MESSAGE FROM GM (TSX & SAS).......

Dear Colleagues,
It is our pleasure to present you the fourth issue of “Takniki Darpan”,
compiling feedbacks from sites.
Lot of innovations are taking place around us and in the present
competitive environment, the rule for survival is innovate or perish.
Better methods for doing things always exist and we have to inculcate
the habit of continuously looking for such methods to improve upon
the existing ones.
The cases included in this compendium are only representative of this
trend. We are sure at different sites, many such innovative methods for
process improvement are being evolved and tried out that needs to be
shared with all.
We request you to send us such methods for process improvement and
trouble shooting so that the same can be shared with a larger cross
section of our organisation either through this journal or through the
Knowledge Management Portal of PSWR.
One idea leads to another and most of the times, the crossing of two
ideas have the combined effect that is much larger than the original
ones. Therefore, let us come together and make things better.
With warm regards,

R. L. Ranwas
General Manager (TSX & SAS)
PSWR

TECHNICAL SERVICES, BHEL-PSWR 1

 GLIMPSES OF THE SITES ………

STATUS OF THE SITES UNDER COMMISSIONING:

1. NSPCL BHILAI (2 x 250MW )
Unit No.01:
A. At present it is running at various loads depending on load requirement and coal availability. PG test
of TG Cycle is planned in the month of February 2010.

Unit No. 02:

A. COD of Unit is completed and NSPCL declared the Unit is under Commercial operation from 0000 HRS
on 21/10/09. At present running at various loads depending on the load requirement and coal
availability.

2. TATA TROMBAY (1 x 250MW)

A. COD of Unit is completed and Unit is running under commercial operation from 29/03/09.
B. PG Test of Turbine, Boiler and ESP successfully completed on 4th February 2010.

3. MAHAGENCO PARAS (1 X 250MW AND 1 X 250MW Extn.)

Unit No.01:
A. Unit is running at full load and PG Test of Boiler, TG, Pumps and Mills have been completed.
B. ESP PG test was successfully completed on 8th January 2010.

Unit No. 02:

A. Unit Synchronised on 30th November 2009.
B. Coal firing is expected in February 2010.

4. PARLI (1 X 250MW AND 1 X 250MW Extn.)

Unit No. 01:
A. Unit is running smoothly at full load.
B. ESP PG Test is successfully completed on 15/02/2010.

Unit No. 02:

A. Unit synchronised on 12th November 2009.
B. Coal firing was done on 1st January 2010.
C. Machine has reached full load on 10th February 2010.

TECHNICAL SERVICES, BHEL-PSWR GLIMPSES OF THE SITES ……… 2

5. MPPGCL BIRSINGHPUR (500MW)
A. PG Test of Boiler completed on 15th Sept 2009.
B. PG Test of Turbine completed on 28th Sept 2009.
C. PG Test of ESP is scheduled in March 2010.

6. IOCL, BARODA (2X33 MW)

Unit No. 01:
A. Machine synchronised on 4th November 2009.
B. At present running at various loads depending upon customer's requirement.

7. KUTCH LIGNITE (1 X 77MW)

A. Full load achieved on 1st Oct. 2009 at 1320hrs.
B. Trial Operation was completed on 19th Dec 2009.
C. At present the unit is continuously running at various loads depending on customer's requirement.

8. SULEMANIYAH, IRAQ (4 X123MW, FR9)

Unit No. 01:
A. Machine is at present running at base load.

Unit No.02:
A. Machine is at present running at base load.

Unit No 03:
A. The unit was synchronised on 19th November 2009.
B. Trial operation was completed on 14th December 2009.
C. Machine is at present running at base load.

9. SLPP MANGROL (2 X 125MW PHASE II)

Unit No. 03:
A. Unit was synchronised to Grid on 29th November 2009.
B. Coal firing was also done on 29th November 2009 and maximum load achieved was 50 MW.
C. On 22nd December 2009 the unit tripped and the turbine bearing got damaged due to oil starvation.
D. At present the turbine repair work is under progress at BHEL Hyderabad.

Unit No. 04:

A. Boiler lighted up and Chemical cleaning with EDTA was completed on 4th February 2010.
v
v
v
TECHNICAL SERVICES, BHEL-PSWR GLIMPSES OF THE SITES ……… 3
 FEEDBACKS ………

UNLOADING OF GENERATOR STATOR AT KHAPERKHEDA, 1 X 500 MW, PROJECT

Shri. A.K.MUKHOPADHYAY, CM, KHAPERKHEDA SITE
Shri. A.K.SAHA, DGM
Shri. AJIT PARMAR, DGM
Shri. SUNIL SHARMA, ENGINEER

BACKGROUND:
Existing practice followed by BHEL-Power Sector Regions:
The all important milestone operation of unloading, lifting and placement of 500MW Generator Stator
weighing about 265 MT on TG deck, used to be done with the help of Portal Crane arrangement.
The consignment of Generator Stator [BOX NO. 501] used to be carried to site on a Rail-wagon
arrangement specially designed by DRDO
for the said purpose.
Our site i.e. 1x500MW Khaperkheda
Expansion Project of Mahagenco had been
unique in the sense that, the said
consignment was transported from
Haridwar Unit, BHEL on a 144 wheeled
Trailer of M/S. Reach Cargo Movers Pvt.
Ltd. changing the total scenario which
called for a completely different approach
for safe handling and unloading of the
heaviest consignment of the project.
The modalities of the process of “Jacking &
Packing” used to be done as a standard
practice needed to be reviewed with
respect to changed geometric parameters posing a challenge towards safe handling & unloading of the
Generator Stator from the Trailer before its lifting and placement on the TG deck.

