MANALI PETROCHEMICALS

LIMITED

ELECTRICAL DEPARTMENT
voltage….?
Current….?
power….?
Power factor?
 VOLTAGE

 Voltage is the electric potential energy transported between

two points.

 The SI units of Voltage is V

 LV - Where voltage does not exceed 250 V

 MV- Where voltage does not exceed 650 V 
 HV - Where voltage does not exceed 33000 V
 EHV - Where voltage exceeds 33000 V
 CURRENT

 An Electrical current is a flow of electric charge in

electric circuits this charge is often carried by moving
electrons of a conductor.
 The SI units of current is Ampere.
 Power

 Electric power is the rate of doing work, which is measured in

WATTS.
 The rate at which electrical energy is transferred by an electric
circuits is called as energy demand.
 Single phase power P  V  I  p. f (cos  )

 Balanced 3 phase power P  3  VP  I P  p. f (cos  )

 In star and delta P  3  VL  I L  p. f (cos  )
Simple Electrical circuit
 TYPES OF ELECTRICAL
POTENTIALS

Alternate current

Direct current
 AC & dc DIFFERENCE
AC
IT REVERSES ITS DIRECTION WHILE
FLOWING IN A CIRCUIT
IT IS THE CURRENT OF MAGNITUDE
VARYING WITH TIME
IT IS OBTAINED FROM AC
GENERATORS
THE FREQUENCY OF AC IS 50 HZ OR
60 HZ DEPENDING UPON THE
COUNTRY
DC
IT FLOWS IN ONE DIRECTION IN THE
CIRCUIT
IT IS THE CURRENT OF CONSTANT
MAGNITUDE
IT IS OBTAINED FROM BATTERY
THE FREQUENCY OF DC IS ZERO
Ac & dc waveform
 Electrical loads
 Resistance: Resistive loads are loads which consume electrical
energy in a sinusoidal manner. This means that the current flow is
in time with and directly proportional to the voltage.
Example: Electrical heaters, Incandescent lightings.
 Inductance: An inductive loads is a load that pulls a large amount
of current when first energized. After a few cycles the current
“settles down” to the full load running current.
Example: Transformers, Motors
 Capacitance: A capacitive load is an AC electrical load in which the
current wave reaches its peak before the voltage. Capacitance
loads are loads that capacitance exceeds inductance.
Example: Flash of a camera.
 Ac Power
 In AC circuits energy storage elements such as
inductance and capacitance may result in periodical
reversal of the direction of energy flow.
 The portion of power flow that averaged over a
complete cycle of the AC waveform results in net
transfer of energy in one direction is known as Real or
Active power.
 The portion of power flow due to stored energy that
returns to the source in each cycle is known as
reactive power.
 Power factor

 It is defined as the ratio of the real power flowing to

the load to the apparent power in the circuit.
 ACTIVE AND REACTIVE
POWER
 Most loads in modern electrical distribution systems
are inductive. Inductive loads needs a magnetic field
to operate.
Examples: Induction motors, transformers.
 Inductive loads require two kinds of current:
 • Working power (kW) to perform the actual work of
creating heat.
• Reactive power (kVAR) to sustain the magnetic
field
POWER FACTOR CORRECTION
 To calculate kVAR required to correct power factor to
a specific target value, use the following formula:

 KVAR(reqd) = HPx0.756 √1-PFa2 - √1-PFt2

% efficiency Pfa PFt
Generation Transmission and distribution
 Necessity of hv transmission

 High voltage is used for electrical transmission to

reduce the energy lost in resistance of the conductor.
For a given quantity of power transmitted, doubling
the voltage will deliver the same power at only half
the current.
 Current flowing through the transmission, the voltage
got reduce due to I2R losses.
 Electrical equipment

 Transformer
 Circuit breakers
 Relays
 Cables or conductors
 CT, PT and measuring devices
 Motors
 Transformer

 Transformer is a device that transfers energy between two or

more circuits through Electro magnetic induction.
 Transformer in our plANT

 Step-up Transformer
Low Voltage level into high Voltage level.
 Step-down Transformer
High Voltage level to low Voltage level (11 kv/433 v)
In our plant Totally 6 no of step down transformer
4 No of 1600 KVA Transformer
2 No of 1250 KVA Transformer
Ideal Transformer
Input Voltage = Output Voltage
1 No of 3.150 MVA
 TRANSFORMER DETAILS

