Training Report

Of
Sitara Chemical Limited

Bsc Electrical Engineering

Technology

Submitted

By

Johar Hassan

2016-GCUF-072727

Session:2016-2020

Training period

4 months

Department of Electrical Engineering

Government College University Faisalabad

 Declaration

I am here by declare that, I have developed this report entirely on the basis of my personal
efforts made under the sincere guidance of my supervisor. No portion of the work presented in
this report has been submitted in the support of any other degree or qualification of this or any
other University or Institute of learning, if found I shall stand responsible.

Name: Johar Hassan

Signature…………….....
 CERTIFICATE

I Johar Hassan Registration No 2016-GCUF-072727 certify that this industrial

training is my own work for the award of degree of Bsc Electrical Engineering and
Technology. I confirm that I will not use the award for award of any other
degree.

Signature of student………………………………..

Examined by …………………………………………

ELECTRICAL ENGINEERING DEPARTMENT

 ACKNOWLEDGEMENT

All praises belong to almighty “ALLAH” who is the supreme Authority Knowing

the ultimate relations underlying all sorts of phenomenon going on in this universe

and whose blessings and exaltation flourished my thoughts and thrived my ambitions

to have the cherished fruit of my humblest thanks to the Holy Prophet Hazrat

Muhammad (Peace be upon him) who is forever a torch of guidance and knowledge

and knowledge for humanity as a whole.

I deem it my utmost pleasure to avail this opportunity to express gratitude and

deep sense of obligation to my reverend teachers , for their valuable and dexterous

guidance, scholarly criticism, untiring help, compassionate attitude, kind behavior,

moral support and enlightened supervision during the whole study and completion of

the project.

I am also gratitude to staff of Sitara Chemical Industries Ltd .who provides me useful

Information during the internship program. I am thankful to all those people, who

provide me valuable information.

Finally, I should like to extend heartfelt thanks to my adoring PARENTS, for

Their day and night prayers, sacrifices, encouragement, moral and financial support

Through out the course of my study.

Johar Hassan
 Abstract

This report defines my internship experience at the Sitara Chemical Industries, and it is divided
into four chapters. Chapter One reviews the background of training organization. It also
contains necessary information about the organization. Chapter Two delivers the schedule of
training and eliminated. Chapter Three describes the working experiences, work performed,
learning skills and safety at work. Chapter Four discusses the complications that I encountered
while completing the whole training. I use to get help from my supervisor about the electrical
panels works and reading from the books also . As the Sitara chemical industries have their own
Coal Fired Power Plant (CFPP) I gain my one month training from there also and get to know the
different kind of electrical devices and whole process about the generation of Electricity. The
whole industry and also give me knowledge of different kind of electrical equipment’s e.g.,
types of motors, types of transformer, cable sizing, tests of motors and test of transformer.To
sum-up I can say Sitara is the best industry to get knowledge and experience there we can apply
our all theoretical and practical knowledge Sitara is the only industry which give chance to their
internee to learn something and lead the other industries.
List of contents

