.

22
HV winding is wound around the LV winding symmetrically, which makes both of them has
same electrical center. Electromagnetic forces are acting on them when transformer is loaded.
These electromagnetic forces should be neutralized but due to tap changes of the HV winding,
forces on the HV winding also changes. Copper foil gives the ability to LV winding to change
the line of action of forces which acts on LV winding. Therefore, LV winding is fix the its
forces according to the forces changes on the HV winding to neutralize the resultant force.
Another important advantage of foil winding is that it will conduct higher currents under
transient conditions as skin effect will limit the effective cross section of conducting current.

Main steps of the LV winding (Copper foil)

1. According to drawing, setup the LV former on the machine.

2. Clamp the LV lead and copper foil together on the support on the machine.( this
provided a place which is good for the welding.)
3. Weld copper foil to LV Lead together.
4. Position the welded LV inner lead and DDP insulation on the former.
5. Set the counter to the required no of turns of LV coil. Select the numbers of edge strips
to match the thickness of foil .Place the edge strips as given on drawings and proceed
winding.

After the LV winding, operator should measure the OD 1&2 (outer Diameter) and ID 1&2
(Internal Diameter) of the LV winding.

After LV winding is finished, it is bought to the place HV winding

is done. There is a reason to HV winding is wound on the LV
winding which makes LV winding closer to the transformer core.
Because the insulation provided between the LV winding and core
Figure 2.5 – ID 1&2 of the transformer is quite less compared to the insulation
provided between the HV winding and the core of the transformer.
If we wound HV winding first, then we have to use larger insulation layer between HV-earth
and again HV-LV which makes transformer more costly and bulky.

23
2.4.2 HV Winding
After LV winding is finished, HV winding is wounded around it. Chinese automatic winding
machine and Tuboly machine are mainly used for HV winding.

Tuboly machine has high efficiency between them and it is very convenient to work with it.
Lots of works is like putting insulation layers and edge strips are done by automatically in this
machine. But in Chinese automatic winding machine, those works should be done by the
operator and copper coil also need to guide by the operator in order to avoid overlapping and
reduce the spacing between two adjacent copper rounds. In both machines, design criteria of
the HV winding can be entered to the control panel of the machine. It takes data about no. of
copper layers, copper windings per one layer and tapping positions of the HV winding. When
machine is operated, ie reminds the operator about finishing the copper layers, winding the
insulation edge strips and put the tap positions of the HV winding.

Materials required for the HV winding

 Copper coil ● Cooling duct

 DDP (Diamond Dotted Papers) ● 2mm thickness pressboard strip

 Insulation papers ● Sleeving

 Stick barrier ● Permasal tapes

Main steps of the LV winding (Chinese automatic winding machine)

1. Mount the LV winding to the correct former on the machine.

2. Cover the LV lead with the relevant lead strip.
3. Put the HV/LV barrier with corrugated board (stick barrier) as specified in the drawings.
4. Place the lead strip(press board strip) on HV side of the winding and fasten to winding
with permasal tape.
5. Wrap bottom end edge strip over the stick barrier.
6. Start the winding from top or bottom as given in the drawing. If winding starts from
bottom, cover the enamel wire with a crape paper tube(sleeving).
7. Proceed with the winding as given in the winding chart.
8. When one layer is completed insert insulation layers as given on winding chart.
9. Insert cooling ducts as given on winding chart.

24
 10. Fold the enamelled winding wire and obtain the tapings at given positions and Cover
the tapping wires with crape paper tubes.
11. Insert a strip of DDP between tapping wire and winding.
12. Use self adhesive tape to position tapping wire on the winding.
13. When main winding is complete, keep a gap at the break as given on charts before
starting the next portion of the winding.
14. Apply shelax properly on last layer.
15. Paste the relevant sticker & fill the data of the winding.

Figure 2.6 – Mount the LV Figure 2.7 – Put the stick barrier
winding on the Former
Transformer Tapping

In the production process of the HV winding, there is important criteria named tapping.
Generally, in HV winding design, all the tapping measurements are given.

Importance of the HV winding tapping

 There can be a voltage variation in the transformer due to large number of turns in HV
winding. Therefore, there should be a mechanism to change the turns ratio by changing
no. of turns in one winding.
 But tapping cannot be put in LV winding because of the high current flows through it.
Therefore, if tapping is in the LV winding, we should consider about the high current
interruptions.
 Putting tap positions is also easier because HV winding is in outside of the transformer
while LV winding is in the inside.

In assembly stage 2, tap changer is added into HV side of the transformer to change the voltage
using tap positions.

25
Off Load (No Load) Tap Changer

Off load tap changer is a tap changer which is required transformer should be disconnected in
order to change the taps. This is essential because in this tap changers, there is no mechanism
to deal with the transients of voltage. It can be done in manually or can be automated. This kind
of tap changers are used in step down transformers where tap changing is required rarely. If
someone tries to change the taps in o load conditions, a circuit breaker, which is interlocked
with the tap changer is activated and cut off load from the transformer.

Tapping

Figure 2.9 – Diagram of delta connection

Figure 2.8 – Tap positions of the HV side with tap connections
2.4.3 Core Cutting
Cold rolled gain oriented steel is used for the core making. The laminated steel sheets are cut
by the core cutting machine and they came out as a packets consisting 5 laminated sheets in
each. Those 5 laminated sheets are having 5 different sizes and they are placed on each other
starting from largest to the lowest. There are two types of cores named two step and multi-step
which are made in LTL transformers. Two step cores consist of packets with 2 sizes and multi-
step cores consists of packets with multiple sizes. Generally, multistep cores were used for
transformers with ratings above 1000kVA (Non oval) in LTL.

26
There are five main parts in transformer core. They are, top York, bottom York. Right limb,
left limb and center limb.