 Rating :- 1600 KVA Un tanking Mass:- 1900 Kg

 HT Voltage :-11000V Mass/ Volume of oil Kg/Lts:- 925/1075
 LT Voltage :-433V Total Mass:-4650 Kg
 HT Current :-84 A Transportation mass :- 3800 Kg
 LT Current :- 2134 A Connection:- DYN11
 Frequency :- 50 Hz Phase Displacement : +30 degree
 Phase HT/LT :- 3/3
 Impedence @ tap no 1-6 :- 5.62
@ tap no 3-8 :- 5.962
@ tap no 5-10 :- 6.35
Layout
 Circuit breakers

 A circuit breaker is an automatically operated electrical

switch designed to protect an electrical circuit from
damage causes by OVERLOAD and SHORT CIRCUIT.
 The main objective of circuit breaker is to minimize the
arcing while open or close the circuit.
 The various arc quenching medium used in circuit
breakers are AIR, SULFUR HEXAFLUORIDE(SF6),
VACUUM.
Air circuit breaker
 Relays

 A relay is a electrically operated switch.

 Relays are used where it is necessary to control a circuit by a
low power signal or where a several circuits must be
controlled by one signal.
 conductors

 A conductor is an object or a type material that allows the flow

of electrical current in one or more directions.
 For example a wire is an electrical conductor that can carry
electricity along with its length. In metal such as copper and
aluminum, the movable charged particles are electrons.
 Electrical cable

 Material :-
Copper
Aluminum
 Core:-
Single core
Multi core
 LT Cable:-
1.5 Sq mm Withstand up to 1100V
 HT Cable:-
120 ,300,600 Sq mm XLPE(Xross Link Poly Ethelene)
 motors

Electrical is a device that creates motion, it converts electricity into a

mechanical motion.

Types of Motors:-
 Category :-
 Flame proof
 Weather proof
 Poles :-
 Single pole (6000 rpm)
 Two pole (3000 rpm)
 Four pole (1500 rpm )
 Six pole (750 rpm
 Parts

1. Stator
2. Stator winding
3. Rotor
4. Bearings
5. Connection terminal
6. Cover
 Name plate Details

High Speed Low Speed

 Frame size :LE180M  Frame size :LE315LMkii

 Speed :2940 rpm  Speed :1485
 Capacity :22 KW  Capacity :125 KW
 Current :37.7 A  Current :210 A
 Enclosure :IP55  Enclosure : ip54
 Efficiency :92.2  Efficiency :88.8
 Duty :S1  Duty : s1
 Ins class :F  Ins class :F
 Connection :Delta  Connection :Delta
 Starting methods of Motors
DOL
 High Starting Torque & starting
current
 Design & space Easy
 Common Starting method &
consist only main contactor & relay
 3 core *1 run cables needed.
Star-Delta
 Low starting Torque &Starting
current reduced 1/3 rd compare DOL
 Design & Space more Difficult
 For higher capacity Motors & consist
of 3 Contactors ,timer & relay
 3 core * 2run core cables needed
DOL STARTER
STAR-DELTA STARTER
 VFD
 Variable Frequency Drive (VFD)
 A VFD can be used to control both the speed and torque
of a standard induction AC electric motor.
 It varies both the frequency and amps of the AC
waveform being delivered to the motor saving money in
electricity.
 Basic components of a VFD:
 Input section, draws AC electric power from the
utility, Rectifier section, converts the AC into DC
power.
 Inverter section, converts DC back into a controllable
AC waveform.
 Purpose of the VFD

 VFDs help to limit demand and electrical consumption

of motors by reducing the amount of energy they
consume.
 Standard motors are constant speed and when they are
energized they run at a 100% no matter the load.
 Soft Start
 Only use energy you need
VARIABLE FREQUENCY DRIVE
MAINS


RECTIFIER

INVERTER

M
LOAD

 Variable frequency,
Fixed frequency Variable voltage AC
Fixed voltage AC AC DRIVE supply keeping v/f
supply ratio constant

FILTER
INVERTER
RECTIFIER WITH
SUPPLY LOAD
BRIDGE VOLTAGE
CONTROL

AC DRIVE
 Potential Problems

 Improper Circuit Design

 Harmonic Distortion
 Safety
 3 phase generation
 Microcontroller programming
 Electrical measuring devices

