Internship Report

INDEX

S. No Topic Page No.

1 Introduction 2

2 Safety Instructions 3

3 Generation 4

4 Transmission 8

5 Substations and Distribution 11

6 Motors and their Starting Techniques 13

7 Miscellaneous Protection Equipments 16

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Introduction

Byco is Pakistan’s emerging energy companies engaged in the businesses of oil refining,
petroleum marketing, chemicals manufacturing and petroleum logistics. Headquartered in
Karachi, Byco is serving its mission to fulfill the energy demand within and beyond borders.

Companies under Byco umbrella are:

Byco Oil Pakistan Limited (BOPL)

Byco Petroleum Pakistan Limited (BPPL)

Byco Terminals Pakistan Limited (BTPL)

Byco's operational refinery has a capacity to refine 35,000 barrels a day of crude oil into various
saleable components including Liquefied Petroleum Gas, Light Naphtha, Heavy Naphtha, High
Octane Blending Component, Motor Gasoline, Kerosene, Jet Fuels, High Speed Diesel and
Furnace Oil. After expanding our refining complex by setting up another refinery, with the
capacity of 120,000 barrels per day, Byco is now one of the largest refineries of Pakistan. Byco
takes pride in having the largest capacity crude oil storage tanks in the country. Its petroleum
distribution network supports movement of petroleum products and provides greater economies
of scale. Having marketing network supports retail outlets in more than 80 cities all over
Pakistan Byco is an emerging leader in oil marketing sector of our economy.

The training program I had at Byco (ORC2) helped me bridge the gap between the theories and
practical applications of my field related subjects. Being a student of electrical engineering I was
employed at the electrical department of Byco where I observed how power is generated,
transmitted and distributed practically. During my tenure I also learnt about different motors
employed at the refinery and circuitry related to it.
While I focused on my field of engineering, being on a refinery I also managed to learn the basic
process taking place at the refinery just for the sake of knowledge.

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Safety Instructions
Health and safety is an important part of any industry. Reducing the number of dangerous
occurrences, injuries and hydrocarbon releases remains a top priority and is a key focus of the
industry’s absolute commitment to continually improving process safety standards. No other
industry puts more effort into improving its safety performance through leadership,
communication and co-operation.

Since Byco is an oil Refinery and in petroleum refineries, the concern for safety could be said to
focus on two main areas: process safety and labor or personnel safety. These two areas are very
different from each other, but both are important. They require two very different approaches to
what one might call “the safety problem.” Process safety involves the development and
implementation of interventions concentrated on preventing or minimizing the effects of loss of
containment of flammable, toxic, or reactive chemicals. Labor or personnel safety interventions
focus on the prevention or mitigation of hazards that can result in individual injuries or
exposures; a much less catastrophic problem, but a no less important one. Through both
approaches to the safety problem, we attempt to prevent or minimize the impact of accidents.
There are many definitions for an accident, but for the purposes of this chapter, they will be
considered unintentional events that result in undesirable consequences. Accidents occur in
nearly every facet of our lives. Because in petroleum refineries, there is extensive heavy manual
work (especially during maintenance turnarounds); there is large, heavy equipment; there are
toxic, flammable and reactive chemicals; and there are high temperatures and pressures in many
processes, it is no surprise that accidents occur here. To reduce these accidents prevention
measures are taken such as Personal Protective Equipment (PPE) is compulsory for all, which
includes a cover all, helmet and safety shoes. This helps reduce the effects of hazards and
accidents. Also a permit system is maintained to avoid unforeseen circumstances.

There are two basic type of permits; Red for hot work permit and Green for cold Work Permit.

Then there are other permits; Confined Space Entry Certificate (yellow), Excavation Breaking
Certificate (White), Electrical Isolation and Inter Plant Isolation.

Fire Safety systems are installed throughout the plant and safety drills are carried out weekly
basis to prepare the workers for any emergency situations.

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Generation

Running a refinery at the above mentioned capacity needs Electric power of huge amount.
Buying this power from any electric company would be easier but its transmission up to the plant
would be a hectic task and would cost a lot. That is why Byco has set up its own power plants for
both of its refineries separately.
In ORC2 the power plant is capable of generating up to 15 MW. It has 15 generating units, each
capable of producing 1 MW of power.