Figure 2.10 – Main components of the transformer core

2.4.4 Assembly Process 1
After completing the LV and HV winding and core assembling process is initiated. In LTL,
assembling process is done by two steps. In assembly process 1, LV and HV windings are insert
to limbs and core assembly is done. First, transformer core is brought without the top york and
paste DDP strips to the sharp corners of core legs for safety. Then suitable windings are selected
for inserting to limbs and insert them using crane or manually. After that, insulation strips are
inserted into gap between core and winding. Then insulation boards are placed on top of the
windings and complete the core by stacking top york. Wooden frame is used to clamp York and
insert the earthling strips into core and insert the stay rods. Upper wooden frame is tightened
with steel strapping. Finally, fix the correct lifting traverses to stay rods and tighten properly.

Figure 2.11 – Inserting winding into

transformer limb

27
2.4.4 Assembly Process 2
After assembly stage 1, active part is brought to the assembly stage 2. Star connection for LV
side and Delta connection for the HV side is connected in here. First prepared neutral copper
bar is fixed in LV side and then other LV bus bars also fixed using ratchet. After that, LV
flexible leads fixed and E blocks are glued at correct place. Then LV phase to neutral bar is
tighten the with suitable cable ties. Finally, LV lead insulation board also tied properly.

In HV winding assembly process, first enamel insulations of the tapping wire should be
removed. Then tapping support board and tapping selector is positioned properly. Insulation
paper tubes were inserted into tapping leads. After the assembling process 2 both HV and LV
connections should be inspected and recorded on the yellow card.

2.4.5 Ovening
Active part undergoes a ratio test after the assembly process 2. Then, it put inside the oven for
melting the glues in DDP and tighten it. Remaining moisture inside the active part is also
removed in this process. 33kV-415V active parts are kept in the oven for 36 hours and 11kV-
415V active parts are kept in the oven for 24 hours.

2.4.6 Tanking
Active part is placed inside the tank in this process. There are two ways to do that.

1. Tank mount
2. Cover mount

In tank mount, active parts is mounted inside the tank using crane and transformer oil is filled
in the tank immersing the active part. Then top cover is placed on the tank.

In cover mount first top cover is placed on the active part

Figure 2.12 – Transformers
after tanking
and placed all the other components like HV LV
bushings, flags and pressure relief valve. Then the tank is
sealed using silicon sealer or cork gasket. After that,
active part is placed inside the tank and sealed. After that,
transformer is placed in the vacuum chamber where
pressure is reduced to 0.5 mbar. Transformer kept in
there for 2 hours and then filled with oil.

28
2.6 Transformer Testing
Transformer testing is done to ensure the transformer quality. There are three types of testing.

1. Routine tests
2. Type tests
3. Special tests

These all transformer testing are done according to the IEC 60076 standards.

2.5.1 Routine Tests

These tests can be considered as main tests of the transformer. All transformers which are
produced are undergoing these tests and there should be a 100% success level of these tests.
Routine tests done each manufactured unit and its results recorded to the yellow card of the
transformer. There are nine electrical tests and one mechanical test under this category.

1. Pressure test
2. Insulation resistance test
3. Vector group test
4. Voltage ratio test
5. DC resistance test
6. Oil dielectric strength test
7. Separate source voltage withstand test
8. Induced over-voltage test
9. No load test
10. Full load test

2.5.1.1 Pressure Test

This test is done after oil filling of the transformer. Then it moved to the pressure testing area
and transformer surface should be cleaned. After that extra oil volume which is obtained
according o below equation, is inserted into the transformer using pump. (Normally, in CEB
transformers oil is filled for its maximum rated pressure 1.3 bar)

Extra oil volume = Tranformer oil volume × top oil temperature rise × 0.8 × 0.00075

Then after keeping the transformer for duration of 8 hours, check for any leaks on the
transformer surfaces. If there is no any leaks, then tested transformer can be considered as pass
for the pressure test. Then extra oil volume is evacuated from the transformer using pump.

29
2.5.1.2 Insulation Resistance Test
Megger tester is used to measure the insulation resistance of this test. Therefore, this test also
called as megger test. In this test, insulation resistance is tested between LV-HV, LV-Earth and
HV-Earth. To do that tester probes is connected accordingly.

Eg: When HV-Earth insulation resistance testing, probes should be connected to the HV
winding terminal and earth. Same time LV winding and core should be connected to the earth.

Figure 2.13- Test connection for insulation resistance testing between HV

winding and earth

Table 2.1 - Applying DC test voltages and recommended insulation resistances

Transformer Coil Minimum DC Test Recommended minimum insulation

Rating Type Voltage resistance (MΩ)

(V) (V) Liquid Filled Dry

0-600 1000 100 500

601-5000 2500 1000 5000

>5000 5000 5000 25000

30
2.5.1.3 Vector Group Test
In this test, vector group of the transformer
is identified using transformer ratio meter.
First, HV and LV leads of the meter should
be connected to the HV and LV bushing
terminals of the transformer.

Then, vector group can be observed by

switch on the meter and pressing ‘Group’
Figure 2.14 - Connection diagram of the vector
button on measurement column.
group test
2.5.1.4 Voltage Ratio Test
In this test, voltage ratio is tested to confirm it has correct turn to turn ratio. Transformer ratio
meter is used for this test. First, HV and LV leads of the meter should be connected to the HV
and LV bushing terminals of the transformer. Connection is same as the vector group test. Then,
switch on the meter and press the ‘Ratio’ button on measurement column. After the entering
vector group of the transformer and the required Phase or A/N (to get ratio of all phases at
selected position) we can observe voltage ratio of the transformer for corresponding tapping.
Then voltage ratio can take for all the tap positions of the transformer. Transformer can be
considered as pass this test if the result value of the tappings shall be within the range in between
-0.5% to +0.5% of the calculated ratio.