I. TREND SETTER
The following table gives a clear impression regarding mode of transport of 500MW GENERATOR STATOR
to various on going sites. In that case, the process of unloading of stator calls for a complete review of
existing procedure and suitable modification to the same for safe unloading of stator.

TECHNICAL SERVICES, BHEL-PSWR SITE FEEDBACKS ……… 4

 SR. NO. PROJECT MW WEIGHT BOX SIZE MONTH PLANNED
1 Mejia-2 500 275MT 8830 X 4100 X 4120 July'09
2 Simhadri-3 & 4 500 275MT 8831 X 4100 X 4120 Aug'09 & Jan'10
3 Koderma-1 & 2 500 275MT 8832 X 4100 X 4120 Sep'09 & Mar'10
4 Jhajjar 500 275MT 8833 X 4100 X 4120 Oct'09
5 Durgapur-1&2 500 275MT 8834 X 4100 X 4120 Nov'09 & Mar'10
6 Bhusawal 500 275MT 8835 X 4100 X 4120 Dec'09
7 Maithon-1 500 275MT 8836 X 4100 X 4120 Jan'10
8 Kalpakkam 500 275MT 8837 X 4100 X 4120 Feb'10

Sending Stator on Trailer by mfg. unit is going to stay.

Modus Operandi for Stator Unloading & Lifting NEEDS to be RE-ESTABLISHED.
Unloading of Generator Stator from a 144- wheeled Trailer which travelled right from BHEL, Haridwar Unit
on 13 June 2009 & reached at Khaperkheda Project Site on 10 Sep 2009 is already a trendsetter itself and its
successful placement in TG Hall on 25 Oct 2009 ,a milestone activity is a trend setting accomplishment.

II. USE OF NEW METHODOLOGY

ACTIVITIES INVOLVED IN THE EXISTING PRACTICE

(i) Unloading of Generator Stator from the Generator Special Wagon on Aux. Pedestals with the help of
Hydraulic Jacks
(ii) Removal of the Load carrying beam from inside Generator Stator and taking it out completely from
the Generator Stator
(iii) Lifting of Generator stator from Aux. Pedestals with the help of Strand Jack method
(iv) Rotation of the Generator Stator to suit insertion of the stator inside A Row as the position of the
Stator on the Rail track is 500 mm offset.
(v) The dragging operation is done with the help of 2 nos. hydraulically operated jacks of 15 MT Capacity
each towards B- row from A-row. Further to readjust the movement of generator stator from other
side is done with the help of 2 manually operated Maxpullers of Capacity 5.0 MT each and to give
breaking action in case of emergency.
(vi) Once the above rotation is complete, the Stator is further rotated to make parallel to TG Axis and
slowly it is made almost in line with TG Axis with the help of swivelling beam assembly.
(vii) Placement of Generator Stator on TG Hall foundation
(viii) Joining of the Two parts of Special wagons for dispatching of the Generator Special wagon back to
BHEL, Haridwar Unit.
TECHNICAL SERVICES, BHEL-PSWR SITE FEEDBACKS ……… 5
NEW METHODOLOGY
As the Generator Stator is dispatched to site on a trailer instead of Railway wagon, operation no. (ii)
through (viii) become null and void.

Here Non value adding process elements i.e. Operation Nos. ii), iv), v), vi) & vii) are completely
eliminated.

Instead of dragging the Stator, in our case, special care is taken to place the trailer along A-row, so that
Stator comes directly under the reach of Portal Crane and axis of Stator matches with the axis of it on TG
Hall where it is to be placed. This also helps in visualising constructional obstacle if any, on the trajectory of
Stator from 0.00m to 17.0m.

The unloading methodology was discussed with BHEL, Haridwar Unit and the following shortcomings were
pointed out.
1. Space chosen for jacking was not practically feasible.
2. Jacking was to be done at a height > > 3.0m ; unsafe proposition
3. No. of Items called for in Drg. were many and cumbersome, i.e. #3, Plate 100x380x450.
4. Jacking area provided limited space for placing packers for unloading.
5. Overall Architectural Geometry appeared to be unstable & unsafe.

Considering the weight of the consignment, we were of the view that Jacking area must not be very far
away from the ground and area available for jacking and placing packers must be sufficient and close-by.

In the new methodology proposed Calculations for mechanical stability and bending moment, MS Plates of
40tk for stiffeners and 60tk for jacking force proved to be sufficient.

Four nos. fixtures were to be welded at the four corners of two outward saddles, leaving the two middle
saddles undisturbed.

This took care of above deficiencies.

Generator Stator of 1X500MW KHAPERKHEDA EXPNANSION PROJECT OF MAHAGENCO is unloaded from

trailer, lifted & placed in TG Hall, safely & successfully.