Chapter#1

1.1 Introdution of Sitara Chemical Limited. …………………………………………………………………........... .01

1.2 Chemical products………………………………………………………………… ………………………………..……....02

1.3 Mission & vision…………………………………………………………………… ………………………………………… 03

1.4 Social responsibility……………………………………………………………… ……………………….……..……… ..03

1.5 Enviromental policy ……………………………………………………………… ……………………….…………………04

Chapter#2

2.1 Parts of Grid stastion………………………………………………….. …………………………………….…….……..05

2.2 Transformer………………………………………………………………… …………………………………………..……..06

2.3 Parts of transformer………………………………………………………………………………………..………..…….07

2.4 Current transformer…………………………………………………………………………………………………….…..17

2.5 Potential transformer…………………………………………………….….………………………………..………..….17

2.6 Insulator…………………………………………………………….……………………………………………… ………….…18

2.7 Isolator………………………………………………………………….……….. ……………………………………………….19

2.8 Protective relays………………………………………………………………….…………………….………….………….20

2.9 Circuit breakers…………………………………………………………..……………………………….…….……………..21

2.10 Surge Arresters……..……………………………………………………………………………………….…….………….23

2.11Distribution Panel…………………………………………………………………………………………..………...………24

2.12 Precautions…………………………………………………………………..………………………………………….……..25
Chapter#3

3.1 Powerhouse…………………………………………………………………… ………………………………………………...26

3.2 Engine Model…………………………………………………………………………………………………..…………………26

3.3 Engine rating………………………………………………………………………………………………….………….……….26

3.4 Alternator………………………………………………………………..………………………………………….…………… 27

3.6 Earthing ……….……………..…………………………………………………………………………………………………….28

3.7 Precautions…………………………………………………………………………………………………………….………….29

Chapter#4

4.1 Introdution pf motor…………………………………………………………………………………………………………30

4.2 Induction Motors……………………………………………………………………………………………………………….31

4.3 Parts of induction Motor……………………………………………………………………………………………….….32

4.4 Types of Rotors of induction motor……………………………….…………………………………………………..34

Chapter#5

5.1 Electrical workshop tools…………….…………………………………………................……………………….. 35

5.2 Precautions………………………..………………………..…………………………………………………………………..36

Chapter#6

6.1Generator…………………………………………………………………………………………………………………………..38

6.2 Parts of Generator…………………………………………………………………………………………………………….39

Chapter#7

7.1 Star Delta motor starter……………………………………………………………………………………………….40

Chapter#8

8.1Power factor ………………………………………………………………… …………………………………………....44

8.2 Methods to improve power Factor……………………………………………………………………………….45

Chapter#9

9.1 Industrial Safety……………………………………………………………………………………………………………46

9.2Safety Equipments………………………………………………………… …………………………………………….48

9.3Industrial Accidents……………………………………………………………………………………………………...49

9.4Protection agaist Fire……………………………………………………………………………………………………51

Conclusion…………………………………………………………………………………………………………………………52
Chapter#1

Sitara Groups of Industries

SCIL is an industrial unit belongs to one of the largest Group of Industries in Pakistan

“Sitara Group Of Industries Ltd.”

Sitara Group of industries comprises of following business units.

Sitara Group Of Industries

Sitara Chemical Industries Ltd. _

Sitara Fabrics

Sitara Agri Model Farm

Sitara Per Oxide

Sitara PVC Ltd.

Sitara Shopping Mall

Chemical Division

Sitara Chemical Industries Ltd. – Textile Division

Sitara Textile Limited

Sitara Energy Limited

 Chemical Products

As the name SCIL expresses us that this is a chemical industry. Its main product is caustic soda
laterally with some other by-products. The chemical products of the SCIL are given below in the
list.

Basic Chemicals ;-

Ammonium Chloride
Bleaching Powder
Caustic Soda Flakes
Caustic Soda Liquid (32-50 %)
Caustic Soda Solid (99 %)
Hydrated Lime
Hydrochloric Acid
Liquid Chlorine
Sodium Hypochlorite

Specialty Chemicals :-

Aluminium Sulphate
Calcium Chloride Dehydrate
Copper (I) Chloride
Magnesium Carbonate

Gases :-
Carbon Dioxide
Organizational Overview: -

SCIL was integrated in 1981 and start producing caustic soda in 1985, primarily at a rate of 30
metric tons Caustic a day. The plant’s ability was steadily increased over years to current level
of 610 metric tons a day. In accumulation, several by-product facilities have been added and
extended from time to time to manage with growing demand. Company entered into Textile
Spinning Business in 1995. Its specialty chemicals and export partition was established in 2001
and agri chemicals division in 2003. In 2014 SCIL add a power plant in its way of success for to
generate its own electricity.

Mission & vision

Strive to develop and employ innovative technological solutions to add value to business with
progressive and proactive approach.

Continuing growth and diversification for bottom line results with risks well contained.

Social Responsiblity

Sitara Chemical Industries Ltd is a renowned entity of Sitara Group of Industries is well
acknowledged for its contribution to socio-economic uplift of the region and strengthening
social safety nets. . We value our workforce as the most integral part of our organization. We
have introduced numerous tools to train, upgrade our people. In this context, a Human
Development Center has been established at Sitara Chemical Industries Ltd where internal
training sessions are held regularly. The renowned trainers are also called at the Center to
impart training in the fields of technical, supervisory and management skills.