2.5.1.5 DC Resistance Test

Resistance of windings and terminal are measured in this test. This is done by using transformer
winding resistance meter. In this meter, known DC current is passed though the winding which
is has to be tested and measure the voltage drop across the winding. DC current is using in this
test because we want to measure only the resistance part of the winding. This method is called
as current voltage method.

First, transformer should be put under liquid for at least 3h without excitation. After that,
measuring the top and bottom liquid temperatures, average liquid temperature can be taken as
the mean of above two temperatures. Then winding temperature also can be considered same
as average liquid temperature. Then connection should be made as the below table.

31
Then transformer is set to the principle tapping and switch on the unit and press ‘start’ button
after selecting the suitable range of the current (10% of the rated of HV side current). Reading
can be taken after de-energized the output circuit. This test is repeated for highest current and
lowest current tapings of each phase. Temperature readings also should be obtained same time
of the resistance readings. When all the readings are obtained, transformer core should be de-
magnetized by pressing the ‘Demag’.

Table 2.2 - Connection for the DC resistance test

Windings under Channel 1 Channel 2 Jumper Current

measurement terminals terminals connection Terminals

HV LV

A&B a&b A&B a&b B&a A&b

B&C b&c B&C b&c C&b B&c

C&A c&a C&A c&a A&c C&a

2.5.1.6 Oil Dielectric Strength Test

Test the breakdown voltage of the transformer oil is the purpose of doing this test. Two hemi
spherical metal electrodes of radius 25mm ± 0.25 mm consists of the device which is used for
this testing and both of them are separated with a gap of 2.5mm ± 0.1mm. The electrodes shall
be made with either brass, bronze or austenitic stainless steel.

Fist oil containing compartment should be filled with transformer oil. This oil sample is
collected from the bottom part of the transformer. And when oil sample is collected we have to
take every precaution in order to avoid any contaminant of the oil. Then put the magnetic stir
in to the test vessel. Temperature of the oil cannot be larger than 5oC to the ambient temperature.
After 5 minutes from the oil filling and make sure that there are no air bubbles between the
electrode gap, first application of the test voltage can be started. Then, standard and the mode
of the operation can be selected and after that, test voltage can be increased until the breakdown
occurs. The rate of rise of applied test voltage should be 2 kV/second ±0.2 kV/second. We have

32
repeat the test for six times for same oil sample with having 2 minutes’ time gap between two
readings and we can take the mean value of the six breakdowns as the breakdown voltage. If
mean value of breakdown voltage ≥ 30kV, test will be passed.

2.5.1.7 Separate Source Voltage Withstand Test

Purpose of this test is to assess the alternating voltage withstand strength of the line and neutral
terminals and their connected windings to earth and other windings. First we have to make sure
that transformer tap selector at the principle tap position. Then bushing terminals of the winding
which is tested, have to connect together using one conductor wire and rest of the terminals are
connected together using another winding. ( If there is separate core earth, it should be properly
earthed during the test.)

Figure 2.15 – Connection for test between HV and Earth and LV and Earth

Then test voltage is applied to the relevant winding according to the given table below.

Table 2.3 – Applying test voltage according to the relevant winding

Highest voltage for equipment winding Test voltage

Um/(kV)
(kV)

< 1.1 3

3.6 10

7.2 20

12 28

17.5 38

24 50

36 70

33
Eg:- For a 33kV/415kV transformer, to check the withstand capability of HV side, 70kV test
voltage is applied for the HV side for 60 seconds (In this time, HV terminals are connected
together and LV terminals are connected together and earthed). And to check the withstand
capability of LV side, 3kV test voltage is applied for the LV side for 60 seconds (In this time,
LV terminals are connected together and HV terminals are connected together and earthed).

This test voltage is applied for 60s. And if there’s no any breakdown occurs of the test voltage
within 60s, test is passed. Then, reduce the test voltage rapidly to less than one-third of the test
value before switching off.

2.5.1.8 Induced Over Voltage Test

This test is done to assess the withstand capability of turn to turn (HV coil enamel) insulations
in windings, layer to layer (between DDP) insulations, HV windings to tank insulations and for
insulations between different phase terminals. For this test also we have to make sure that
transformer tap selector at the principle tap position. Then LV windings are connected to the
high frequency generator output while the HV windings are in open circuited. Then test voltage
is applied to the LV winding which is equals to the (2 × rated voltage / √3). With double
frequency (120Hz) for 50s time period. Test voltage is applied with doubled frequency to avoid
core from getting magnetically saturated.

𝑇𝑒𝑠𝑡𝑖𝑛𝑔 𝑡𝑖𝑚𝑒 = (𝑟𝑎𝑡𝑒𝑑 𝑓𝑟𝑒𝑞𝑢𝑒𝑛𝑐𝑦 / 𝑡𝑒𝑠𝑡 𝑓𝑟𝑒𝑞𝑢𝑒𝑛𝑐𝑦) ⨯ 120

Maximum frequency which is applied in this test is 400 Hz for 15s duration. If no collapse of
the test voltage occurs, then it will be considered as pass.

34
2.5.1.9 No Load Test
No load test is done to assess the no load loss and no load current of a transformer. Transformer
body should be connected to the ground. Before the testing it is essential to confirm that the
external cooling medium temperature is in range 10 0C – 40 0C, transformer has passed the
insulation resistance test and transformer temperature is at ambient temperature. After that,
connect the LV side of the transformer to the AC analyzer as shown below while HV side open
circuited.

Then rated voltage will be applied by means of

circuit breaker. No load loss and current of the
transformer can be measured after applying
correct current transformer and potential
transformer ratios to the power analyzer. If The
deviation of the measured no load loss value to
the guaranteed value is less than 15%, then we
can conclude transformer has passed test.