TECHNICAL SERVICES, BHEL-PSWR SITE FEEDBACKS ……… 6

III. REPEATABILITY & CONSISTENCY OF OUTPUT
The technique applied in this site can be repeated every time whenever this consignment is sent to sites on
a Trailer instead of a Railway Wagon.
The fixtures at four corners are simple, same in shape & construction, tested and above all safe.
Here, we suggest, these four fixtures may be included/merged in the existing design of outer two saddles
so that no further work is required to be done by the site people saving a lot of material, cost, labour, time
and efforts.
Once the above fixtures are inculcated in the saddles, the same can be used repeatedly by BHEL, Haridwar
Unit while sending Generator Stator to all other sites as proposed in Table-I.
As to consistency of output, the above approach is foolproof & safe unloading is ensured.
Here we suggest & plead strongly for institutionalising this improved process for future use in future
projects by simply including/superimposing our design with the existing saddle design thereby
standardising the new simplified method for the benefit of similar projects.

IV. EASE OF ERECTION: SYSTEMATIC APPROACH FOR IMPROVEMENT

The design of new saddles is quite simple and one time activity if our suggestion is inculcated. The
standardised outer saddles would help in saving time & money of similar sites in a big way. The sequence of
activities is much less, safe and easy. Not only our site has been benefited, lots of in - coming project would
be benefited.

IV. NEW METHODOLOGY: ADVANTAGES IN TERMS OF COST REDUCTION

1. Placement of Trailer along A-Row of TG Hall needs a little manoeuvring of Trailer steering that reduces
dragging and other activities involved in existing process thereby saving on time.
2. The fixtures are simple with lesser components, easy to fabricate, geometrically similar and can be
pre-fabricated
3. Cargo detention time is largely minimised thereby saving a lot on demurrage charges to the tune of
lacs of Rupees.
4. The concept is simple, repeatable and can be standardised. Other similar projects can reap rich
benefits.
5. Maintenance free concept is foolproof & safe cent per cent.

TECHNICAL SERVICES, BHEL-PSWR SITE FEEDBACKS ……… 7

 FIG-1 ARRIVAL OF GENERATOR STATOR AT KHAPERKHEDA PROJECT SITE

FIG-2 POSITIONING OF CARGO TO MATCH STATOR AXIS WITH PLACEMENT AXIS IN TG HALL

TECHNICAL SERVICES, BHEL-PSWR SITE FEEDBACKS ……… 8

Figure 3 FABRICATION OF UNLOADING FIXTURE Figure 4 UNLOADING FIXTURE:
JACKING & PACKING

Figure 5 STATOR LOAD OFF THE TRAILER

TECHNICAL SERVICES, BHEL-PSWR SITE FEEDBACKS ……… 9

 Figure 6 TRAILERS BEING MADE READY TO MOVE OUT

Figure 7 GENERATOR STATOR FINALLY UNLOADED OFF 144 WHEELED TRAILER

v
v
v
TECHNICAL SERVICES, BHEL-PSWR SITE FEEDBACKS ……… 10
 CASE STUDY ON AIR PRE-HEATER LUB OIL FLUSHING AT 1X500 MW NTPC KORBA
By: Rejeev Lalwani
Engineer, BHEL, Korba Site
PROBLEM IDENTIFICATION:
A 500 MW unit boiler consumes 1000 TPH primary and secondary air to burn 300 TPH coal. In order to
improve to efficiency of boiler specific heat carried by flue gases is transferred to secondary and primary air
by air pre-heaters. Two numbers of secondary and two numbers of primary, bi-sector type rotary air pre-
heaters are provided. Each APH has separate lub oil system for its guide and support bearing. Acid cleaning
and lub oil flushing of system is carried out to clean the lines of these lub oil systems before trial run of air
heater. To remove dirt and debris free from lub oil lines, acid cleaning is done by HCl. Lub oil flushing is
completed in two stages, bypassing bearing and thru bearing. Customers like NTPC, NSPCL are demanding
mechanical impurities and moisture lesser than 100 ppm to declare completion of oil flushing and hence
takes more time to meet the criteria.

ANALYSIS:
SAPH (B) guide bearing lub oil flushing started on 17/09/2009. Oil used for lub oil flushing was diverted
from 1x500 MW Birsinghpur site having 250 ppm moisture and 400 ppm mechanical impurity.
The size of filter of oil system is 60 micron and the analysis of oil done by 0.45 micron filter to find the
mechanical impurities. So the mechanical impurities lies between 60 micron to 0.45 micron could be
removed by centrifuge only. A centrifuge of mandatory spares for MDBFP oil flushing was kept in clarifier
mode for oil purification. Atmospheric temperature was decreasing day by day due to winter and
decreasing the purification efficiency of centrifuge. The available centrifuge was not equipped with built-
in heater. So two numbers of stress reliving heating coils (16 gauges, 20 amp each) were wrapped on
suction line of lub oil system and maintained 80 oC temperature.
A temporary tank (reservoir) is required to start the first stage (bypassing bearing) oil flushing. Earlier a
lower half of 200 lit drum was used as a reservoir filled approx 100 lit oil. The time consumed in flushing can
be minimized by using small quantity of oil. So a 275x400 mm pipe was blanked at one end used as
reservoir to minimize the oil used and reduced purification time.

RESULT:
The lab analysis w.r.t time shown in fig 1.