The CEO is the Managing Trustee of over 500 bed Aziz Fatima Hospital, Group Educational
Institutions; Aziz Fatima Education Complex, Bashir Naziran Kid Campus.
Enviromental policy

Sitara Chemical Industries Ltd (SCIL) is committed to continual improvement of its

Environmental Management System (EMS) by adoption of appropriate pollution prevention
measures and complying with all relevant environmental legislation / regulations through
training, teamwork and procedures as implemented from time to time.

Chapter#2
 Grid station

Parts of Grid station

Transformer.

Insulator.

Isolator.

Protective relays.

Circuit breakers.

Distribution Panel

Current transformer

Potential transformer

Fig.2.1

Transformer:-
 A transformer is a stastic electrical device which is used to step up voltage or current
without changing the frequency”. A varying current in any one coil of the transformer
produces a varying magnetic flux in the transformer's core, Electrical energy can be
transferred between separate coils without a metallic (conductive) connection between the
two circuits. Faraday's law of induction, “Its working principle is mutual induction..”

Transformers are most commonly used for increasing low AC voltages at high current (a
step-up transformer) or decreasing high AC voltages at low current (a step-down
transformer) in electric power applications, and for coupling the stages of signal processing
circuits.

Fig.2.2

Steel Tank :
It is a main part of transformer. Transformer core is placed inside this tank. Windings and other
helpful devices are placed inside this tank. It is filled with insulating oil (mineral oil). There is
vent pipe connected to it to allow in and out of the air. When the load increases the oil in the

transformer expands and the air is released out. Windings and other helpful devices are placed
inside this tank. It is filled with insulating oil. It have usually cylindrical or cubical shape
depending on transformer construction. It is coated internally and externally with colour for
safety point of view. Colour coating also provide protection in case of winding connection with

tank accidentally .

Fig 2.3
Iron Core:-

The core works to the winding in the transformer. It also gives a low reluctance path to the flow
of magnetic flux. It is made of laminated iron core to reduce eddy current loss and Hysteresis
losses. The composition of a transformer core depends on such as factors voltage, current, and
frequency. The diameter of the transformer core is directly proportional to copper loss and is
inversely proportional to iron loss. If the diameter of the core is decreased, the weight of the
steel in the core is reduced, which leads to less core loss of the transformer and the copper loss
increase. Core is made with laminated steel sheet in all type of transformers to provide
continuous magnetic path and also to provide minimum air gap. For this purpose silicon
enriched steel is used. Sometimes heat treatment is also used on steel to increase permeability
of steel. hysteresis losses also decreased in core with increase in permeability. By making core
laminated eddy current losses also reduced in core. Laminations of core also insulated from
each other through varnish.

Fig.2.4
Copper winding:-

Two sets of winding are made over the transformer core and are insulated from each other.
Winding consists of several turns of copper conductors bundled together, and connected
connected in series.Winding can be classified in two different ways:

Based on the input and output supply

Based on the voltage range

Within the input/output supply classification, winding are further categorized:

Primary winding - These are the winding to which the input voltage is applied.
Secondary winding - These are the winding to which the output voltage is applied.

Fig.1.5

The windings of signal transformers minimize leakage inductance and stray capacitance to
improve high-frequency response.
Conservator Tank:-

Transformers have a cylindrical tank, known as the conservator tank, mounted on

the roof of its main tank to provide adequate space for expansion of oil within the
transformer. When the temperature rises, the volume of oil inside the
transformer also increases; thus, it is this conservator tank that acts as a reservoir
for the expanded oil. Its main function is to provide additional space for heated oil
that expands with temperature rise. As a result, there is no oxidation occurrence
in the main tank and no sludge formation too.The Conservator is placed over the
Main Tank. It is not completely filled with oil, nearly half of its space is filled with
air. When oil in the main tank expands, some of the oil is transferred to the
conservator tank and the air in the conservator tank is taken out. It saves the
Main Tank from the exposure of air and moisture.