Generators

The generators being used at Byco comprises of two portions. Firstly the Engine and then comes
the alternator

Engine

Engines are although not much related to electrical engineering but without at running the
alternator is not possible hence Electricity cannot be generated. Here at Byco Diesel power
Perkins engines are used as the prime mover. It is being run at 1500 RPM and then it is coupled
with the Alternator. Details of the engine are as follows:
The Perkins 4000 Series family of 6, 8, 12 and 16 cylinder diesel engines was designed in
advance of today’s uncompromising demands within the power generation industry and includes
superior performance and reliability. The 4012-46TAG3A Electropak is a newly developed
turbocharged, air-to-air charge cooled, 12 cylinder diesel engine. It offers with either Temperate
or Tropical cooling packages (with or without fuel oil cooling). Their premium design and
specification features provide economic and durable operation as well as exceptional power to
weight ratio, improved serviceability, low gaseous emissions, overall performance and reliability
essential to the power generation market.

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General data
Number of cylinders ........................................................... 12
Cylinder arrangement ........................................................ 60º Vee form
Bore and stroke ................................................................. 160 x 190 mm
Displacement .................................................................... 45.842 litres
Induction system ...............................................................Turbocharged and air to air charge
cooled
Cycle .................................................................................. 4 stroke
Combustion system .......................................................... Direct injection
Compression ratio ............................................................ 13.6:1
Rotation ............................................................................. Anti-clockwise, viewed from flywheel
end
Cooling system ................................................................... Water-cooled
Firing order ....................................................................... 1A, 6B, 5A, 2B, 3A, 4B, 6A, 1B, 2A,
5B, 4A, 3B
Total lubrication system capacity ...................................... 177 litres
Total weight (dry) ............................................................... 4400 kg
Temperate .……..Tropical
Total coolant capacity (1500 rpm) ......... 207 litres ......... 210 litres
Total coolant capacity (1800 rpm) ......... 225 litres ......... 209 litres
Dimensions – Length .......................... 3915 mm ...........3883 mm
Width ............................ 2198 mm ...........2164 mm
Height ........................... 2259 mm ...........2610 mm

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Alternator
Now comes the real part of Electrical Engineering. An alternator is an electrical generator that
converts mechanical energy to electrical energy in the form of alternating current. For reasons of
cost and simplicity, most alternators use a rotating magnetic field with a stationary armature.
Occasionally, a linear alternator or a rotating armature with a stationary magnetic field is used. In
principle, any AC generator can be called an alternator, but usually the term refers to small
rotating machines driven by automotive and other internal combustion engines.
Principle of Operation

A conductor moving relative to a magnetic field develops an electromotive force (EMF) in it,
(Faraday's Law). This emf reverses its polarity when it moves under magnetic poles of opposite
polarity. Typically, a rotating magnet, called the rotor turns within a stationary set of conductors
wound in coils on an iron core, called the stator. The field cuts across the conductors, generating
an induced EMF (electromotive force), as the mechanical input causes the rotor to turn.

The rotating magnetic field induces an AC voltage in the stator windings. Since the currents in
the stator windings vary in step with the position of the rotor, an alternator is a synchronous
generator.

The rotor's magnetic field may be produced by permanent magnets, or by a field coil
electromagnet. Automotive alternators use a rotor winding which allows control of the
alternator's generated voltage by varying the current in the rotor field winding. An automatic
voltage control device controls the field current to keep output voltage constant. If the output
voltage from the stationary armature coils drops due to an increase in demand, more current is
fed into the rotating field coils through the voltage regulator (VR). This increases the magnetic

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field around the field coils which induces a greater voltage in the armature coils. Thus, the output
voltage is brought back up to its original value.

Here at Byco Leroy Somer Alternators are being used with the Perkins engines (Prime Movers)
to generate 1MW electricity by a single unit at 415 volts (phase to phase) and 50 Hz. Its details
are as follows:

V = 400v

Phase = 3

Conn. = Delta

Continuous Duty Stand By.