TECHNICAL SERVICES, BHEL-PSWR SITE FEEDBACKS ……… 11

SOLUTION:
The following suggestions are made to speed up the purification of oil during flushing:
1. Lesser viscosity (SAE 68 or 46) oil should be used for both (thru and bypassing bearing) flushing.
2. Centrifuge should be used to speed-up the purification of oil.
3. While flushing oil temperature should not be less than 80 oC.
4. For rapid heating the oil, stress relieving (SR) heating coil can be used on suction lines of lub oil systems.
5. Never use SR heating coil without its control system.
6. Do not heat oil up to the flash point.
7. Centrifuge has to be cleaned every day.
8. Maintain extra cleanliness during sample collection.
9. Run both pump together during flushing.
10. To avoid starvation in pumps during initial run top up the oil accordingly in reservoir.

SAPH Guide Bearing Lub Oil Flushing Arrangement (Bypassing Bearing)

v
v
v

TECHNICAL SERVICES, BHEL-PSWR SITE FEEDBACKS ……… 12

 LT POWER SYSTEM - THE BACKBONE OF POWER PLANTS
BY: S.K.Choudhary
Manager (Electrical), BHEL- Bhilai Site

LT Power system which is backbone of any power plant, requires lot of insight and care at initial stage of
commissioning for subsequent reliable and trouble free operation. Most of the important and life saving
equipments are powered by LT system. However, commissioning of LT system does not get the amount of
attention and efforts it deserves, may be due to a notion of being innocuous and less hazardous. This
commonly held notion remain alive in the backdrop of the statistics that 90% of the accidents occur in LT
power system causing unwanted disruption , damage to the equipments and delay in E&C schedule.
Technical wisdom calls for providing attention and efforts towards E&C of LT SWGR at par with that
provided for HT equipments. It being the basic power source for automation of the equipments needs to
be automated fully at the initial level of commissioning the entire changeover between various sources
needs to be established right in the beginning and not at the stage of precommissioning of other
equipments when its full time availability becomes critical. There is lot of scope of time and resource
saving if the LT SWGRS are properly handled, stored and erected at site. 20% of its lifespan is reduced due
to inappropriate erection sequence .Misplaced zeal for the time saving often prompts to erect the
switchgear amid moist and dusty ambience of civil works ,and many a times , notwithstanding the due care
taken by the agencies, the SWGR panels are erected during curing of adjacent walls. Visible effects may not
be immediate but surfaces after few months or till the time of handing over resulting in pending issues like
deterioration of metal surfaces and rusting of articles like selector switches , control transformers, control
and power terminals.

Following points are indispensable for E&C of LT SWGR:

1. Shorts, ground, poor connection and loose hardware lead to nuisance tripping. Ingress of water
leakage from ceiling and seepage through water must be taken care of immediately. This can lead to
breakdown if allowed to continue for a prolonged period.

2. Contacts of a worn out contactor be replaced in sets. The new contact and old one should not be put
together. Flashover may occur during motor start-up if all the three contacts are not identical. The contact
shape should not be changed by grinding or filing. These simple measures of carbon removal ultimately
results in destruction of motor itself. However, cleaning of dirty contacts with liquid cleaners may be taken
up if immediate replacement of contacts is not possible. Application of LICOM grease on current carrying
parts such as terminal, ACB jaws helps improve operation life of the SWGR. Switches, contactors and circuit
breakers should not be operated without fitting the arc chutes.

TECHNICAL SERVICES, BHEL-PSWR SITE FEEDBACKS ……… 13

3. In no case a wire be used as a substitute for HRC fuse. On line replacement of HRC fuses should not be
permitted even if fuse separators are installed and a proper fuse puller is available. Most of the flashover
/burning cases occur during HRC FUSE installation/removal. HRC fuse installation / removal can be carried
out only in dead circuit condition. Safety regulations require that the HRC Fuse holders of the power circuit
must have electrical isolation provided at source end. Many of the supplied MCC/PCCs do not conform to
this requirement. At 2 X 250 MW Bhilai site, the control transformer has been connected to 415V Bus
through HRC fuse and therefore, for each time, during replacement of the control fuses the Bus is to be
made dead. This could have been avoided by using an isolating switch between the HRC Fuse and the Bus.
On similar lines, Bus PT has been connected to bus through control fuse and for PT fuse replacement bus is
to be de-energized.

4. Dust and humidity are responsible for fast deterioration of electrical equipments. Therefore, SWGR
must be protected from dust and humidity during transportation , handling and at all the stages of E&C.
Deposit of dust invariably deteriorates power and control contactors and mitigates the service life of the
SWGR substantially. Regular cleaning and use of space heaters is necessary for reliable performance.

5. Suitability of the protection of the MCC should be ensured adequately at design stage. Use of definite
time type overcurrent relays is not suitable for incomer protection as fault current will be feeding to the
fault location for a definite minimum time period even in the case of a small fault. Tripping devices like
relays and overloads should be tested individually for proper operation. All mechanical /electrical
interlocks must be in place prior to energization of the SWGR. Trip tests of all the incomer and feeders must
be carried out by simulation of actual operating condition i.e. by primary injection. It is equally important
to ensure the stability of the tripping relays in non tripping conditions. Suitability of application (to be
decided at design stage) is another important criterion besides discrimination. An unsuitable or faulty
overload can give real nightmare to operating staff. Therefore, an exercise of determination of suitability of
various feeders vis-à-vis drives is must at the time of SWGR erection in order to avoid the surprise at
eleventh hour. Site experience shows that many a times, it is found that the drives which require a motor
feeder has been provided with a SFU type feeder. Another kind of unsuitability is marked by perfectly
correct rated motor feeder connected to a low power factor, low speed motor which takes higher current
as compared to their normal power factor counterpart and in such conditions ,overload operates very
frequently causing unwarranted trips .All the internals of the feeders should be checked during erection.
At 2 X 250 MW Bhilai site, in UNIT and Station DCDB, 125 A feeders were found having 2.5 sqmm copper
wires for power connections. Similarly 10 sqmm Cu wires were used for the module of 15 KW DC EOP and
250 A SFU were provided for 60 KW DC JOP. These feeders were modified during E&C of DCDB itself