Figure 2.16 – Connection for the no

load test

2.1.5.10 Full Load Test

Full load test is done to assess the load loss and short-circuit impedance of a transformer.
Transformer body should be connected to the ground. Before the testing it is essential to confirm
that the external cooling medium temperature is in range 10 0C – 40 0C and transformer has
passed the insulation resistance test. First LV terminals of the transformer should be short
circuited using flat copper bar. After that, connect the HV side of the transformer to the AC
analyzer as shown below.

35
 Then, calculate the rated current of the high voltage
winding and select the current transformer tap
position according to it and switch on the circuit
breaker and inject rated current of HV. Measure the
voltage, current and power by pressing the hold button
of instrument. After reaching to the desired rated
current, by pressing the hold button again, the
measured values will be stored. Finally, load loss can
be calculated which is corrected to the reference
Figure 2.17 – Connection for the full
temperature, by selecting the reference temperature
load test
as 75 oC.

2.5.2 Type Tests

Type tests are done to confirm main and design criteria of transformer. Therefore, type tests are
done for the prototype transformers and not for all manufactured units. There are four main
type tests done in LTL Transformers Pvt. Ltd.

1. Impulse voltage withstand test

2. Three phase symmetrical short circuit test
3. Temperature rise test
4. Sound level test

2.5.3 Special Tests

These tests are done as per the customer requirement. Generally, purpose of these tests is to
obtain information useful to the user during operation and maintenance of the transformer.
There are two main special tests are done in LTL Transformers Pvt. Ltd currently.

1. Tan-Delta (tan𝛿) test

2. Partial discharge test

36
2.7 Design of Transformers
When CEB requires a transformer, they manage the design. Therefore, there’s no need to worry
about the designing it. But any other customers, all the information about the required
transformer is taken s frequency, capacity, rated voltages, no of phases, vector group, the
manner in which it is placed (indoor or outdoor) etc. though the customer requirement sheet.
Then it is possible to design the transformer. All the deigned data will enter to the transformer
design program to evaluate the other required information like cost.

Figure 2.18 – Transformer design program

After the designing, transformer appearance can be drawn

using software like solid works.

When the customer approves the drawing layouts the

production will start and the radiators are ordered if
required. In the design output sheet, all the information
like core details, LV details, HV details, losses, clearances
and weights are included. Therefore, even workers can
also understand the design easily.
Figure 2.19– Drawing of a
designed transformer

37
3.Ceylon Electricity Board (CEB)
3.1 Introduction
CEB was established in 1969 under the act of parliament no 17. Currently it is regulating under
the Public Utilities Commission of Sri Lanka (PUCSL). CEB is the only government
organization which has the authority for power generation, transmission and distribution. Since
power sector plays major role in economy sector in Sri Lanka, CEB is very important
organization.

In our training session we had a chance to undergo training in

transmission for 1 week and in Colombo city in another week.
After that physical training is cancelled due to Covid-19 situation
in the country. Therefore, rest of the training sessions were
conducted through online.

Figure 3.1 – CEB logo

Vision:- “Enrich Life through Power”

Mission:- “To develop and maintain an efficient, coordinated and economical system of
electricity supply to the whole of Sri Lanka, while adhering to our core values: quality,
Service to the nation, Efficiency and Effectiveness, Commitment, Safety, Professionalism
and Sustainability.”

3.2 Organizational Structure

Attached to the report as Annex 2.

3.3 SWOT Analysis

Strengths

CEB has maintained its monopoly in electricity field in Sri Lanka. It is the CEB’s main strength
because electricity is necessary factor in today world and it has increasing demand due to
economic growth and population growth of the country. In addition to that, being a government
owned organization is another strength of the CEB. Therefore, it can withstand in economic
failures since it is government fund organization. And because of that trust within their
customers about quality and economical power supply and trust within their employees about
their job security also protected. CEB has well experienced and skilled technical staff.
Therefore, workforce also become its main strength.

38
Weaknesses

Since CEB is government owned organization, it has the influence from the remaining
government. That is the main weakness of the CEB because due to these political interferences
sometimes CEB couldn’t fulfill their long term generation and transmission expansion plans.
As an example, in 2016 Sampur power plant project was cancelled by the president due to
environmental organization’s request when tenders are about to call. Therefore, CEB has to
change their future plans immediately. In addition to that, CEB has to follow long and time
consuming procedures in order to implement their plans. This is due to protect the transparency
and strengthening the good governance in CEB but yet because of that lots of plans are not done
in time. Another weakness is lack of use new technologies. As an example CEB still uses
mechanical energy uses which has higher energy consumption. If they use smart meters instead
of mechanical ones, it will save time and labor cost. In addition to the due to power failures in
recent reliability of the services of CEB has reduce. It also a weakness.

Opportunities

CEB has opportunities for generating electricity from renewable energy sources to enhance
their performances. CEB has focused on the solar and wind power plants currently and they
mentioned that solar and wind power will be effectively used for the power generation in next
20years in their long term expansion plan. In addition to that, there are plans to expand the
existing hydro power plants and develop the pump storage hydro power plant. Sri Lanka is
blessed with the renewable energy sources. Therefore, those are perfect opportunities for CEB.

Threats

The main threat of the CEB is changing weather patterns in country. Due to this, rain patterns
also change and therefore expected power from the hydro power plants also may not be got.
Therefore, CEB has to purchase energy from the IPP. Mainly these energy comes from the oil
based thermal power plants which is expensive. Therefore, CEB’s profit is getting reduced
because CEB cannot raise electricity selling prices from current ones. Another threat is
environmental constraints for new power plants. Sampur power plant incident is the best
example for that. Therefore, CEB lose its chance to generate electricity for low cost and they
have to go for the expensive options.