1250 KVA 1375 KVA

1000 KW 1100 KW

40 ΦC = 1804 A 27 ΦC = 1984 A

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Transmission
Following the standard procedures, Byco does it power transmission by stepping up 400V from
the generators to 11KV, with the help of step up transformer. First let us define a transformer and
its details.

Transformer

Electrical power transformer is a static device which transforms electrical energy from one
circuit to another without any direct electrical connection and with the help of mutual
induction between two windings. It transforms power from one circuit to another without
changing its frequency but may be in different voltage level. The working principle of
transformer is very simple. It depends upon Faraday’s law of electromagnetic induction.
Actually, mutual induction between two or more winding is responsible for transformation action
in an electrical transformer.

According to Faraday’s laws,

"Rate of change of flux linkage with respect to time is directly proportional to the
induced EMF in a conductor or coil".

Basic Theory of Transformer

In a Transformer we have one winding which is supplied by an alternating electrical source. The
alternating current through the winding produces a continually changing flux or alternating flux
that surrounds the winding. If any other winding is brought nearer to the previous one, obviously
some portion of this flux will link with the second. As this flux is continually changing in its
amplitude and direction, there must be a change in flux linkage in the second winding or coil.
According to Faraday’s law of electromagnetic induction, there must be an EMF induced in the
second. If the circuit of the later winding is closed, there must be a current flowing through it.

Construction of Transformer

Basically a transformer consists of two inductive windings and a laminated steel core. The coils
are insulated from each other as well as from the steel core. A transformer may also consist of a
container for winding and core assembly (called as tank), suitable bushings to take out the

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terminals, oil conservator to provide oil in the transformer tank for cooling purposes etc. The
figure at left illustrates the basic construction of a transformer.
In all types of transformers, core is constructed by assembling (stacking) laminated sheets of
steel, with minimum air-gap between them (to achieve continuous magnetic path). The steel used
is having high silicon content and sometimes heat treated, to provide high permeability and low
hysteresis loss. Laminated sheets of steel are used to reduce eddy current loss. The sheets are cut
in the shape as E, I and L. To avoid high reluctance at joints, laminations are stacked by
alternating the sides of joint. That is, if joints of first sheet assembly are at front face, the joints
of following assemble are kept at back face.

Types of Transformers
Transformers can be classified on different basis, like types of construction, types of cooling etc.

(A) On the basis of construction, transformers can be classified into two types as; (i) Core
type transformer and (ii) Shell type transformer, which are described below.

(I) Core Type Transformer

In core type transformer, windings are cylindrical former wound, mounted on the core limbs as
shown in the figure above. The cylindrical coils have different layers and each layer is insulated
from each other. Materials like paper, cloth or mica can be used for insulation. Low voltage
windings are placed nearer to the core, as they are easier to insulate.

(II) Shell Type Transformer

The coils are former wound and mounted in layers stacked with insulation between them. A shell
type transformer may have simple rectangular form (as shown in above fig), or it may have a
distributed form.

(B) On the basis of their purpose

1. Step up transformer: Voltage increases (with subsequent decrease in current) at

secondary.

2. Step down transformer: Voltage decreases (with subsequent increase in current) at

secondary.

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(C) On the basis of type of supply

1. Single phase transformer

2. Three phase transformer

(D) On the basis of their use

1. Power transformer: Used in transmission network, high rating

2. Distribution transformer: Used in distribution network, comparatively lower rating than

that of power transformers.

3. Instrument transformer: Used in relay and protection purpose in different instruments in

industries

 Current transformer (CT)

 Potential transformer (PT)

(E) On the basis of cooling employed

 Oil-filled self cooled type

 Oil-filled water cooled type

 Air blast type (air cooled)

System at Byco

At Byco for transmission of power from power house to substations/feeder three phase Step up
transformers are used. They can also be called as Power Transformers as they work at high
voltage and power and their load remains constant throughout normal operations.

Since there are 15 generation units therefore for each unit there is a separate transformer. Each
transformer has a capacity of 1500 KVA and operates at 400V/11KV 50Hz. All the transformers
are connected in series through a connecting bus forming a ring main unit (RMU). The power
RMU is divided in half by an isolator so that it gives the flexibility to the system in case of fault
on either side. One cable from both ends carries the power at 11KV to the substations.