Fig.2.6
Breather:-

Breather is cylindrical type container which is fitted to the conservator tank through a pipe line
which is totally filled with silica gel crystals used for absorbing any moisture present in the air
during breathing action of transformer due to expansion and contraction of transformer oil. The
size of Breather depends on the volume of transformer main tank as well as quantity of

transformer oil in the transformer .When the Silica gel breather is first installed, the crystals
have a blue tint, and after a period of operation, the colour of the tinted crystals gradually
changes to pink , this is an indication that the silica gel is becoming saturated and losing its
absorbent properties.

Fig.2.7
Thermometer:-

On the transformer above 50 KVA the thermometer is installed to check it temperature

regularly.when the temperature of a winding increases it provides alarm and trip the circuits.its
placed on the surface of a oil through sensor with records reading directly.

Fig.2.7

Pressure relief pipe:-

This is a bended pipe attacthed with the conservator tank used for the safety purpose when the
temprature of the oil rises and it starts decomposing then the pressure is generated in the
transformer .this pipe use to release that temprature .

Fig.2.8
Buchholz Relay:-

Buchholz relay is a security device which is normally used in large oil absorbed transformers. It
is a kind of oil and gas activated security relay. The Buchholz relay purpose is to give the
protection to a transformer from the different faults happening in the transformer like the
Short circuit, inter-turn, core, incipient, etc. This relay will sense these faults and shuts the
alarm circuit.At normal condition it is completely filled with oil. When transformer is
overheated due to any fault, the oil evaporates. The vapors leave the main tank and travel to
the conservator tank. The Buchholz relay is located between the Main tank and Conservator
tank. The vapors start to accumulate at the top of the relay when the float area is filled with
vapor then float hits the mercury switch and completes the alarm circuit. Which means there is
something wrong? If the vapors accumulate the whole space, then the Trip circuit is completed
by flap and the transformer supply is broken.The amount of vapors depends on the severity of
fault.

Fig.2.9
Bushings:-

A transformer bushing is an insulating structure that facilitates the passage of an energized, current-
carrying conductor through the grounded tank of the transformer.The bushings used for the low voltage
winding(s) of a transformer are often solid type with a porcelain or epoxy insulator. The Bushings are
selected on the basis of voltage and current ratings. The insulator can bear specific voltage and the
conductor can pass specific current safely. For low voltage transformer such as (11KV), porcelain
bushings are used. In porcelain bushings conductor is surrounded by porcelain. For High Voltage
Transformers (below 66KV), Oil filled Porcelain Bushings are used. porcelain bushings, there is oil
present between the terminal and porcelain which provides more insulation than a simple
porcelain bushing.

Fig.2.10
Oil gauge:-

This is a gauge which is used to know the level of mineral oil in the transformer.this gauge is
very important for transformer safety purpose.because if the oil gauge is not installed on
transformer in case of decreasing the oil level cause overheating and damange in winding of a
transformer

Fig.2.11
Radiator:-

The transformer which are above 50kva need more cooling.to fulfil this purpose the radiator
are installed in the body of a transformer.from this the surface area of a transformer increases
and get better coolong.this method is called ONAN “oil natural air cooled”In 26MVA and above
transformers, cooling fans are also used on radiator. Oil temperature gauge provide on or off
signal for cooling fans. When temperature becomes greater than 75º, temperature oil gauge
turn on cooling fans. This method of cooling is called ONAF. Transformers oil pumps are also
used along with cooling fans and radiator.oil pumps used to rotate oil in transformer. This
method of cooling is called OFAF.

Fig.2.12
Instrument Transformer:-

Instrument transformers are high accuracy class electrical devices used to isolate or transform
voltage or current levels. The most common usage of instrument transformers is to operate
instruments or metering from high voltage or high current circuits, safely isolating secondary
control circuity from the high voltages or currents. The primary winding of the transformer is
connected to the high voltage or high current circuit, and the meter or relay is connected to the
secondary circuit.Instrument transformers may also be used as an isolation transformer so that
secondary quantities may be used in phase shifting without affecting other primary connected
devices. These transformer are used to reduce the voltage or cuttent of (volt,ampere,or wantt
meter)there are two types of instrument transformers.

Current transformer: Current transformer is a transformer which is used to step up or down

current.its winding consists of think copper conductor

Potential transformer:- This is atransformer used to step up or step down voltage.the turns are
consists of many turns of thin copper conductor.