39
Suggestions to Improve

Energy management should be enhanced properly. Both supply side and demand side
management should be improved. Customers should be properly aware about the energy saving
in the peak hours. It can be achieved by introducing ‘time of day tariffs’ and awareness
programs. And new technologies should be utilized. As an example replacing mechanical
meters by smart meters step by step lots of time and labor cost can be saved and meter reading
ca be taken very accurately. In addition to that, reliability of the system should be enhanced to
win the customer’s trust about reliability. And renewable power sector should be developed in
order to generate cheap energy because coal power generation is currently restricted by the
environmental constraints.

3.4 Generation
I haven’t get the opportunity to visit to the hydro power station due to the recent Covid-19
situation of the country. Therefore, power generation section of the training session is conduct
through the online lectures. There are two online sessions were conducted regarding power
generation. They are Lakvijaya power plant and the hydro power generation.

3.3.1 Lakvijaya Power Plant

Lakvijaya power plant had been planning since 1990’s. Environmental impact assessment of
the power plant for phase 1 (for 300MW) in Kalpitiya peninsula was finished in March 1998
by Electrowalt Engineering Ltd, Zurich, Switzerland. After nearly 14 years, environmental
impact assessment of the power plant for phase 2 (for 600MW) was finished in December 2012
by Green Tech Consultants (Pvt) Ltd, Colombo, Sri Lanka. Lakvijaya power plant was
constructed under two stages and three units. Unit 1 was finished and synchronous to the
national grid in 2011 and unit 2 and 3 was completed in 2014. Construction cost of the power
plant is 1.34 billion USD.

In 2019 it generates 5916 GWh to the energy sector. In addition to that it saved 97,472 million
rupees to the country due to the cheap prices of the coal compared with the oil. It saved
approximately 536 billion rupees upto 2019. Coal is used as the fuel in Lakvijaya power plant.
Using coal as the fuel, steam is generated inside the boiler. According to the rankine cycle this
steam is used to rotate the turbine. Reheat rankine cycle is used for the power generation in

40
Lakvijaya power plant. Main components of the power plant are the coal handling system,
boiler, turbine, electrical system and pollution control system.

 Coal handling system

Coal is identified as the cheap energy source in present day. Therefore, lot of countries like
China and USA produced energy using coal due to this cost effectiveness. In Lakvijaya power
plant, auto diesel is used as the startup fuel of the power plant. But coal is used as the main fuel
in the power plant. Lanka Coal Company is handling the coal purchasing and and handling up
to jetty. Coal consumption rate of the boiler is 110Tons/h and nearly 2 million tons of coal is
required for the power plant as the annual consumption. Cranes, grab, self-propeller barge,
stacker, coal yard, coal bunkers and coal mills are consisted in coal handling system. In addition
to that wind barriers and establishment of mist generating systems and mist blowers are used
for the preventive measures for the coal dust.

Figure 3.2 – wind barriers in Lakvijaya power

 Boiler plant

Pulverized coal is used as the fuel. Using heat energy of the steam generate inside the boiler.
Since there is a reheat rakine cycle is used, there are mainly three stages they are preheat stage,
superheat stage and reheat stage.

Characteristics of boiler

 Manufacturer – Harbin Boiler Company of China.

 Boiler is of Sub critical pressure -173 bar, one re –heat, natural circulation, drum type
with low NOx burners.

 Superheated steam temperature : 541C

41
  Boiler capacity : 1025 Tons/hr

 Boiler efficiency : 88.58%

 Turbine

There are mainly three stages in steam turbine. They are high pressure turbine, intermediate
pressure turbine and low pressure turbine. In addition to that in this turbine, there are lubrication
system, turbine jacking oil system, electro hydraulic oil system and seal oil system for different
purposes. Turbine was manufactured by Harbin Turbine Company of China which has 300MW
capacity and 3000rpm speed.

 Electrical system

 Generator – 353MVA/20kV/ 10190 A /0.85pf(lag), 99.02 efficiency

 Main Transformer (360MVA, 20kV/220kV)
 Unit Auxiliary Transformer (50/31.5-31.5MVA, 20kV/6kV/6kV)
 Startup Standby Transformer (50/31.5-31.5MVA, 220KV/6kV/6kV)
 28 Dry type Transformers (6kV/400 V)
 Emergency Diesel Generator (746kW)
 UPS & Battery Bank
 220V DC , 24 DC for control power

3.3.2 Hydro Power Generation

In hydro power plant, potential energy of the huge water reservoirs is used to generate the
electricity. Due to elevation difference potential energy of the stored water is converted into
kinetic energy. That kinetic energy of the water is converted into rotational kinetic energy of
the turbine and then generator which is coupled with the turbine generates electricity. This is
basic principle of the hydro power generation. In 2018 33.8% energy requirement of the country
is fulfilled by the hydro power generation. Hydro power is used for serve the peak demand
because hydro power plants can be energized into its full capacity within few minutes.

Figure 3.3 – General arrangement of the hydro power plant

42
  Reservoir

Reservoirs are huge water storages which can be used for the electricity generation. In this
method hydro power can be generate during the dry seasons and also anytime in the day.
Norally, reservoirs are made by constructing the dam across the large water streams. In Sri
Lanka there are number of huge water reservoirs were constructed like Victoria Kotmale and
Randenigala reservoirs. In order to maintain the full capacity of the reservoirs mud and sand
should be removed which are filled inside the reservoir with the time.

 Dam

Dam is a huge barrier which is made by humans across the water stream and interrupt its natural
water flow. This results to create a water reservoir which can store the water. According to the
water availability and required water quantity dam construction is depended. And dam should
be strong enough to tolerate the high pressure of the water. Dam construction type also depend
on the location, soil type and water capacity of the reservoir.

 Tunnel

Tunnel is used to bring water through underground from reservoir across the dam to a higher
head. In his way electricity generation can be maximized. Tunnel shape and type also depend
on the soil and rock type of the environment.