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Substations and Distribution

Here at Byco there are 4 substations. The step up transformers sends generated power at 11KV
voltage level to the substations where this power is then distributed.

Substations transform voltage from high to low, or the reverse, or perform any of several other
important functions. Between the generating station and consumer, electric power may flow
through several substations at different voltage levels. It may include transformers to change
voltage levels between high transmission voltages and lower distribution voltages, or at the
interconnection of two different transmission voltages.

Substations generally have switching, protection and control equipment, and transformers. In a
large substation, circuit breakers are used to interrupt any short circuits or overload currents that
may occur on the network. Smaller distribution stations may use recloser circuit
breakers or fuses for protection of distribution circuits.

At Byco there are switchgears from ABB and some other company. In an electric power
system, switchgear is the combination of electrical disconnects switches, fuses or circuit
breakers used to control, protect and isolate electrical equipment. Switchgear is used both to de-
energize equipment to allow work to be done and to clear faults downstream. This type of
equipment is directly linked to the reliability of the electricity supply. Typically, switchgears
in substations are located on both the high-voltage and low-voltage side of large
power transformers.

Types of Switchgears

Switchgear may be a simple open-air isolator switch or it may be insulated by some other
substance. An effective although more costly form of switchgear is the gas insulated switchgear
(GIS), where the conductors and contacts are insulated by pressurized sulfur
hexafluoride gas (SF6). Other common types are oil or vacuum insulated switchgear.

The combination of equipment within the switchgear enclosure allows them to interrupt fault
currents of thousands of amps. A circuit breaker (within a switchgear enclosure) is the primary
component that interrupts fault currents. The quenching of the arc when the circuit breaker pulls
apart the contacts open (disconnects the circuit) requires careful design. Circuit breakers fall into
these five types:

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 Oil circuit breakers rely upon vaporization of some of the oil to blast a jet of oil along the
path of the arc. The vapor released by the arcing consists of hydrogen gas.

 Air circuit breakers may use compressed air (puff) or the magnetic force of the arc itself
to elongate the arc. As the length of the sustainable arc is dependent on the available
voltage, the elongated arc will eventually exhaust itself. Alternatively, the contacts are
rapidly swung into a small sealed chamber, the escaping of the displaced air thus blowing
out the arc.

 Gas (SF6) circuit breakers sometimes stretch the arc using a magnetic field, and then rely
upon the dielectric strength of the SF6 gas to quench the stretched arc.

 Hybrid switchgear is one that combines the components of traditional air-insulated

switchgear (AIS) and SF6 gas-insulated switchgear (GIS) technologies. It is characterized
by a compact and modular design, which encompasses several different functions in one
module.

 Vacuum Circuit breakers with vacuum interrupters have minimal arcing characteristics
(as there is nothing to ionize other than the contact material), so the arc quenches when it
is stretched by a small amount (<2–8 mm). Vacuum circuit breakers are frequently used
in modern medium-voltage switchgear to 40,500 volts.

The 11KV voltage is connected to a feeder which then sends it to the step down transformers.
Since there are three different working voltages at Byco therefore the power is distributed to
different transformers rated at 11KV/220V, 11KV/415V and 11KV/3.3KV. Then after step down
of voltages this power is again supplied to a feeder which then feeds it to the different loads by
the help of switchgears.

Since most of these switch gears are controlled by 110 DC (Reliability purpose) therefore in the
substation there are battery chargers than continuously keep charging the batteries. A UPS is also
installed here at BYCO substation as a backup in case of failure of systems.

In emergency situation at Byco if the power plant shuts down, there is a backup generator
located near by the substation 1-2, 3. This substation is also near to the power house so it can be
easily operated. Another substation is located near the CDU namely 4-10.

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Motors and Their Starting Techniques

Byco petroleum, being one of the largest refineries of Pakistan, has a plant that can produce up to
150 thousand barrels per day if running at full capacity. When a plant of this size is installed, it
contains thousand of motors, having different sizes and different ratings. These motors are used
for Pumps, Compressors and Cooling Fans. There are three operational voltage levels; small
motors at 220V, Medium motors at 400V and Large Motors at 3.3KV. The biggest motor at the
plant has the power rating of 850KW at 3.3KV voltage level. All the motors used here are
induction motors.