Fig.2.13
Insulators:-

To provide supportthe over heaad conductor we use poles and tower.to attach the conductor
and insulate condutor from pole and tower the insulator are used.there are two types of
insulators.

Pin type insulators

Disc type insulators

a) Suspension type insulators

b) Strain type insulators

Fig.2.14
Isolator:-

Isolator is a device which is used in grid station to make or break the circuit.its operate
manually or automatically. it is one type of mechanical switch used to isolate a fraction of the
electrical circuit when it is required. Isolator switches are used for opening an electrical circuit
in the no-load condition. It is not proposed to be opened while current flows through the line.
Generally, these are employed on circuit breaker both the ends thus the circuit breaker repair
can be done easily without any risk. These switches are applicable in industrial, distribution of
electrical power, etc. High voltage type isolation switches are utilized in substations for
permitting isolation of equipment like transformers, circuit breakers.
 Fig.2.15

Protection relays:-

Protective relay is a relay device designed to trip a circuit breaker when a fault is detected. The
first protective relays were electromagnetic devices, relying on coils operating on moving parts
to provide detection of abnormal operating conditions such as over-current, over-voltage,
reverse power flow, over-frequency, and under-frequency. An overcurrent relay is a type of
protective relay which operates when the load current exceeds a pickup value. It is of two
types: instantaneous over current (IOC) relay and definite time overcurrent (DTOC) relay.Based

on operation mechanism protection relay can be categorized as electromagnetic relay,

static relay and mechanical relay. Actually, a relay is nothing but a combination of one

or more open or closed contacts. These all or some specific contacts the relay change

their state when actuating parameters are applied to the relay. That means open

contacts become closed and closed contacts become open. In an electromagnetic relay,

these closing and opening of relay contacts are done by the electromagnetic action of a

solenoid.

Fig.2.16

Circuit breakers:-

Circuit breaker isdevice which is use for protection purpose of electrical system.in abnormal
situation it can break or trip circuit automatically.there are many types of circuit breakers.some
of them are given below:
VCB(vacume circuit breaker)

Sf6 circuit breakers.

MCB(miniature circuit breaker)

Vacumme Circuit breaker:- vacuum circuit breaker is a kind of circuit breaker where the arc
quenching takes place in vacuum medium. The operation of switching on and closing of current
carrying contacts and interrelated arc interruption takes place in a vacuum chamber in
the breaker which is called vacuum interrupter. Vacuum Circuit Breaker.

Fig.2.17
 Fig.2.19

Sf6 (sulphur hexa fluoride):-

In Sf6 sulphur hexafluoride gas is used as the arc quenching medium. The sulphur hexafluoride
gas (SF6) is an electronegative gas and has a strong tendency to absorb free electrons. The
contacts of the breaker are opened in a high-pressure flow sulphur hexafluoride (SF6) gas and
an arc is struck between them. The gas captures the conducting free electrons in the arc to
form relatively immobile negative ions. This loss of conducting electrons in the arc quickly
builds up enough insulation strength to extinguish the arc.

Fig.2.20
Surge Arresters

A surge arrester is a used to protect electrical equipment from over-voltage transients caused
by external or internal (lightning or switching) events. Also called a surge protection
device (SPD) or transient voltage surge suppressor (TVSS), this class of device is used to protect
equipment in power transmission and distribution systems. A surge arrester should have a low
impulse ratio, so that a surge incident on the surge arrester may be bypassed to the ground
instead of passing through the apparatus.Surge arresters are not generally designed to protect
against a direct lightning strike to a conductor, but rather against electrical transients resulting
from lightning strikes occurring in the vicinity of the conductor

Fig.2.21
Distribution panel box:-

In the grid station all the controlling and pretecticting circuit are installled inside a distribution
panel box.in this box protection relays,power factor meter,voltmeter,ampere meter.

Fig.2.22

Fig.2.23
Precautions:-

Wear satfety helmets during work.

Wear satety shoes.

Wear rubber gloves during work on live transmission.

Install fire Extinguhsers in various places.

Grounding of body of the transformer is must.