TECHNICAL SERVICES, BHEL-PSWR SITE FEEDBACKS ……… 14

otherwise it could have been in costly surprises, if detected at the time of commissioning of Steam Turbine
oil system.

6. Phasing out between the buses of multi Bus MCC /PCC is required to be carried out during first charging
of the SWGR in order to avoid flashovers due to inadvertent transposing of bus in the duct.

7. All the power connections are essentially associated with a resistance having the value dependent
upon the quality of the connection and this resistance is invariably related with the dissipation of heat
while carrying the current. Therefore, immediate effect of an inappropriate connection is overheating and
prolonged overheating can result in burning of terminal supports, insulators and ultimately flashover. Heat
is generated in the various part of the SWGR like contactors, fuses, protective elements and at all the joints.
During normal operation, this heat is to be dissipated to the surroundings by radiation and conduction or
through the cables connected to it. Therefore, the envisaged cables should not only be capable of carrying
out the load current but also should be capable of taking away the heat generated in switchgear
equipment. At site, it is one of the most important jobs to ensure proper sizing of the cables for given
application and in no case, any terminal connection should be allowed to become heat source, while
carrying out the rated current. This can be achieved by proper joining of bus bars with suitable torque and
termination of power cable with due care. Following torque values are recommended for use while
carrying out torque tightening of electrical connections:

Another criterion for a good termination is use of appropriate size lug and making proper surface contact at
lug palm. Screw /Bolt size used for the cable termination should fit exactly in the lug palm hole otherwise
uniform tightening of bolt is not possible and the joint made thereby will have partial contact only.
Aluminium lugs terminated on copper surface without having suitable plating also lead to corrosion of the
contact due to higher contact resistance.

Size of Bolt Torque in Meter-Kg

M8 0.85
M10 1.88
M12 3.20
M16 7.30

8. Battery health of the UNIT/Station DCDB (Ultimate lifeline of the power plant) is required to be ensured
on weekly basis as the only available shield beyond this is protection of luck.

v
v
v
TECHNICAL SERVICES, BHEL-PSWR SITE FEEDBACKS ……… 15
 A NOVEL APPROACH FOR MEASUREMENT OF WINDING RESISTANCE
By: Deepak Gehlot
Engineer, BHEL Paras Site
Abstract:
In many cases it is necessary to characterize the resistance of inductors and transformers. For circuit
simulation and modelling, characteristics such as inter-winding capacitance and resonance, as well as DC
resistance and inductance are necessary for accurate predictions of circuit performance. This paper
describes the various factors with adversely affect the Winding Resistance measurement and compares a
new approach to Presently Practiced techniques.

Purpose of Winding Resistance Measurement:

Winding resistance measurements in transformers are of fundamental importance for the following
purposes:
l Calculations of the I2R component of conductor losses.
l Calculation of winding temperature at the end of a temperature test cycle.
l As a diagnostic tool for assessing possible damage in the field.
l Assessment of Quality of Internal connections made to the transformer Windings

Transformers are subject to vibration. Problems or faults occur due to poor design, assembly, handing,
poor environments, overloading or poor maintenance. Measuring the resistance of the windings assures
that the connections are correct and the resistance measurements indicate that there are no severe
mismatches or opens. Many transformers have taps built into them. These taps allow ratio to be increased
or decreased by fractions of a percent. Any of the ratio changes involve a mechanical movement of a
contact from one position to another. These tap changes should also be checked during a winding
resistance test.

DC winding Resistance differs from the values of resistance, derived through equivalent circuit of
Transformer as resistance shown in equivalent circuit includes Winding I2R loss, eddy Loss in Windings,
stray losses in structural parts and circulating Currents in parallel Conductor. The resistance Shown in
Equivalent Circuit is basically an AC equivalent Resistance. Thus DC winding resistance is a different
parameter, as it is relevant for computing I2R, for determining Winding temperatures and for evaluation of
Electrical Connections Regardless of the configuration, either star or delta, the measurements are
normally made phase to phase and comparisons are made to determine if the readings are comparable. If
all readings are within one percent of each other, then they are acceptable. Keep in mind that the purpose

TECHNICAL SERVICES, BHEL-PSWR SITE FEEDBACKS ……… 16

of the test is to check for gross differences between the windings and for opens in the connections. The
tests are not made to duplicate the readings of the manufactured device which was tested in the factory
under controlled conditions and perhaps at other temperatures.