 Voltmeter - It is used for measuring electrical potential

difference between two points in an electrical circuit.
 Ammeter - It is used to measure electric current in a
circuit.
 Watt Meter - It is used to measure electric power in a
circuit.
 Current Transformer – It is used measuring currents at HV
and EHV systems.
 Voltage Transformer – It is used measuring voltage at HV
and EHV systems.
 earthing

 All the people living or working in residential, commercial and

industrial installations, particularly the operators and personnel
who are in close operation and contact with electrical systems and
machineries, should essentially be protected against possible
electrification. To achieve this protection, earthing system of an
installation is defined, designed and installed according to the
standard requirements.
 ELCB
 RCCB
Electrical Shock
MANALI SUBSTATION
PLANT-1 SLD
PLANT- 2 SLD
Mpl plant - SLD
 Power from tneb to plant-1

 Permitted demand --- 2400KVA

 Power cut imposed from 1st Nov 2008
 Revised base demand --- 2200KVA
 Currently we are having 20% power cut during
normal hours & 90% power cut during evening
peak hours.
 Demand (20% Quota)
 Accordingly the revised demand and energy quota for
plant-1 is as follows:

Normal Hours
 Demand Quota ---- 1760KVA
 Energy quota ---- 10,55,200 Units(per month)
Evening hours
 Demand quota ---- 200KVA
 Energy quota ---- 1,08,400 Units(per month)
 Power from tneb to plant-2

 Permitted Max demand --- 2100KVA

 Power cut imposed from 1st Nov 2008
 Currently we are having 10% (189)power cut
during normal hours & 80%(1680) power cut
during evening peak hours.
 Accordingly the revised demand and energy quota for
plant-2 is as follows:

Normal Hours
 Demand Quota ---- 1680KVA
 Energy quota ---- 1024507 Units(per month)
Evening hours
 Demand quota ---- 189KVA
 Energy quota ---- 81961 Units(per month)
 CPP

 In our plant having Captive Power Plant with 4.2 MW capacity

Bio-Mass power plant.
 CPP parallel with TNEB to avoid Power failure , during that
time lot of production material losses & motor Failures.
 For past 6 months CPP in under maintenance, in that time we
purchase IEX (Indian Energy Exchange) on daily rate based.
 During any Interruption / disturbances in TNEB Grid we will run
the Diesel Generators.
 Diesel Generators

 We our plant 2 No of Diesel Generators( EM DG & CAP

DG) each with 1500 KVA capacity .
 It is fully maintained by Powerica
 KVA:-1500 RPM:- 1500
 FLA :- 2087 connection:- STAR
 Class:- H Enclosure:- IP23
 UPS

 UPS is a device that contains stored energy (DC)

and Invert it into AC to provide an Uninterrupted
output power to the connected equipment.
 Key components : Rectifier, Batteries,
power inverters and static switch.
 BATTERY
 It is a storage device. At first Electrical energy converted and
stored in the form of Chemical energy (Charging),when power
fail by converting Chemical energy into Electrical energy
(Discharging).
Category:-
Maintenance
Maintenance free
Types of batteries:-
 Lead Acid battery
 Nickel – Cadmium Battery
 Battery capacity (Ah) = Current drawn (I) x Time (H)
 In our plant both maintenance & maintenance free Batteries are
Used
 Maintenance-Lead Acid battery(12V 150 AH)used UPS 110V AC
(DCS , Instrument operating valves , DG, FWPH DG)
 Maintenance free –VRLA( 2V 240AH) battery used110 V DC system
(Relay panel ,Breakers)
Layout
 Application

 For emergency purpose(power failure) to open close the valves,

breakers.
 Continues operations (DCS, Relay..etc).
 Easy Store & power handling compare other technique.
 More reliable & portable.
 Life time high compare to others.
 Electrical Safety

 Earthing of a electrical System

 EC
 Work permit
 Gloves
 EC ??

 EC – Electrical Clearance , Isolating electrical supply from

working electrical equipment before doing any job on it.
 Every body knows the equipment Tag NO & what kind of job
to be take?
 Our dept isolate the power & put caution tag on the module
end. Then you will check after that acknowledge or accept EC.
 After finishing Job& permit completed ,ensure all material
remove ? Then only clear the EC