Install surge arresters to protect the transmission from lighting or surge Effects.
Chapter#3

Power House

In sitara chemical limited power house there are 3 jenbacher gas engines are installed.each
engine rating is 1.7 to 3 mw.These engines speed are 1500 rpm.For the protection purpose of
Engine Overload current relay rubber mat,and earthing is done,To avoid disturbance and noise
factor the worker uses head phones.In this engine natural gas have been used as a fuel and the
shaft starts rotating,this shaft is coupled with the alternator and the alternator provide Ac
supply as it’s output.

Fig.3.1
Fig3.2

Alternator:

An alternator is an electrical generator that converts mechanical energy to electrical energy in

the form of alternating current.[2] For reasons of cost and simplicity, most alternators use a
rotating magnetic field with a stationary armature.[3] Occasionally, a linear alternator or a
rotating armature with a stationary magnetic field is used. In principle, any AC electrical
generator can be called an alternator, but usually the term refers to small rotating machines
driven by automotive and other internal combustion engines.
 Fig.3.3

Earthing:-

To connect the metallic parts of electric machinery and devices to the earth plate or earth
electrode (which is buried in the moisture earth) through a thick conductor wire for safety
purpose is known as EARTHING OR GROUNDING.Means to connect the part of electrical
apparatus such as metallic covering of metals, earth terminal of socket cables, stay wires that
do not carry current to the earth. Earthing can be said as the connection of the neutral point of
a power supply system to the earth so as to avoid or minimize danger during discharge of
electrical energy.There are three type of earthing which are used according to the different
situations.their names are given below.

Pipe Earthing System.

Plate Earthing System.

Rod Earthing System.

 Fig.3.4 Fig.3.5

Chapter#4

Motor

Motor is a machine which converts electrical energy into mechanical energy. Motor mainly
depends on the interaction of magnetic and electric field. The electric motor is mainly classified
into two types. They are the AC motor and the DC motor. The AC motor takes alternating
current as an input, whereas the DC motor takes direct current. Electric motors may be
classified by considerations such as power source type, internal construction, application and
type of motion output. In addition to AC versus DC types, motors may be brushed or brushless,
may be of various phase (see single-phase, two-phase, or three-phase), and may be either air-
cooled or liquid-cooled. General-purpose motors with standard dimensions and characteristics
provide convenient mechanical power for industrial use. The largest electric motors are used
for ship propulsion, pipeline compression and pumped-storage applications with ratings
reaching 100 megawatts. Electric motors are found in industrial fans, blowers and pumps,
machine tools, household appliances, power tools and disk drives. Small motors may be found.
 Fig..4.1

Fig.4.2

Stator:-

The laminated stator core is made from stamped sheet steel with slots on the inner surface.
Three identical windings are laid out in a sequential series of overlapping coils.
In motors of higher power ratings, the stator slots are of the open type to allow the insertion of
the large pre-shaped and insulated coils, but in smaller sizes the slots are partially closed to
reduce the air gap as much as possible.

Fig.4.3
Rotor:-

There are two types of induction motor rotors:

Squirrel-cage rotor or simply cage rotor.

Phase wound or wound rotors. The motors that use this type of rotor are known as Slip-ring
rotors.
 Fig.4.4

Squirrel cage Rotor:-

Squirrel cage motor works on the principle of Electromagnetism. It consists of Rotor, Stator and other
parts like bearings, cylindrical laminated core, shaft, etc.The function of bearings in cage rotor motor is
to reduce friction between the rotating and stationary parts of the machine. The rotor of the motor
consists of a cylindrical laminated core with parallel slots for carrying the rotor conductors. The rotor
conductors are not wires, but it consists of heavy bars of copper, aluminum, or an alloy. The shaft is
used in the motor to transfer mechanical power from or to the machine. The stator is the outer
stationary part of the motor.

Wound rotor:-
The wound rotor consists of a slotted armature. Insulated conductors are put in the slots and
connected to form a three-phase double layer distributed winding similar to the stator winding.
The windings of the rotor are connected in star.Rotor windings are distributed uniformly and
usually connected in the star with here leads brought out of the machine by via slip rings placed
on the shaft. The slip rings are tapped using copper carbon brushes. Wound rotor construction
is generally used for large size machine, where the starting torque requirements are stringent.
External resistance can be added in the rotor circuit through slip ring for reducing the starting
current and simultaneously the starting torque.