There is a special component called surge tank at the end of the tunnel, where tunnel and
penstock is combined. In case d sudden pressurization and travelling wave, this chamber will
protect the chamber by water hammer. And when the sudden loading of generators this will act
as a quick storage. Therefore, surge chamber act as a damper.

 Penstocks

Penstocks are used to bring water from end of the tunnel to the power house. In order to obtain
maximum electricity generation, penstock is designed along the higher slop area. Penstocks are
made by high strength steel pipes in order to tolerate for water hammering. And to achieve the
flexibility at water hammers, penstocks are made on wheels between anchors. For safety of the
penstocks from water shortages in the penstocks, anti-vacuum valve is used.

 Turbines

Water turbines are used to convert kinetic energy of the water into rotational kinetic energy.

43
There are mainly two types of turbines.

 Impulse Turbine - Eg:- Pelton wheel

 Reaction Turbine - Eg:- Francis turbines, Kaplan turbines

Suitable turbine type for the power plant should be selected according to the head and discharge
rate of the water flow.
 Synchronous generator
Generator is coupled with the turbine and ir converts turbines rotational kinetic energy into
electrical energy. Normally it has around 95-98% efficiency. There are two main components
named rotor and stator. Rotor winding is supplied with a DC current and when it rotates rotating
magnetic field in the air gap is developed and due to electromagnetic induction, stator winding
will induce a voltage. Damper windings are used as sock absorbers in rotor poles.

In CEB they constructed the hydro power complexes in order to get maximum electricity. They
constructed no. of reservoirs from same water stream.
Eg:- Mahaweli river basin power stations , Kelani river basin power stations

Figure 3.4 – Mahaweli river basin power

stations
44
3.5 Transmission
3.4.1 Training experience
I had an opportunity to undergo training under transmission branch of CEB of 1 week. First we
visited to the transmission operation and the maintenance – southern office and then we
assigned to the western province central region. Then we were given assignment to prepare
presentations about battery charges and LVAC system, GIS and power transformers. I did
presentation about battery charges and LVAC system All the study materials and documents
were given by the chief engineer.
Then after the presentation, we went to see the grid substations E & F in Colombo city and we
had a chance to see the GIS and study about the grid substation.

Figure 3.5 – Auto Transformer in grid Figure 3.6 – Power Transformer in grid
substation substation

Figure 3.7 – Transmission cables in Figure 3.8 – Indicator of GIS

grid substation arrangement

Then after the cancellation of the physical training in CEB few online lectures were conducted
regarding the transmission branch of the CEB. We had Transmission System Planning,
Introduction to Transmission Design Unit, Substation Grounding, An Overview of Overhead
Transmission Lines, Overhead Line Hardware Fittings and Overhead Bare Conductors sessions
through online.

45
Generating voltage in Sri Lanka is in 11-20kV range. Then that voltage level is step up to the
132/220kV in order to transmit to long distances. Then that HV level is step down to 33kV MV
level in grid substations. From that point it belongs to distribution sector.

Figure 3.9 – Transmission Sector

3.4.2 Grid Substation

In grid substations HV levels are converted into MV level. Then it sent to the primary
substations.
In substation there are several important components.
1. HV and MV switchyard electrical equipment
2. Control building
3. Control and protection system
4. SCADA and communication facilities
5. Substation earthing system
6. Lightning protection system
7. Batteries and DC equipment, LVAC, chargers and inverter equipment
8. Diesel generator

 AIS and GIS

When designing the substation type of the switch gear plays major role because space requires
for the substation is highly dependent on whether it is GIS or AIS.
In AIS, atmospheric air is used as the insulation layer
between phase to phase and phase to ground.
Therefore, all the live components can be seen from
outside. Mainly AIS is used for areas where space
and environmental conditions are not as issue. Low
construction cost, low construction time and easy
maintenance due to visible of components are some
Figure 3.10 - AIS advantages of the AIS. High space requirement and

46
dielectric properties of the air is affected by the environmental conditions are the major
disadvantages.

Figure 3.11 & 3.12 - GIS

In GIS, all the live components are enclosed in a grounded metal enclose. Therefore, whole
system is in the chamber which is full with gas. In GIS, SF6 is used as the primary insulator.
High cooling properties, maintaining its atomic and molecular properties even in high voltages
and superior arc quenching and dielectric properties are made SF6 more suitable for the insulator
in GIS. Low space requirement compared with the AIS, low maintenance requirement, provide
safety environment for the workers in substation, no need to top up the SF6 throughout the
equipment lifetime are main advantages of the GIS. But it requires very high installation cost
and need highly skilled persons for the maintenance. Therefore, GIS is installed where land for
the substation is very hard to find and expensive. Eg:- Colombo city

Table 3.1 - Space requirement for the substation according to type

HV MV Space requirement

132/33kV AIS AIS 4 acres

132/33kV AIS GIS 2-2.5 acres

132/33kV GIS GIS 0.5-0.8 acres

220/132/33kV AIS GIS 12 acres

220/132/33kV GIS GIS 1-3 acres

47
  Switchyard Equipment
There are many electrical components inside the substation. Some of them are,
 Power Transformer
 Circuit breaker
 Disconnector / Earth Switches
 Surge Arrestor
 Current Transformer
 Voltage Transformer
 Capacitor Banks
 Shunt Reactors
 Static Var Systems

Figure 3.13 – Switchyard equipment

 Bus bar schemes

There are different bus bar schemes are used in CEB for diffferent aspects and different aspects.
1. Single bus bar – In most 132/33kV substations.
2. Double bus bar – In 220kV substations and important 132kV substations
3. One and a half breaker – Kotmale and Victoria (for security of supply, maintainability,
extendibility and operational flexibility)
Excess to above bus bar schemes, there are several bus bar scheme types also used in CEB like
double bus bar with transfer bus, double bus double breaker, triple bus bar and ring bus/mesh.
And there is a substation automation system for monitoring the substation.