Measurement of Winding Resistance

Resistance of a conductor is determined by dividing the voltage across the conductor by the current
flowing through it. Such resistance measurement assumes steady state conditions where the current
through the sample remains steady and so does the voltage drop across it. This must be satisfied
throughout the measurement period if inductance or capacitance is associated with the resistance to be
measured, a transient will be generated on the application of voltage/current to the test specimen.
The above explained relationship is mathematically expressed as

v = I * R + (L di/dt) where,
v= voltage across transformer winding
I = DC current through transformer winding
R = resistance of the transformer winding
L = inductance of the transformer winding
di/dt = changing value of current (ripple)
The equation explained above can be rewritten as shown below;
Ra = V = R + L dI
I I dt
Where Ra is apparent resistance a
R = V/I (Real Resistance)

The error in resistance measurements under unstable or transient condition is all due to the inductance
which will have a voltage developed across it equal to V=L.di/dt, where L is the inductance in Henries and
di/dt it the rate of change of current in amperes per second. In order to make an error-free measurement,
the inductance must be eliminated from the circuit or the current must remain perfectly steady. Accurate
measurements of resistance will not be possible in R/L/C circuits until the transient is allowed to die down
and steady state conditions prevail.
The Time Constant for transient is equal to L/R ratio where L is inductance in Henries and R is the resistance
in ohms. In Order to achieve a measurable value in this circuit, it takes a time several (5 to 9) time constant.
Time required for achieving a measurable quantity depends upon the accuracy desired. A time of 5 time
constants will provide a accuracy of 1% and a time of 9 time constant will provide accuracy of 0.1 %.

TECHNICAL SERVICES, BHEL-PSWR SITE FEEDBACKS ……… 17

Factor Influencing Measurement:
Some of the major factors which affect the accuracy, time required for measurement are
1) Core Saturation
2) Value of Injected Current
3) Winding Configuration
4) Thermo EMF
5) Residual Induction

1) Core Saturation: In Comparison to exponential, current v/s time relationship for a simple R-L Circuit
with constant Rand L, the current in the transformer winding rises slowly when DC voltage is applied. The
slow rate of rise of current is attributed high initial impedance of the winding. The initial high impedance
results from large effective inductance of the winding within its iron core. As the current increase, the flux
density in core rises until the core begins to saturate .Once the core is saturated it behaves as a air core with
small inductance instead of Iron core. The rate of rise of current increases from this point onwards as the
core saturates, and then it steadies to a steady state value. Typical curve for current voltage and resistance
is as shown below.

Magnitude of voltage applied affects the rate at which flux builds up in the core as
V = N d? /dt

The test equipment must apply “volt seconds” equivalent to the rated voltage of the winding to establish
any appreciable current. The volt-seconds can be calculated by integrating the area under on half cycle of
the voltage and dividing this value by 2. Thus, a winding rated at 100KV at 50 Hz will be rated at approx 450
volt second while a 100KV, 60 Hz winding will have a rating of 375 volt-seconds, approximately. The 50 Hz
winding will need the application of 6 volts for 75 seconds before the current is established. The saturation
TECHNICAL SERVICES, BHEL-PSWR SITE FEEDBACKS ……… 18
will occur much faster if a higher voltage is applied. Thus only 15 seconds will be required if a voltage of 30
volts is applied.
Thus as showed above it can be stated that “Higher the magnitude of applied voltage shorter is the time
required for saturation of core, because of higher value of d? /dt”.
It is also important, that the required Magneto motive force in ampere turns (N x I) is provided by the Coil,
needed to force the coil into saturation. Thus a minimum value of Dc current is required for a given number
of turn.

2) Value of Injected Current: It is general thinking that with increase in injected DC current, accurate and
fast results are achieved. Although this may be true of many cases, this is NOT true in all cases. For best
results, the test current should be selected according to requirements of the transformer. Thus, when
measuring transformer winding resistance, it is desirable to use a current that is larger than the excitation
current for that winding. This will tend to saturate the core and reduce the settling time for the
measurement. The selected current should be less than 10% of the rated current for that winding, as
excessive current will be heating up the winding and causing its resistance to increase. A current of 10% will
cause only 1% of the normal heating of the winding. Caution should be exercised when selecting the test
current as excessive DC excitation of the core produces undesirable stresses. These stresses are similar to
the stresses when a transformer is energized, saturates, and draws in-rush current. Therefore, it may be
desirable to limit the test current to 2-4 times the excitation current for the winding being tested. As the
excitation currents for larger transformers are typically less than 1% of rated, one should consider test
currents in the range of 2-4% rated.

3) Winding Configuration: Transformers with delta connected windings encounter an additional

transient during the start-up period. As this current is coupled by transformer action to all the windings on
the transformer, it causes a delay due to the L/R time constant within the delta circuit. This time constant
increases with the increase in the KVA rating and efficiency of the transformer.

We have little control over this time constant except to try and modify the inductance by selecting a higher
or lower test current. It should not be assumed that a higher current will reduce the inductance. In fact
when testing the low voltage windings of a large transformer, the inductance of the winding will increase
with an increase in current, the current in such situations must be reduced or increased past the knee point
to effectively reduce the inductance.

4) Thermo EMF: Measurement process in discussion involves the measurements of DC milli volts, it is

TECHNICAL SERVICES, BHEL-PSWR SITE FEEDBACKS ……… 19

important to avoid the introduction of thermal EMFs. This means that all connections to be made are
copper-to-copper.

5) Residual Induction: In all the discussion till now we have assumed constant R and L, but practically this
is not the case. The Inductance Changes with time due to nonlinear B-H curve of the Core Steel and it varies
according to slope of core steel saturation curve.