An induction or asynchronous motor is an AC electric motor in which the electric current in

the rotor needed to produce torque is obtained by electromagnetic induction from the magnetic
field of the stator winding. An induction motor therefore does not require mechanical
commutation, separate-excitation or self-excitation for all or part of the energy transferred from
stator to rotor. An induction motor's rotor can be either wound type or squirrel-cage type. Three-
phase squirrel-cage induction motors are widely used in industrial drives because they are
rugged, reliable and economical.

Motor Starting Techniques

Different starting methods are employed for starting induction motors because Induction Motor
draws more starting current during starting. To prevent damage to the windings due to the high
starting current flow, we employ different types of starters.

DOL

The simplest form of motor starter for the induction motor is the Direct on Line starter. The
Direct On Line Motor Starter (DOL) consist a MCCB or Circuit Breaker, Contactor and an
overload relay for protection. Electromagnetic contactor can be opened by the thermal overload
relay under fault conditions.

Typically, the contactor will be controlled by separate start and stop buttons, and an auxiliary
contact on the contactor is used, across the start button, as a hold in contact. I.e. the contactor is
electrically latched closed while the motor is operating.

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Star/Delta

Star/Delta starters are probably the most common reduced voltage starters in the 50Hz world.
They are used in an attempt to reduce the start current applied to the motor during start as a
means of reducing the disturbances and interference on the electrical supply.

The Star/Delta starter is manufactured from three contactors, a timer and a thermal overload. The
contactors are smaller than the single contactor used in a Direct on Line starter as they are
controlling winding currents only. The currents through the winding are 1√3 = 0.58 (58%) of the
current in the line. this connection amounts to approximately 30% of the delta values. The
starting current is reduced to one third of the direct starting current.

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Soft Starters

A soft starter is a solid-state device that protects AC electric motors from damage caused by
sudden influxes of power by limiting the large initial inrush of current associated with motor
startup. They provide a gentle ramp up to full speed and are used only at startup (and stop, if
equipped). Ramping up the initial voltage to the motor produces this gradual start. Soft starters
are also known as reduced voltage soft starters (RVSS).

Variable Frequency Drive

A variable frequency drive (VFD) is a motor control device that protects and controls the speed
of an AC induction motor. A VFD can control the speed of the motor during the start and stop
cycle, as well as throughout the run cycle. VFDs are also referred to as adjustable frequency
drives (AFDs).

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Miscellaneous Protection Equipments

Magnetic Contactors

A contactor is an electrically controlled switch used for switching a power circuit, similar to
a relay except with higher current ratings. A contactor is controlled by a circuit which has a
much lower power level than the switched circuit. A contactor has three components.
The contacts are the current carrying part of the contactor. This includes power contacts,
auxiliary contacts, and contact springs.

When current passes through the electromagnet, a magnetic field is produced; this attracts the
moving core of the contactor. The electromagnet coil draws more current initially, until
its inductance increases when the metal core enters the coil. The moving contact is propelled by
the moving core; the force developed by the electromagnet holds the moving and fixed contacts
together. When the contactor coil is de-energized, gravity or a spring returns the electromagnet
core to its initial position and opens the contacts.

Overload Relay

Electronic overload relays have been designed primarily to protect electric motors and associated
electrical circuits. These devices operate on the principle of monitoring the current in a motor
starter circuit which, when the current exceeds a pre set condition, or there is a loss of current in
any phase, the device will initiate a trip circuit which in turn causes the power to the starter
(contactor) to be disconnected thus making the circuit safe.

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Earthing Transformer

Earthing Transformer or grounding transformer is the neutral grounding transformer - star

connected on the primary and has an open delta on secondary. Open Delta has two terminals. A
resistor is connected across these two terminals. Whenever a fault occurs, voltage will be
induced in the open delta and there will be a voltage drop in the resistor connected. This voltage
drop will be sensed by the earthing transformer connected across this resistor. At the secondary
of the earthing transformer we have the neutral displacement relay which will give a trip signal
or an alarm whenever its settings exceed a particular value.

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