48
3.4.3 Transmission Lines
Delivering power in bulk from where in excess to where scares is done in the power
transmission. When designing the transmission system, it should be designed for long-term
because it is very high investment, transmission facilities’ long life and very lengthy period of
implementation of transmission system. When planning the transmission systems reliability and
stability plays major roles. Identify the system weakness, develop available options and select
the best option are the major steps of the planning transmission sysems.

Figure 3.14 – Transmission network in Sri lanka

And when designing the transmission lines, line route, no. of conductors, type of conductors
and voltage levels should be considered. When line route selecting, first route is selected using
google earth, contour map, surveyed maps. Then after the site visits route will be finalised.

49
Some time drone images also used for this process. Then PLS CAD designs are done using
available datas and inspects the transmission tower locations.
Generally overhead lines used as a transmission lines in Sri lanka but in some places like
Colombo city underground cables are also used.

There are several conductors which are used as overhead bare conductors.
 ACSR – Aluminium conductor steel reinforced (Mostly used in Sri Lanka)
 AAC –All aluminum conductors
 AAAC –All aluminium alloy conductors

In addition to that, Galvanised ateel earth wires and Aluminium clad steel wires are used for
the earthing wire in order to provide the lightning protection.
When transmission line is designed normally, steel lattice towers and gantry structures are used
to weigh the transmission lines. Generally, towers has low cost compared with the poles but
requires larger foot print area. In contrast, poles has high cost compared with the towers but
requires lower foot print area. In Sri lanka steel lattice towers are used mainly.

Types of the transmission lines can be categorized based on the,

 Supporting – Self supported towers / Guyed towers
 Circuits – Single / double / multi circuits
 Insulator configuration – Suspension / Tension tower
 Purpose – Line / Angle / Transposition / Dead Towers
 No. of phase conductors – Single / Double / Quadruple Conductors

Line towers are used for when the angle of deviation of the transmission line is 0o. When there’s
a angle of deviation, then different type of angle towers are used depend on the angle size.

50
 Figure 3.15 – Line Tower Figure 3.16– Angle Tower

Transposition towers are used to change the position of phase conductors in order to reduce the
mutual induction. Eg:- RYB order change to BRY
Hardware fittings of the towers
 Insulators (Long rod and disc shaped insulators are used in transmission lines)
o Suspension insulators
o Tension insulators
o Post insulators
 Vibration dampers
 Space dampers
 Danger plates and name plates
 Anti climbing devices
 Step bolts
Figure 3.17 – Insulator
 Aircraft warning spheres and lights
 Bird guards and diverters

Figure 3.18 & 3.19 –

Vibration Dampers

51
 Figure 3.20 – Space Dampers Figure 3.21– Anti Climbing Devices

3.6 Distribution – Colombo City Operation

3.5.1 Training Experience
I had an opportunity to undergo distribution in colombo city of CEB for 1 week. First we visit
to the DGM office in kollupitiya and then we went to the CEB depot in Fort. We had a chance
to observe a maintenance of a pillar at there. Then we went to the control centre of Clombo city
at Classen place. In there, we observed a radial substation’s panel board and learn about the
optical fiber cables. We observed the connecting two optcal fiber cables.

Figure 3.22 – RTU Panel

Figure 3.23 – HT Panel

We also visited to the bulk supply branch of the CEB and engineer in there, explained us about
the distribution system in Colombo city. In addition to that we had an opportunity to watch
insulation test carried out for MV switchgear which was conducted in online.After that we
visited to the maintenance branch at Maligawatte and we further clarified about the distribution
system in colombo city.

52
We would have another week remaining for the Colombo city operation. But due to current
Covid-19 situation in country, physical training is cacelled. Therefore, after that online lectured
were conducted through online. We had sessions regarding Planning of Distribution Network,
Introduction to the Electrical Installation works of Colombo City, Material Management,
Maintenance Unit of Colombo city, HTM Unit, SCADA System and Bulk Service Connections
by UG Networks.

3.5.2 Distribution Network in Colombo City

Unlike the other sectors in the country in Colombo city there’s no overhead lines all the
distributions are done by UG cables because it is very important and the commercial hub in Sri
Lanka and it has very high building density, most of them are high rise buildings.Therefore,
UG cable network is maintaining in the colombo city. Even though it is very expensive.

Simplified diagram of the distribution network of colombo city is shown below.

Figure 3.24 – Distribution network of Colombo City

There are eight grid substations and five primary substations in colombo city. Primary
substations are fed in 11kV voltage level by grid substation. Then it fed the radial substations.
Radial substations are directly fed by the primary substation. Ring substation are connected in
between two radial subtations or radial substation and another ring substation. Every radial and

53
ring substations have more than one connection. Therefore if one line is disconnected, it is fed
by another connection without interupting. Every ring and radial sustations have HT panel. And
voltage levels of there is 11kV. Satellite substation are connected in between ring/radial
substation and another sattelite substation or in between two satellite substations. In satellite
substations there’s a step-down transformer which convert 11kV voltage level into 400V level.

Then from satellite substations feeder pillar are fed and mini feeder pillars are fed by feeder
pillars. Then LV distribution is done by feeder pillars or mini feeder pillars.

Figure 3.25 – LV Distribution from Feeder

pillars

For these different purposes different types o UG cables are used.

 Feeder cables – 240mm2, 4C, Al, XLPE, SWA cables
 Distribution cables – 70mm2, 4C, Al, XLPE/PILC, SWA cables
 Service cables – 35mm2, 4C or 2C, Al, XLPE/PILC, SWA cables
(From distribution cables to end point/LV users)

3.5.3 Bulk Supplies

Bulk supplies is an electricity connection having a capacity more than 42kVA.
There are mainly two categories in Bulk supplies
1. Bulk Supply with LT metering
 Type A – This is supplied by feeder pillars. And metering is done at 400V
level. This type of bulk supply has capacity 112kVA or 70kVA.
 Type B – This is supplied by satellite substations. And metering is done at
400V level. This type of bulk supply has capacity 113kVA to 1000kVA.