Fig.4.5

Chapter#5

Electrical workshop tools

In electrical maintenance workshop there are many tools which are used for opening and
reparing electrical machines and equipments.some of importants tools are given below:

Plier

Megger
Digital multimeter

Screwdriver

Phase tester

Cutter

Drill machine

Fig.5.1 Fig.5.2

Precautions:-

Wear googles during welding.

Don’t wear lose clothes.

Wear safety shoes.

Use rubber gloves during working on live machine.

Layout of Sitara Chemical Limited
Chapter#6

Generator
Generator is a device which converts mechanical energy into electrical energy. In electricity
generation, a generator is a device that converts motive power (mechanical energy)
into electrical power for use in an external circuit. Sources of mechanical energy include steam
turbines, gas turbines, water turbines, internal combustion engines, wind turbines and even
hand cranks. Generators provide nearly all of the power for electric power grids.The reverse
conversion of electrical energy into mechanical energy is done by an electric motor, and motors
and generators have many similarities. Many motors can be mechanically driven to generate

electricity and frequently make acceptable manual generators.

Working Principal:
The working principal of generator is based on faraday’s law of electromagnetic induction
which states that
“The emf is always produced in the conductor which is placed in the magnetic field when there
is a relative motion between conductor and the magnetic field”
There are two types of generators – DC generators and AC generators. Both DC and AC
generators convert mechanical power to electrical power. A DC generator produces direct
power, while an AC generator produces alternating power.
Both of these generators produce electrical power based on the principle of Faraday’s law of
electromagnetic induction.
This law states that when a conductor moves in a magnetic field it cuts magnetic lines of force,
which induces an electromagnetic force (EMF) in the conductor.
The magnitude of this induced EMF depends upon the rate of change of flux (magnetic line
force) linkage with the conductor. This EMF will cause a current to flow if the conductor circuit
is closed.
Hence the most basic two essential parts of a generator are:
The magnetic field and the Conductors which move inside that magnetic field.
 Fig.6.1

Parts of Generator:-
The Engine
Fuel System
Alternator and Voltage Regulator
Cooling, Exhaust and Lubricating Systems
Stator
Rotor
Bridge Rectifier
Brushless Exciter
 Chapter#7
Star-Delta Starter
A star delta starter is the most commonly used method for the starting of a 3 phase induction
motor. In star delta starting an induction motor is connected in through a star
connection throughout the starting period. Then once the motor reaches the required speed,
the motor is connected in through a delta connection. A star delta starter will start a motor
with a star connected stator winding. When motor reaches about 80% of its full load speed, it
will begin to run in a delta connected stator winding.A star delta starter is a type of reduced
voltage starter. We use it to reduce the starting current of the motor without using any external
device or apparatus. This is a big advantage of a star delta starter, as it typically has around 1/3
of the inrush current compared to a DOL starter.The starter mainly consists of a TPDP switch
which stands for Tripple Pole Double Throw switch. This switch changes stator winding from
star to delta. During starting condition stator winding is connected in the form of a star. Now
we shall see how a star delta starter reduces the starting current of a three-phase induction
motor

Fig.7.1

VL = Supply Line Voltage

ILS = Supply Line Current and

IPS = Winding Current per Phase

Z = Impedance per phase winding at stand still condition.

As the winding is star connected, the winding current per phase (I PS) equals to supply line
current (ILS).
As the winding is star connected, the voltage across each phase of the winding is

Hence, the winding current per phase is

Since here, the winding current per phase (IPS) equals to the supply line current (ILS), we can
write,

Fig.7.2

ILD = Supply Line Current

IPD = Winding Current per Phase

Z = Impedance per phase winding at stand still condition.

As the winding is delta connected, supply line current (ILD) is root three times of the winding
current per phase (IPD)

As the winding is delta connected, the voltage across each phase of the winding is

Hence, the winding current per phase is

Now, we can write,

By comparing supply line currents drawn by an induction motor with star and delta connected
winding, we get

we can say that the starting current from the mains in case of star delta is one-third of direct
switching in the delta. Again, we know that the starting torque of an induction motor is
proportional to the square of the voltage applied to the winding per phase

The equation shows that star delta starter reduces the starting torque to one-third of that
produced by DOL starter. The star-delta starter is equivalent to an autotransformer with a
57.7% tapping.
 Chapter#8
Power Factor

The power factor is defined as the ratio of the active power (P) and volt-amperes. The active
power is the real power which is assumed in an AC circuit, whereas volt-amperes is the
apparent power which is produced in the circuit when the waves of voltage or current are not
in phase
Methods of Power Factor Improvement:
There are three main ways to improve power factor:
Synchronous Condensers.
Phase Advancers.
Capacitor Banks.