Proposed Methodology
In the proposed method HV and LV Winding of transformer are connected in series as shown in figure. By
connecting primary and secondary in series, the speed of saturation is increased because there are more
amp-turns contributing to the flux in the core.
With this method for same rate of Increase of Flux a lesser current is required as compared to conventional
approach. Thus the effects of High Current on Winding resistance measurement are also eliminated.
Further as shown in the fig one of the winding is connected to earth. This Connection with earth eliminates
the effects of AC induction into a floating winding.

TECHNICAL SERVICES, BHEL-PSWR SITE FEEDBACKS ……… 20

 Stabilization/time for winding resistance measurement on a delta side of Y-D transformer

As it can be seen for Dual HV LV winding injection the time taken is less than 1 min as compared to single
winding injection for which even after 7 min real values are not achieved.

TECHNICAL SERVICES, BHEL-PSWR SITE FEEDBACKS ……… 21

 Time Dual winding injection(milli ohms) Single winding injection(milli ohms)
0.5 3 19.85
1 2.01 17.2
1.5 1.87 15.04
2 1.41
2.5 1.35 12.008
3 1.31
3.5 1.31 9.06
4 1.3
4.5 1.29 7.21
5 1.29
5.5 1.29 6.47
6
6.5 5.32
7
8 5.01
8.5
15 2.64
20 1.98
25 1.76
30 1.63
45 1.5
60 1.42
75 1.301

Site Results for Testing of LV side (delta) of 300 MVA Generator Transformer at BHEL PARAS.
Above Result clearly indicates the Advantages of Proposed Methodology.

v
v
v
TECHNICAL SERVICES, BHEL-PSWR SITE FEEDBACKS ……… 22
 REPORT ON COMMISSIONG MAXLINK WITH GRP RELAYS
By: Dinesh Jawade,
Sr. Manager (TSX)
BHEL, PSWR, Nagpur

Communication with GRP/STRP/HT Switchgear relays with maxDNA system is always a pending point for all
the commissioned sites. To avoid this as pending points, the following steps to be followed during erection
stages preferably before synchronization of the unit.
1. The relays either SIEMENS or AREVA make which are required to be communicated to maxDNA DCS
system are to be connected in a bus as per the scheme provided by BHEL, Bhopal. As these relays are
scattered in the various panels, the cabling cannot be done at works, at Bhopal. Hence, the required
cabling is to be done when the GRP/STRP panels are being erected and being commissioned.
2. A typical scheme for 250MW for Parli/Paras and JPL, Raigarh is attached herewith for ready reference.
3. AREVA 3 series relays cannot communicate through IEC protocol and Hence KALKI convertor is used in
between relays and maxLinks station.
4. In between relays and KALKI convertor, a KITZ convertor is used as 3 AREVA relays do not have extra
serial port which is required for centralized computer.
5. KALKI convertor is always gives trouble during commission as it is not tested using the setup at AREVA
works. M/s. BHEL, Bhopal along with EDN Bangalore should arrange integrated testing of the KALKI
convertor before dispatch to site.
6. KALKI convertor when connected with maxLinks, the port gets damaged due to loading. Hence, an
isolator is required to be provided by KALKI. The availability of the same should be verified and
communicated to M/s. AREVA before start of the commissioning activities.
7. A 26AWG twisted pair cable (2/4 Pair) can be used for connecting between relay panel and maxLinks
station.
8. In maxDNA, to have 8 RS485 serial ports, MOXA PC add on card is used. This comprises of an PC add on
card located inside the maxLinks PC, a MOXA extender board normally mounted inside the network
panel and an interconnecting cable to connect the PC add on card and MOXA extender board. The
MOXA extender board also requires an external power adaptor. The board needs software driver to
work which has to be installed if not already done in factory by BHEL/EDN.
9. Connecting cables between MOXA port and TBs in the network panel should be made available. This
cable has D-type male (25 PINS) connector at one end and open at the other end. Generally, the cable is
always not traceable at site.

TECHNICAL SERVICES, BHEL-PSWR SITE FEEDBACKS ……… 23

10. Sufficient nos. of 9 pin D type male and female connectors should be made available for connectivity
between GRP relays and local PC as well as between KITZ connector and KALKI connector.
11. PIN configuration shall be confirmed from M/s. KALKI/AREVA.
12. 230 V AC UPS supply is required for KALKI convertor as well as for RS485 isolator. The power supply
cabling to be completed before start of the commissioning activities.
13. 6 series AREVA relay and SIEMENS relays communicate with maxLinks through IEC 103 protocol and
hence no convertor is required.
14. For relays to communicate with maxLinks additional software has to be installed in the maxLinks PC.
This software once installed will be available under C:/Mcs/IEC folder. If not available this has to be
obtained from BHEL/EDN.
15. PEM is to provide the details of the tags to be made available in max along with corresponding relay
address, info address and function type based on which the required data base is to be made by
BHEL/EDN, Bangalore. A typical configuration file is attached herewith.
16. Executable file IEC103Master.exe and data base IE103Master.mdb are to be obtained from EDN and are
to be copied in CUSTOM/IEC and MCS/IEC folders of maxLinks station.
17. Clicking on application file, an application will be launched along with the data base. On maximizing,
we will be able to identify the relays which are communicating as well as EVENTs generated by the
particular relay.
18. For events to be made available in max network, the following entry to be made in the maxStation
where EVENT COLLECTOR is running;
SERVICE=[LINKS]_1GRP_EVENTS
SERVICE=[LINKS]_1KALKI_EVENTS
19. The OMIKRON test kit is required to create the EVENTs in the protection relays.
20. Time synchronization is done using IEC protocol and hence no external time sync is required.