54
 Those two types supplies can be obtained as single bulk supply and multiple connections
through a bulk supply.
2. Bulk Supply with HT metering (Type C)
This is supplied by ring/radial substations. And metering is done at 11kV level. This
type of bulk supply has capacity 1MVA or 16MVA.

3.5.4 SCADA System

In SCADA status of the distribution network can be monitored. SCADA system is at the control
centre of Colombo city. Maintaining such a system provides several benefits.
 Real time fault alarming in most unplanned outages.
 Reduce the man power requirements.
 Minimize the time taken for load transfer and supply restorations.
 Reduce the time delays and operational costs.
 Convenient data archiving.

55
 Conclusion
As an undergraduate student, industrial training is valuable for us because it is the place where
our theoretical knowledge applying for the practical aspects. There is a huge gap between
theoretical knowledge and how they apply to the practical applications in industry. There are
lot of factors we have to consider when apply theoretical knowledge to real world applications.
We have to face various challenges when we do that and have to find a way to overcome it. I
witnessed that all along during my training session. In addition to that I had a chance to work
with the technical staff and works. So that, I leant to how to deal with them and handle them
for some particular job and what is their attitude about the engineers and the executive staff.

I spent my first 9 weeks of the training in Yugadanavi power plant. Even though there’s no any
physical attend for the training, they well scheduled our training program. Online lectures were
well scheduled and we had an opportunity to clarify all our doubts through online. In addition
to that, all the given assignments were encouraged us to explore the further details about taught
lessons. Therefore, even though we had one-day session of the power plant in our first 8 weeks,
we had well understanding about the power plant and how the processes are done. In our last
week, we had an physical training in the power plant. That session also well planned and
accommodation and transportation also were supplied by the power plant. We had the
opportunity to see the HRSG, Gas Turbine, Steam Turbine, Seawater intake plant, Water
Treatment Plant and Fuel Oil Treatment Plant. Also we were able to ask anything from the
engineer or resource person anything and clarify them. Therefore, I got clear idea about how
things are done. I saw several transformer routine tests like oil breakdown test are done and did
several practical in corporate with the technical staff. And I saw water quality and the fuel
quality tests were done in our training session. In components like steam turbine there are so
many sub systems in there other than steam turbine in order to make the process smooth and
increase the durability of that component. Therefore, I think this training is very useful for
undergraduate like us. But I think I could be able to gain more knowledge and opportunities if
physical training were bit longer. One week is not sufficient to learn everything in power plant
even though we had several sessions through online.

We had two weeks physical training session in LTL Transformers Pvt. Ltd. At first day, we
factory manager Mr. Rukshitha and he gave us an assignment to make a video about given
machine. Therefore, we spent our first and half week in the workshop. I had recorded all the
related processes and machine. So that, I got familiarize with the workers who worked with
machine. It was a great opportunity to me to understand how to deal with them. They also very
56
friendly with us and explain about all the assembly processes with their knowledge. Because of
that assignment we had an opportunity to visit to everywhere in the workshop ask and learn lot
of things from the technical staff. And all the supplementary documents were provided us and
some of the documents like process manuals and test manuals we got from the office staff. They
also helped to us to complete that assignment. After the assignment is finished, we had the two
sessions about the marketing and sales and material management of the LTL. In those sessions
also I got a understanding about how the real world processes were done. Due to scheduling
issue, we didn’t get to spend sufficient time in transformer testing. But we had an opportunity
to saw how few routine tests of the transformer were done. As a summary I think LTL training
also very useful for trainees like me. But as an electrical engineer undergraduate student I think
it is valuable for us if we had an opportunity to spend some time in transformer testing.

Rest of the 6 weeks I had to have a CEB training but due to Covid 19 situation, we only have
two weeks physical training and rest of the 4 weeks are done on the online. I undergo the
physical training in transmission and the distribution in Colombo city. It is very great
opportunity for me. In transmission session I did a presentation about the DC battery pack and
the LVAC system of the substation and chief engineer evaluated us. Then I had an opportunity
to went to grid substation and see how the things are actually done. And in Colombo city
training session I went to various places like AGM office, CEB depot, control center and the
maintenance branch. Once I could saw a maintenance is done relating the feeder pillar. In that
maintenance, one street lamp tower was tended to fall down but technical staff was clever
enough to avoid such accident. It was huge experience for undergraduate student like me to see
how the engineer will handle such a situation and how they take care of it. In the control center
session was very effective to us. We were able to see a radial substation and a satellite
substation. In addition to that we had a basic knowledge about fiber optic cables and how the
communications were done. Online sessions also helpful for me to complete the training
session. All the resource persons are very kind and gave us opportunity to clarify any doubts. I
able to recall the theories and processes which I learnt in the physical training sessions through
online sessions.

Basically I am satisfied with the training. Due to the 2nd 3rd waves of the Covid situations I
didn’t think that I would be able to complete my training this far. But I had an opportunity to
learnt lot of things. Training Division of our university, LTL and Yugadanavi power plant staff
and training branch of the CEB tried hard to make our training session very effective. I think it
is very valuable for us have a physical training in CEB and LECO because unlike the online

57
sessions, it is more clear to remember when something is actually seen. But I missed that
opportunity due to current situation in country. So I hope undergraduate in next year won’t miss
that opportunity unlike us. Anyway overall training session was very valuable for me. It was
like a golden opportunity for myself to be prepared for the industry.

58
Annex – 1

59
Annex - 2

60