Capacitor Banks:
Improving power factor means reducing the phase difference between voltage and current.
Since the majority of loads are of inductive nature, they require some amount of reactive
power for them to function. A capacitor or bank of capacitors installed parallel to the load
provides this reactive power. They act as a source of local reactive power, and thus less reactive
power flows through the line. Capacitor banks reduce the phase difference between the voltage
and current.
Synchronous Condensers:
Synchronous condensers are 3 phase synchronous motor with no load attached to its shaft.
The synchronous motor has the characteristics of operating under any power factor leading,
lagging or unity depending upon the excitation. For inductive loads, a synchronous condenser is
connected towards load side and is overexcited.
Synchronous condensers make it behave like a capacitor. It draws the lagging current from the
supply or supplies the reactive power.
Phase Advancers:
This is an AC exciter mainly used to improve the PF of an induction motor.
They are mounted on the shaft of the motor and are connected to the rotor circuit of the
motor. It improves the power factor by providing the exciting ampere turns to produce the
required flux at the given slip frequency.
 Chapter# 09
INDUSTRIAL SAFETY

Industrial safety is primarily a management activity which is concerned

with :

Reducing

Controlling

Eliminating hazards from industries or industrial units

DEFINITION
"Industrial safety is defined as policies and protections put in place to ensure plant and factory
worker protection from hazards that could cause injury. Safety policies put in place by the
occupational safety & health administration (OSHA) are examples of industrial safety policies."
Safety Systems
The function of a safety system is to monitor and control conditions on a machine or process
that are hazardous Potential risks for machine operators Potential damage to machines/goods
Potential damage to environment
Systems and components must be designed such that they are safe under normal conditions
Faults, failures and external influences must not result in an undetected loss of safety

Fig.9.1
Importantance of safety
Injury/death to the workers & damage to the asset Responsible to society & Answerable to laws
of the country Lose of the business opportunity Business continuity is in question Employees
and contractors will loose the morale Industrial harmony will be poor Brand of the product
/name of the organization will be at stake

Fig.9.2
INDUSTRIAL ACCIDENT
It can be define as "An accident or occupational accident is an event of accident that suddenly
occurs when one or no. of employees / workers placed in plant.
For instance, In an organization a person / labor while working receiving an electric current, a
labor cut his finger from machine, blast in chemical industry because of various reasons, fired in
textile section etc

Protection against fire

A fire extinguisher is an active fire protection device used to extinguish or control small fires,
often in emergency situations. It is not intended for use on an out-of-control fire, such as one
which has reached the ceiling, endangers the user (i.e., no escape route, smoke, explosion
hazard, etc, or otherwise requires the expertise of a fire brigade. Typically, a fire extinguisher
consists of a hand-held cylindrical pressure vessel containing an agent that can be discharged to
extinguish a fire. Fire extinguishers manufactured with non-cylindrical pressure vessels also
exist but are less common.

Fig.9.3
 Fire hydrant are installed on various points of industries to fulfil water requirements in case
of Emergency.

Fig.9.4
 Conclusions
The main work performed as a trainee student in the industry is regarding the learning of new

equipment’s and tools utilization and working and also studying the major knowledge involved

in these devices. And also I did project of bleaching plant. As a training student I worked in

electrical workshop where the motor rewinding is done and also some other fixing work

completed. I also studied the different forms of circuits like DOL (Direct On-Line Circuit),

Reverse Forward and Star Delta motor starter circuits. I also perform some of the repairing

work occurs on daily basis with the main electrical technician at any part of the plant where

fault occurs. The other main focus point of my training is to learn the basic working of coal fired

power plant. I performed as an observer of all the MCC equipment’s working and there various

purposes for installation.