TECHNICAL SERVICES, BHEL-PSWR SITE FEEDBACKS ……… 24

TECHNICAL SERVICES, BHEL-PSWR SITE FEEDBACKS ……… 25
 v
v
v
TECHNICAL SERVICES, BHEL-PSWR ISSUE SPECIAL- NON CONVENTIONALSITE FEEDBACKS
ENERGY ………
SOURCES…… 26
 FREQUENT TRIPPING OF TURBINE ON OVERSPEED PROTECTION
By: Shri. P.R.Chiwarkar
DGM (Ser.), Nagpur

v
v
v
TECHNICAL SERVICES, BHEL-PSWR SITE FEEDBACKS ……… 27
 OIL FLUSHING OF PEDESTALS BY USING DUMMY PLUGS AFTER OVERHAULS
(Applicable to KWU Design)
By: Shri. P.R.Chiwarkar
DGM (Ser), Nagpur
After carrying out overhauling of TG sets, it is a recommended practice to carry out oil flushing of bearing
pedestals for avoiding entry of any foreign material in bearing during operation of the machine.
The original scheme envisaged removal of the throttles from bearing inlet lines and installing line filters in
each line. During oil flushing, it is required to stop the oil pump periodically and inspect the line filters for
presence of any foreign materials. After cleaning, the line filters are put back and oil flushing is restarted.
This process is continued till satisfactory condition of the line filters is achieved.
However, in this method, sometimes the meshes of the filters get punctured and some foreign particles
and portion of the metallic filter mesh may enter into the bearings. At one site, the nut bolts of the
supporting cage of the filter in bearing no. 2 inlet line got loosened and went missing during oil flushing. It
was suspected that these nuts might have travelled to the bearing and might cause damage during rolling.
So the bearing had to be reopened for thorough inspection which resulted in considerable time loss and
rework. Also, for periodical inspection of line filters, oil flushing has to be stopped and started frequently
which results in time loss.
The above problems led to a thought process of finding some other suitable alternative method of oil
flushing after overhauls. SAS, Nagpur service Engineers came out with an alternate method which was
later on adopted in all sites of PSWR as well as most of the sites of other regions also and has now become
an established practice.
In this method, after removing the throttles from inlet lines, taper plugs, preferably made from brass are
tightly fitted in the port which blocks entry of oil to bearing. The top cover flange of the throttle chamber is
kept open. The inspection covers of the oil chamber are tightened securely. During oil flushing, the oil falls
in the chamber which opens from bottom side in the pedestal. So the oil travels inside the pedestal over the
bottom opening and then travels to drain header. Any dirt and foreign particles lying in the pedestal are
carried away to the MOT basket filter and can be removed by cleaning the basket.

Precaution to be taken is thorough cleaning of the inlet line from throttle upto bearing inlet before box up,
and the top and bottom halves of bearing should also be free from any dirt or foreign material because
bearings will not get flushed in this method.
Oil flushing is concluded after checking the condition of Duplex filter in the lub oil inlet line and when the
filter does not get choked for minimum 4 hours, oil flushing can be stopped. The dummy plugs are then
removed and throttles are re-installed in position.
This improvised method allows continuing the oil flushing uninterruptedly, thus resulting in time saving
and the other problems faced in original system are also overcome.
TECHNICAL SERVICES, BHEL-PSWR SITE FEEDBACKS ……… 28
AND THE LAST PAGE ………

Dear Friends,
In the present Issue of “Takniki Darpan” we are pleased to present you a collage of
feedbacks received from various on going sites of PSWR. Engineers at site are
continuously striving for better methods of erection, commissioning and
servicing activities so as to save time, money and provide a quality job to the
customer. There are many steps involved in converting such isolated efforts into a standard
practices at the organization level and the first step in that direction is of course to share it with
others.
In this issue, we have included a new method of unloading a 500MW Generator rotor that was
tried at Khaperkheda. Similarly in commissioning area, we have included a better method of oil
flushing of Air-Preheater that was tried at 500MW NTPC Korba Project, suggestion for
improvement in LT Switchgear commissioning based on our experience at NSPCL Bhilai site and a
better method of measurement of winding resistance of Transformers.
It is heartening to note that these feedbacks have come from some of our best experienced
engineers as well as from new engineers with hardly one or two years of experience. It is this great
combination of experience and fresh ideas that makes us really optimistic about our future.
We request you all to try out these methods in your work area and give feedbacks about your
experience so that these efforts can be refined and converted into standard practices to be
followed by all.

With best wishes,

S N Maiti
General Manager
PSWR, Nagpur

TECHNICAL SERVICES, BHEL-PSWR 29

 Designed & Printed at AQUA PROCESS Ph. : 9371162862

BHARAT HEAVY ELECTRICALS LIMITED

POWER SECTOR WESTERN REGION
Shree Mohini Complex, 345, Kingsway, Nagpur-440001.